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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
Dirt
4. Before reassembling, lubricate all parts
in contact with each other using silicone
Jumper
fat spray or a specific oil for seals.
5. Always grease the lip seal rings before
reassembling.
1,5
6. Use wrenches with metric size only.
Wrenches with inch size might damage
QR20
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
special tools only.
ARZOCCHI
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Table of Contents
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Summary of Contents for Marzocchi Dirt Jumper 1,5 QR20
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing the M special tools only. ARZOCCHI 2. On reassembling the suspension system, always use new seals. 3. Clean all metal parts with a special, preferably biodegradable solvent, such as trichloroethane or trichloroethylene.
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Page 2: Failures, Causes And Remedies
FAILURES, CAUSES AND REMEDIES This paragraph reports some failures that may occur when using the fork. It also indicates possible causes and suggests a remedy. Always refer to this table before doing any repair work. FAILURES CAUSES REMEDIES Dirt Oil leaking though the top of slider 1. -
Page 3: Recommendations For Maintenance
RECOMMENDATIONS FOR MAINTENANCE forks are based on advanced ARZOCCHI technology, supported by year-long experi- ence in the field of professional mountain biking. In order to achieve best results, we recommend to check and clean the area below the dust seal and the stanchion tube after each use and lubricate with silicone oil. -
Page 4: Installation
INSTALLATION Installing the fork on a bicycle is a very Lock the quick release lever (B) and make DISC BRAKE SYSTEM ASSEMBLY delicate operation that should be carried sure the bushings (A) are properly seated WARNING: If a disc brake system out with extreme care. -
Page 5: Spring Preload
ADJUSTMENT SPRING PRELOAD REBOUND ADJUSTMENT VIA IMPORTANT: Do not remove the springs Spring preload determines COMPRESSION INNER PUMPING ROD or this will alter the amount of oil inside the damping and is adjusted by turning the (only right leg) fork legs. adjustment knob (2) on the top of the fork The adjuster controlling REBOUND damp- legs. -
Page 6: Disassembly Diagram
DISASSEMBLY GENERAL – The reference numbers given in this section relate to the components shown in the fork exploded view. – Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence. Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to remove first. - Page 7 SPRING CHANGE FIG. 2 PILOT BUSHING AND SEAL FIG. 1 Push the stanchions into the sliders and ASSEMBLY CHANGE Unscrew the caps (5) with a 21 mm socket remove the lower washer (11) and the FIG. 3 wrench. spring (34) from each fork leg. Remove foot nuts (29) with a socket Remove the caps complete with O-ring (6) Drain all oil from the fork legs.
- Page 8 FIG. 4 FIG. 5 FIG. 6 Withdraw the crown and stanchions as- Remove the dust seal (19) from the top of Remove the stop ring (20) from the sliders sembly (1) from the sliders (30). the sliders using a small screwdriver. by placing the screwdriver bit in one of the three openings on the stop ring.
- Page 9 FIG. 7 FIG. 8 FIG. 9 Fit the slider protector (A) onto the slider Remove the upper washer (22) from the Fit the bit of a small screwdriver into upper and remove the oil seal (21) with the help slider. edge slot of the pilot bushing (23) and lift of a large screwdriver.
- Page 10 REPLACING PUMPING ELEMENT FIG. 11 VALVE ASSEMBLY CHANGE SEALS Withdraw the pumping elements (14) and (only right leg) FIG. 10 (12) and the rebound springs (15) from FIG. 12 Remove the foot buffer (18) and (42) the stanchion tube top. To check that the valve assembly is operat- complete with ring (25) from the pumping ing correctly, it is necessary to work on the...
- Page 11 REASSEMBLY CAUTION: before reassembling, all metal FIG. 14 FIG. 15 components should be washed carefully Fit the upper washer (22) into the slider so Lubricate the oil seal (21) and place it onto with inflammable, preferably biodegrad- that it touches the pilot bushing. the seal press (B) with the hollow side able, solvent and dried with compressed toward the slider.
- Page 12 FIG. 16 FIG. 17 VALVE AND PUMPING ROD Insert the stop ring (20) into the slider Lubricate the dust seals (19) and fit them ASSEMBLY making sure it is properly seated into place. into the stanchions from the spring end. FIG.
- Page 13 FIG. 19 FIG. 20 (only right leg) FIG. 21 (only left leg) Lubricate the O-rings (24) and (25) and Insert the RH pumping element you have just Fit pumping element (12) from stanchion reassemble the foot buffer (18) onto pump- assembled into the stanchion tube and top with only one rebound spring (15) on ing element end (14) and foot buffer (42)
- Page 14 CROWN AND STANCHIONS FIG. 23 HOW TO FILL WITH OIL ASSEMBLY Screw the foot nuts (29) on the threaded FIG. 24 FIG. 22 elements of pumping elements (14) and Pour oil little by little when the stanchions Fit the crown and stanchions assembly (1) (12).
- Page 15 SPRING AND CAP FIG. 26 FIG. 25 Lubricate the O-ring (6) on the cap (5). Fit the springs (34) into each stanchion Turn the preload adjuster (9) counterclock- tube. wise until it is at its minimum setting and install the lower washer (11). Start the caps with the O-ring (6) in place into the stanchion tube threads by hand.
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