Marzocchi MX Comp ETA 2005 Technical Instructions
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Marzocchi MX Comp ETA 2005 Technical Instructions

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© Marzocchi Suspension
2005 - MX Comp ETA
2005 - MX Comp ETA
Technical instructions

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  • Page 1 © Marzocchi Suspension 2005 - MX Comp ETA 2005 - MX Comp ETA Technical instructions...
  • Page 2 © Marzocchi Suspension 2005 - MX Comp ETA Exploded view - MX Comp + ETA 85 Rif. Code Quantity 1 818286/E 1 818286/A 1 818286/R 2 549072AD 3 701208/C 4 528226 5 701254/C 6 520363 7 549077AD 8 528149 12 533301 13 523261 14 528172NOK>B...

  • Page 3: Table Of Contents

    © Marzocchi Suspension 2005 - MX Comp ETA Spare part list - MX Comp + ETA 85 Q.ty in the Rif. Code Description model 818286/E CROWN+STANCH+ALLOY STEM MX 05 (replaces 818211/E) 818286/A CROWN+STANCH+STEEL STEM MX 05 (replaces 818211/A) 818286/R CROWN+STANCHIONS MX 05...

  • Page 4: Table Of Contents

    © Marzocchi Suspension 2005 - MX Comp ETA Exploded view - MX Comp + ETA 105 Rif. Code Quantity 1 818286/E 1 818286/A 1 818286/R 2 549072AD 3 701208/C 4 528226 5 701254/C 6 520363 7 549077AD 8 528149 12 533301 13 523261 14 528172NOK>B...

  • Page 5: Table Of Contents

    © Marzocchi Suspension 2005 - MX Comp ETA Spare part list - MX Comp + ETA 105 Q.ty in the Rif. Code Description model 818286/E CROWN+STANCH+ALLOY STEM MX 05 (replaces 818211/E) 818286/A CROWN+STANCH+STEEL STEM MX 05 (replaces 818211/A) 818286/R CROWN+STANCHIONS MX 05...

  • Page 6: Table Of Contents

    © Marzocchi Suspension 2005 - MX Comp ETA Exploded view - MX Comp + ETA 120 Rif. Code Quantity 1 818286/E 1 818286/A 1 818286/R 2 549072AD 3 701208/C 4 528226 5 701254/C 6 520363 7 549077AD 8 528149 12 533301 13 523261 14 528172NOK>B...
  • Page 7 © Marzocchi Suspension 2005 - MX Comp ETA Spare part list - MX Comp + ETA 120 Q.ty in the Rif. Code Description model 818286/E CROWN+STANCH+ALLOY STEM MX 05 (replaces 818211/E) 818286/A CROWN+STANCH+STEEL STEM MX 05 (replaces 818211/A) 818286/R CROWN+STANCHIONS MX 05...
  • Page 8 © Marzocchi Suspension 2005 - MX Comp ETA Technical characteristics: Technical characteristics Single-crown fork with ø 30mm legs. Available travels: 85 mm, 105 mm, 120 mm. Right fork leg damping element: air. Left fork leg damping element: spring. Right fork leg damping system: SSV pumping element with internal rebound adjustment.

  • Page 9: Replaces

    Always grease the seal lips before reassembling. All of the components of Marzocchi forks require the use of metric tools. Use only metric tools. Imperial (US) tools may have similar sizes, but can damage the bolts, making them impossible to loosen or tighten.
  • Page 10 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. Improper installation of the disk brake system can overstress the caliper mountings, which may break. The installation of the brake system must be carried out following the instructions of the brake system manufacturer.
  • Page 11 © Marzocchi Suspension 2005 - MX Comp ETA Dismantling: Removing the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. Dismantling: Removing the top right cap Remove the protection cap (1). Using a small pin screwdriver, blow the air off the fork leg, pushing on the air valve.

  • Page 12: O-Ring

    © Marzocchi Suspension 2005 - MX Comp ETA Holding locknut (6) with the 10mm spanner, use the 21mm spanner to unscrew lock cap (2) completely. Remove lock cap (2). Dismantling: Draining the oil 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 13: Stop Ring

    © Marzocchi Suspension 2005 - MX Comp ETA Pull the crown-stanchion unit (3) off the arch-slider assembly (4). Dismantling: Dismantling the right pumping element and valve Remove the bottom pad (1). Using the special round-nose pliers, remove stop ring (2).
  • Page 14 © Marzocchi Suspension 2005 - MX Comp ETA Remove bushing (4), valve (5) and three-point ring (6) from the pumping element. only for models with 105mm travel Remove the preload tube (9) ( Remove the rebound spring (7). If the piston segment (8) is damaged, you can prize it off with a small flat-tip screwdriver.
  • Page 15 © Marzocchi Suspension 2005 - MX Comp ETA The ETA cartridge (5) has been sealed through machining and cannot be overhauled. In the case of faults or a malfunctioning, this cartridge must be replaced. Dismantling: Removing the seals Prize the dust seal (1) off its seat with a small flat-tip screwdriver.
  • Page 16 © Marzocchi Suspension 2005 - MX Comp ETA The old sealing rings and dust seals must not be used again. Dismantling: 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 side with smaller diameter towards the edge opposite to striker (D).
  • Page 17 © Marzocchi Suspension 2005 - MX Comp ETA...
  • Page 18 © Marzocchi Suspension 2005 - MX Comp ETA Assembling: 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.
  • Page 19 © Marzocchi Suspension 2005 - MX Comp ETA Using a hammer, knock in introducer (A) and drive the sealing ring home into the arch-slider assembly. Using a small flat-tip screwdriver, fit the stop ring (2) and check that it fits perfectly into its groove.
  • Page 20 © Marzocchi Suspension 2005 - MX Comp ETA Insert the pre-assembled valve in the piston rod from the three-point ring side as shown. Insert the valve and the pumping element (3) into the stanchion. Take great care not to damage the segment and if necessary use a small flat-tip screwdriver to help the piston of the pumping element into the stanchion.
  • Page 21 © Marzocchi Suspension 2005 - MX Comp ETA Assembling: Reassembling the steering crown unit / arch-slider assembly A special spanner shall be used to assemble the bottom nuts. Do not, at any times, use other tools. Fit both dust seals (11) to the stanchions.
  • Page 22 © Marzocchi Suspension 2005 - MX Comp ETA Using introducer (A) insert the dust seals (11) in their seats. Assembling: Filling with oil Block the fork in the vice, in perfectly vertical position. Lower the crown-stanchion unit on the arch-slider assembly.
  • Page 23 © Marzocchi Suspension 2005 - MX Comp ETA Assembling: Assembling the top right cap Put the fork in the vice in vertical position, fixing it by the dropouts. Check that O-ring is not damaged. Using the 21mm socket spanner, tighten cap (2) to the recommended tightening torque (10 Nm ± 1).
  • Page 24 © Marzocchi Suspension 2005 - MX Comp ETA Fit the protection cap (1). Assembling: Assembling the top left cap Screw the lock cap (2) down on the rod of the ETA cartridge without tightening being very careful not to damage the O-ring.
  • Page 25 © Marzocchi Suspension 2005 - MX Comp ETA...

  • Page 26: Rs/R>A

    During setting don't force the adjusters beyond their limit of travel and don't exceed the max recommended air pressure. To keep the pressure inside the fork’s legs, only use the special MARZOCCHI pump with pressure gauge. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.
  • Page 27 © Marzocchi Suspension 2005 - MX Comp ETA The pressure values in the table are given as a mere example and can be changed to meet the biker’s riding style and the track condition. Setting: Rebound adjustment Right fork leg: With the rebound adjuster you can control the return speed of the fork after compression.
  • Page 28 © Marzocchi Suspension 2005 - MX Comp ETA Pos: UNLOCK Turning knob (A) counter-clockwise brings the fork back to normal function and deactivates the ETA cartridge. NEVER use the "LOCK" position when riding on steep downhills. Failure to comply with these instructions could cause your fork not to react safely enough when hitting an obstacle, resulting in a loss of control of the bicycle, damage and serious or lethal injury.
  • Page 29 © Marzocchi Suspension 2005 - MX Comp ETA Tightening torques Components Tightening torque (Nm) Air pressures Positive air pressure User weight Air pressure 55 - 70 121 - 154 2,00 - 2,75 2.900,00 - 3.987,50 70 - 80 154 - 176 2,40 - 3,10 3.480,00 - 4.495,00 80 - 95 176 - 209 2,90 - 3,80 4.205,00 - 5.510,00...
  • Page 30 © Marzocchi Suspension 2005 - MX Comp ETA...

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