Marzocchi Marathon SL Manual
  1. Manuals
  2. Brands
  3. Marzocchi Manuals
  4. Bicycle Accessories
  5. Marathon SL
  6. Manual
Marzocchi Marathon SL Manual

Marzocchi Marathon SL Manual

Fork
Hide thumbs
Table of Contents

Advertisement

Quick Links

Features

TECHNICAL CHARACTERISTICS

Fork with Ø30 mm legs with "Double Air"
damping system.
Adjustment of the air preload (positive air)
on both legs.
Adjustment of the rebound damping
(negative air) on the left leg.
The ECC5 cartridge in the right leg lets you
adjust the rebound damping in five
positions "on the fly".
The stanchion tubes are pressed into the
crown with a cryogenic process.
New sliding system to improve the stiffness
and operation.
Magnesium alloy cast one-piece assembly,
CNC machined for lighter weight and more
stiffness.
Components subjected to friction are
lubricated and cooled by means of a
special oil
Steer tube : aluminium, 1-1/8", threadless.
Crown: BAM® aluminium alloy forged and
CNC machined.
Stanchions: anodised aluminium.
1/48
Marathon SL
Sliding bushes: made of friction free and
wear free material.
Seals: computer designed oil seals that
guarantee the maximum seal in any
condition.
Oil: special formulated oil that prevents
foam and keeps the viscosity unchanged
while offering high performance; free from
static friction.
Dropout type: Standard.
Disk brake mount: XC International
Standard for 6" disk.
V-Brake fit.
BAM®: Bomber Aerospace Material:
special alloy coming from the aerospace
industry.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Marathon SL and is the answer not in the manual?

Questions and answers

Related Manuals for Marzocchi Marathon SL

Summary of Contents for Marzocchi Marathon SL

  • Page 1 Features Marathon SL TECHNICAL CHARACTERISTICS Sliding bushes: made of friction free and wear free material. Fork with Ø30 mm legs with "Double Air" damping system. Seals: computer designed oil seals that guarantee the maximum seal in any Adjustment of the air preload (positive air) condition.
  • Page 2 Features Marathon SL 2/48...
  • Page 3 Warning Marathon SL INSTRUCTIONS FOR USE GENERAL REGULATIONS FITTING THE FORK ONTO THE FRAME INSTALLING THE DISK BRAKE SYSTEM INSTALLING THE V-BRAKE SYSTEM ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS 3/48...
  • Page 4 Warning Marathon SL INSTRUCTIONS FOR USE MARZOCCHI forks are based on an advanced technology coming from the company’s years long experience in the professional mountain bike industry. For the best results, it is advisable to inspect and clean the area below the dust...
  • Page 5 GENERAL REGULATIONS damage the bolts and screws making it impossible to unscrew them. · After a complete breakdown, always use new MARZOCCHI seals when · Use the right size and sort of screwdriver reassembling. to unscrew slotted or crosshead screws.
  • Page 6 A wrong installation can be dangerous for the rider. Marzocchi does not guarantee the assembly and accepts no liability for damage and/or accidents arising from a wrong installation. The steer tube must be pressed into the crown;...
  • Page 7 INSTALLING THE DISK BRAKE SYSTEM Installing the brake system is a very delicate operation that must be carried out at our specialised service centres only. Marzocchi does not guarantee the installation and accepts no liability for damage and/or accidents arising from a wrong installation...
  • Page 8 INSTALLING THE V-BRAKE SYSTEM Installing the brake system is a very delicate operation that must be carried out at our specialised service centres only. Marzocchi does not guarantee the installation and accepts no liability for damage and/or accidents arising from a wrong installation.
  • Page 9 Warning Marathon SL ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS Install the wheel following the instructions of the bike’s manufacturer. A good and reliable operation of the fork and all of the parts linked to it mainly depend on the correct fixing of the front wheel.
  • Page 10 Diagnostic Marathon SL 10/48...
  • Page 11 Disassembling Marathon SL REMOVING THE TOP CAP – RIGHT LEG REMOVING THE TOP CAP – LEFT LEG DRAINING THE OIL BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY REMOVING THE HYDRAULIC CARTRIDGE - RIGHT LEG REMOVING THE CARTRIDGE – LEFT LEG...
  • Page 12 Disassembling Marathon SL REMOVING THE TOP CAP – RIGHT LEG · Put the fork in the vice in a vertical position, fixing it by the dropouts. · With a 2mm Allen wrench, loosen the screw (2) of the ECC5 control knob.
  • Page 13 Disassembling Marathon SL · Using a small pin screwdriver, blow the air off the fork leg, pushing on the air valve. · Fully unscrew the lock cap (1) with a 21mm socket spanner. 13/48...
  • Page 14 Disassembling Marathon SL REMOVING THE TOP CAP – LEFT LEG · Put the fork in the vice in a vertical position, fixing it by the dropouts. · Loosen and remove the protection cap (6). · Using a small pin screwdriver, blow the air off the fork leg, pushing on the air valve.
  • Page 15 Disassembling Marathon SL DRAINING THE OIL · Remove the leg caps (1) from the crown unit. · Free the fork from the vice and tip it into a container of a suitable size to drain the oil; compress the fork a few times to help the oil flow out.
  • Page 16 Disassembling Marathon SL BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY Use the special spanner to remove the bottom nuts. Do not use other tools. Using the special 12mm spanner (A), loosen the two bottom nuts (1). · Remove the bottom nuts (1) and the O-rings (2).
  • Page 17 Disassembling Marathon SL · Pull the crown-stanchion unit (3) off the arch-slider assembly (4). 17/48...
  • Page 18 Disassembling Marathon SL REMOVING THE CARTRIDGE – RIGHT · Remove the stop ring (8). · Remove the lock cap (1). The ECC5 cartridge (7) is sealed through machining and cannot be overhauled. In the case of faults or a malfunctioning, it must be replaced.
  • Page 19 Disassembling Marathon SL REMOVING THE CARTRIDGE – LEFT · Hold the cartridge rod in the vice using the special jaws (A). · With a 21mm socket spanner, fully unscrew lock cap (2). · Remove lock cap (2). · Hold liner (3) firmly and, with a 19mm hexagonal wrench, remove the cartridge cap (4).
  • Page 20 Disassembling Marathon SL · Pull out the cartridge rod (5) complete with cap (4) and rebound spring (6). · Remove cap (4) complete with rebound spring (6) from the cartridge. 20/48...
  • Page 21 Disassembling Marathon SL · Separate the cap from the rebound spring ( · If the segment (8) or the O-rings (9) are worn out, prize them off with a small flat-tip screwdriver. 21/48...
  • Page 22 Disassembling Marathon SL REMOVING THE SEALS · Remove the dust seal (1) from its seat, using a small flat-tip screwdriver. · With the same screwdriver prize off the metal stop ring (2). Take great care not to damage the internal surfaces of the arch-slider assembly when removing the dust seal and the stop ring.
  • Page 23 Disassembling Marathon SL Protect the upper part of the slider with the special tool (A). With a screwdriver prize the sealing ring (3) off. Remove the sealing ring (3). Take great care not to damage the internal surfaces of the arch-slider assembly when removing the sealing ring.
  • Page 24 Disassembling Marathon SL REMOVING THE GUIDE BUSHES Use the special extractor to remove the guide bushes. Do not use other tools. Fit the aluminium bush (A) to the extractor keeping the small diameter side towards the edge opposite to the striker.
  • Page 25 Disassembling Marathon SL Pull the extractor rod so that the upper face of the washer stops against the lower face of the guide bush. Insert the aluminium bush (A) in the seat of the sealing ring. While holding the main rod in position, the aluminium bush drives the guide bushes during extraction.
  • Page 26 Assembling Marathon SL ASSEMBLING THE GUIDE BUSHES 26/48...
  • Page 27 Assembling Marathon SL ASSEMBLING THE GUIDE BUSHES Insert the guide bushes using the special introducers (short type for the top bush and long type for the bottom bush, both with a black finish). Do not use other tools. Fit first the bottom bushes, then the top bushes.
  • Page 28 Assembling Marathon SL Using the short introducer (B) fit the bottom bush (2). Using a hammer knock the introducer (B) into the arch-slider assembly. 28/48...
  • Page 29 Assembling Marathon SL ASSEMBLING THE SEALS · Smear the dust seal and the sealing ring with some grease. · Refit the sealing ring (3) using the special introducer (A). · Using a hammer knock in the introducer (A ) and drive the sealing ring home into the arch-slider assembly.
  • Page 30 Assembling Marathon SL MOUNTING THE CARTRIDGE - RIGHT · Fit the lock cap (1). · Insert the stop ring (8) and check it fits perfectly into its groove. 30/48...
  • Page 31 Assembling Marathon SL REMOVING THE CARTRIDGE - LEFT LEG · Replace the segment (8) and the O-rings ( 9) if necessary. · Fit the rebound spring (6) on a new cap (4). On the thread of cap (4) a special anti-unscrewing treatment has been applied.
  • Page 32 Assembling Marathon SL · Mount the introducer (B) on the top of the cartridge rod (5). · Insert cap (4) complete with the rebound spring (6) in the cartridge rod (5). · Remove the introducer (B). 32/48...
  • Page 33 Assembling Marathon SL · Insert the cartridge rod (5) complete with plug (4) inside the liner. · Holding liner (3) firmly, tighten cap (4) with a 19mm hexagonal wrench. 33/48...
  • Page 34 Assembling Marathon SL Put the cartridge rod in the vice using the special jaws (A). · With a 21mm socket spanner, tighten lock cap (2) on the cartridge rod to the recommended tightening torque (6 Nm±1). 34/48...
  • Page 35 Assembling Marathon SL ASSEMBLING THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY A special spanner shall be used to assemble the bottom nut. Do not use other tools. · Fit the dust seals (11) to the stanchions. · Insert the crown-stanchion unit (3) in the arch-slider assembly (4).
  • Page 36 Assembling Marathon SL Fit the complete cartridges (10) in both fork legs. · With the special 12mm spanner (A), tighten the bottom nut (1) with O-ring (2) of both legs to the recommended tightening torque (11 Nm±1). 36/48...
  • Page 37 Assembling Marathon SL · Re-assemble the dust seals (11) in their seats using the special introducer (A). 37/48...
  • Page 38 Assembling Marathon SL FILLING WITH OIL · Put the fork in the vice in vertical position. · Lower the crown-stanchion unit on the arch-slider assembly. · Prepare the quantity of oil to pour into the fork leg (see table). · Pour roughly 1/3 of the oil required into each stanchion, then pump the fork a few times to remove any traces of air.
  • Page 39 Assembling Marathon SL · Wait for a few minutes and check the volume of the air (h); if necessary refill to the right level. In order to check the air properly and avoid to alter the reached values, lower the lock caps on the fork crown as much as possible.
  • Page 40 Assembling Marathon SL MOUNTING THE TOP CAP – RIGHT LEG · Put the fork in the vice in vertical position, fixing it by the dropouts. · With the 21mm socket spanner, tighten the lock cap (2) to the recommended tightening torque (20 Nm±1).
  • Page 41 Assembling Marathon SL REMOVING THE TOP CAP · Put the fork in the vice in a vertical position, fixing it by the dropouts. · With a 1.5mm Allen wrench loosen the grubscrew (4) and remove the adjusting knob (5). · Remove the stop ring (8).
  • Page 42 Assembling Marathon SL MOUNTING THE TOP CAP – LEFT LEG · Put the fork in the vice in vertical position, fixing it by the dropouts. · With the 21mm socket spanner, tighten the lock cap (1) to the recommended tightening torque (20 Nm±1).
  • Page 43 Settings Marathon SL POSITIVE AIR NEGATIVE AIR ECC5 43/48...
  • Page 44 Settings Marathon SL POSITIVE AIR Use the MARZOCCHI pump with pressure gauge to inflate the fork legs. Using inadequate tools may lead to a wrong inflation and result in a malfunctioning or damage to the fork. To reduce the leg’s pressure, simply push the valve pin down with a pointed tool such as a small pin extractor.
  • Page 45 Settings Marathon SL Left leg positive air adjustment: Using a 2.5mm Allen wrench, loosen the screw (A) fixing the ECC5 knob. Remove screw (A) and knob (B). Fit and tighten the pump adapter (C) on the valve. · Inflate till reaching the pressure you wish (see table).
  • Page 46 Settings Marathon SL Right leg positive air adjustment: · Loosen and remove the protection cap (A). · Screw the pump adapter (C) down on the external valve (B). · Inflate till reaching the pressure you wish (see table). · Refit and tighten the protection cap (B).
  • Page 47 Settings Marathon SL NEGATIVE AIR Use the MARZOCCHI pump with pressure gauge to inflate the fork legs. Using inadequate tools may lead to a wrong inflation and result in a malfunctioning or damage to the fork. To reduce the leg’s pressure, simply push the valve pin down with a pointed tool such as a small pin extractor.
  • Page 48 Settings Marathon SL ECC5 downhills. The fork would not react safely enough when hitting an obstacle. The ECC5 cartridge lets you adjust the rebound damping “on the fly”. Turning the adjuster (A) changes the hydraulic configuration of the internal valves letting more or less oil flow through or stopping the oil flow in the "LOCK OUT"...

Table of Contents

Save PDF