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Features

TECHNICAL CHARACTERISTICS

Fork with 30 mm legs with spring andhydraulic rebound damping.

Adjustment of the hydraulic reboundbraking through the adjuster in the right leg.

Adjustment of the air preload on both legs.

The stanchion tubes are pressed into thecrown with a cryogenic process.

New sliding system to improve the stiffnessand operation.

Magnesium alloy cast one-piece assembly,

CNC machined for lighter weight and morestiffness.

Components subjected to friction arelubricated and cooled by means of aspecial oil.

Steer tube: steel or (optional) aluminium,

1-1/8", threadless.

Crown: BAM aluminium alloy forged andCNC machined.

Stanchions: anodised aluminium.

Springs: constant pitch.

Sliding bushes: made of friction free andwear free material.

Seals: computer designed oil seals that

guarantee the maximum seal in anycondition.

Oil: special formulated oil that preventsfoam and keeps the viscosity unchangedwhile offering high performance; free fromstatic friction.

Dropout type: Standard.

Disk brake mount: XC InternationalStandard for 6" disk.

V-Brake fit.

BAM: Bomber Aerospace Material:

special alloy coming from the aerospaceindustry.

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Features

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Warning

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

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Warning

INSTRUCTIONS FOR USE

MARZOCCHI forks are based on anadvanced technology coming from thecompanys years long experience in theprofessional mountain bike industry.

For the best results, it is advisable toinspect and clean the area below the dust

seal and the stanchion tube after every useand to lubricate the parts with somesilicone oil.

MARZOCCHI forks usually offer the bestperformances since the very first rides.Notwithstanding this, a short running-inperiod may be necessary (5-10 hours) to

adjust the internal couplings. Thisprecaution will lengthen your forks life andguarantee its best performances.

Changing the oil every 100 hours isrecommended.

The forks with a polished finish must be

treated periodically with polishing paste tokeep the exterior shining like new.

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Warning

GENERAL REGULATIONS

After a complete breakdown, always usenew MARZOCCHI seals whenreassembling.

Before reassembly, wash all new and oldcomponents and dry them with somecompressed air, making sure there are

neither breaks nor burrs.

Never use flammable or corrosivesolvents to clean the parts as this coulddamage the seals. If necessary use specificdetergents that are not corrosive, notflammable or have a high flash pointcompatible with the materials of the seals

and preferably biodegradable.

Before reassembling, always lubricate theparts of the fork in contact with some oil forforks.

Never pour lubricants, solvents ordetergents which are not completely

biodegradable in the environment; thesemust be collected and kept in the relevantspecial containers, then disposed of inaccordance with the regulations in force.

Always grease the seal lips beforereassembling.

Use only metric spanners and notimperial. Imperial spanners may havesimilar sizes to metric ones but they can

damage the bolts and screws making it

impossible to unscrew them.

Use the right size and sort of screwdriverto unscrew slotted or crosshead screws.

When using a screwdriver to assemble ordismantle metal stop rings, O-ring seals,guide bushes or seal segments, avoid

scratching or cutting the components withthe tip of the screwdriver.

Use only original spare parts.

Before servicing the fork, we recommendwashing the fork thoroughly.

Work in a clean, ordered and well-lit place.

Carefully check there are no metalshavings in the work area.

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Warning

FITTING THE FORK ONTO THE FRAME

The fork is supplied with A-Head Set steertube to be cut according to frame size it willbe used on.

Fitting the fork onto the bike frame is a verydelicate operation that must be carried outat one of our service centres only.

The assembling on the frame and theadjustment of the steer tube must becarried out following the instructions of thesteering set manufacturer.

A wrong installation can be dangerousfor the rider.

Marzocchi does not guarantee theassembly and accepts no liability fordamage and/or accidents arising from awrong installation.

The steer tube must be pressed into thecrown; its replacement must be carried

out by one of our service centres usingthe adequate tools.

A wrong installation of the steer tubeinto the crown may cause the rider tolose the control of the bike and lead toserious personal injury.

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Warning

INSTALLING THE DISK BRAKE SYSTEM

Installing the brake system is a verydelicate operation that must be carried outat our specialised service centres only.

Marzocchi does not guarantee theinstallation and accepts no liability fordamage and/or accidents arising from a

wrong installation

Improper installation of the disk brakesystem can overstress the calipermountings, which may break. Theinstallation of the brake system must becarried out following the instructions ofthe brake system manufacturer.

Improper installation can be dangerousfor the rider.

Use only brake systems in accordance withthe forks specifications.

If the fork comes standard with V-brakemounts, remove such mounts andinstall the cable guide (A) on the leftside and cap (B) on the right side.

After installation always check that thebrake tube is correctly fixed to thespecial mount (A).

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Warning

INSTALLING THE V-BRAKE SYSTEM

Installing the brake system is a verydelicate operation that must be carried outat our specialised service centres only.

Marzocchi does not guarantee theinstallation and accepts no liability fordamage and/or accidents arising from a

wrong installation.

The installation of the brake systemmust be carried out following theinstructions of the brake systemmanufacturer. Improper installation canbe dangerous for the rider.

Use only brake systems in accordance withthe forks specifications.

If the fork does not come standard withV-brake mounts, after removing thecable guide (A) and the disk brakemount cap (B), install the adapter (A)and the bolt (D) on both legs, check thatthe adapter is correctly oriented asshown and tighten the bolt to therecommended tightening torque (111Nm).

On the thread of bolts (D) a specialanti-unscrewing treatment has beenapplied; as a result, the removed boltscannot be re-used as they lose suchtreatment.

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Warning

ASSEMBLING THE WHEEL ON FORKS

WITH STANDARD DROPOUTS

Install the wheel following theinstructions of the bikes manufacturer.

A good and reliable operation of the forkand all of the parts linked to it mainlydepend on the correct fixing of the front

wheel.

For a correct operation of the fork, installthe wheel as explained below:

Check the correct fork-wheel alignment byfully compressing the fork a few times.

Lift the front wheel above the ground; turnthe wheel a few times to verify the correctalignment with the disk brake.

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Diagnostic

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Disassembling

REMOVING THE TOP CAPS

DRAINING THE OIL

BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY

BREAKING DOWN PUMPING ELEMENT AND VALVE

REMOVING THE SEALS

REMOVING THE GUIDE BUSHES

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Disassembling

REMOVING THE TOP CAPS

Put the fork in the vice in a verticalposition, fixing it by the dropouts.

Remove the protection cap (1).

Using a small pin screwdriver, blow the airoff the fork leg pushing on the preload valve.

Fully unscrew the lock cap (2), using a21mm socket spanner.

Remove the lock cap (2).

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Disassembling

DRAINING THE OIL

Remove the preload tube (1) and spring (2).

Free the fork from the vice and tip it into acontainer of a suitable size to drain the oil;compress the fork a few times to help theoil flow out.

Do not pour used oils on the ground.

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Disassembling

BREAKING DOWN THECROWN-STANCHION UNIT /ARCH-SLIDER ASSEMBLY

Use the special spanner to remove thebottom nuts. Do not use other tools.

Turn the arch-slider assembly upsidedown.

Using the special 12mm spanner (A),loosen the two bottom nuts (1).

Remove the bottom nuts (1) and theO-rings (2).

Pull the crown-stanchion unit (3) off thearch-slider assembly (4).

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Disassembling

BREAKING DOWN PUMPING ELEMENTAND VALVE

Remove the bottom pad (1).

Using the round-nose pliers remove thestop ring (2).

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Disassembling

Pull out the pumping element (3) completewith rebound spring and valve.

Remove bushing (4), valve (5), three-pointring (6) and rebound spring (7) from thepumping element.

Pull out the preload tube (9) (only formodels with 105mm travel).

If the piston segment (8) is damaged,prize it off with a small flat-tip screwdriver.

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Disassembling

REMOVING THE SEALS

Remove the dust seal (1) from its seat,using a small flat-tip screwdriver.

With the same screwdriver prize off themetal stop ring (2).

Take great care not to damage theinternal surfaces of the arch-sliderassembly when removing the dust sealand the stop ring.

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Disassembling

Protect the upper part of the slider with thespecial tool (A).With a screwdriver prize the sealing ring (3)off.Remove the sealing ring (3).

Take great care not to damage theinternal surfaces of the arch-sliderassembly when removing the sealingring.

The old sealing rings and dust sealsmust not be used again.

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Disassembling

REMOVING THE GUIDE BUSHES

Use the special extractor to remove theguide bushes. Do not use other tools.

Fit the aluminium bush (A) to the extractorkeeping the small diameter side towardsthe edge opposite to the striker.

Fit the extraction washer (B) with a whitefinish to the extractor.

During use, remove the non-usedwasher from the extractor.

Remove first the top bushes, then thebottom bushes.

Fit the extraction washer keeping the bluntside towards the threaded grubscrew (C)fixed crosswise on to the main rod asshown.

The slot in the rod lets the extractionwasher swing inside the rod itself.

Insert the extractor in the arch-sliderassembly from the side of washer (B) asshown.

The slot in the extractor rod will let thewasher pass underneath the bush to beextracted.

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Disassembling

Pull the extractor rod so that the upper faceof the washer stops against the lower faceof the guide bush.

Insert the aluminium bush (A) in the seat ofthe sealing ring.

While holding the main rod in position, thealuminium bush drives the guide bushesduring extraction.

With striker (D) knock out and extract theguide bush (1).

Remove the guide bush (1) from theextractor.

Repeat the steps above to remove the

bottom guide bush.

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Assembling

ASSEMBLING THE GUIDE BUSHES

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Assembling

ASSEMBLING THE GUIDE BUSHES

Insert the guide bushes using thespecial introducers (short type for thetop bush and long type for the bottombush, both with a black finish). Do notuse other tools.

Fit first the bottom bushes, then the topbushes.

Using the long introducer (A) fit the bottombush (1).

Using a hammer knock the introducer (A)into the arch-slider assembly.

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Assembling

Using the short introducer (B) fit the bottombush (2).

Using a hammer knock the introducer (B)into the arch-slider assembly.

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Assembling

ASSEMBLING THE SEALS

Smear the dust seal and the sealing ringwith some grease.

Refit the sealing ring (3) using the specialintroducer (A).

Using a hammer knock in the introducer (A) and drive the sealing ring home into the

arch-slider assembly.

With a small tip screwdriver mount thestop ring (2) and check it fits perfectly intoits groove.

Take great care not to damage theinternal surfaces of the arch-slider

assembly when fitting the stop ring.

The dust seals shall be refitted whenreassembling the crown-stanchion unit /arch-slider assembly.

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Assembling

ASSEMBLING PUMPING ELEMENT ANDVALVE

Replace the piston segment (8) ifnecessary.

Insert the preload tube (9) (only for modelswith 105mm travel) and the rebound spring (7) in the piston rod.

Assemble the valve unit in this order:bushing (4), valve (5), three-point ring (6)and check that the parts are oriented asshown.

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Assembling

Insert the pre-assembled valve in thepiston 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 thesegment and if necessary use a smallflat-tip screwdriver to help the piston of

the pumping element into the stanchion.

Using the special round-nose pliers,mount the stop ring (2) and check it fitsperfectly into its groove.

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Assembling

Fit the bottom pad (1) to the pumpingelement rod.

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Assembling

ASSEMBLING THE CROWN-STANCHIONUNIT / ARCH-SLIDER ASSEMBLY

A special spanner shall be used toassemble the bottom nut. Do not useother tools.

Fit the dust seals (11) to the stanchions.

Insert the crown-stanchion unit (3) in the

arch-slider assembly (4).

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Assembling

With the special 12mm spanner (A),tighten the bottom nut (1) with O-ring (2) of

both legs to the recommended tighteningtorque(11 Nm1).

Reassemble the dust seals (11) in theirseats using the special introducer (A).

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Assembling

FILLING WITH OIL

Put the fork in the vice in vertical position.

Lower the crown-stanchion unit on thearch-slider assembly.

Prepare the quantity of oil to pour into thefork leg (see table).

Pour roughly 1/3 of the oil required intoeach stanchion, then pump the fork a fewtimes to remove any traces of air.

Pour the rest of the oil in.

Lower again the crown-stanchion unit onthe arch-slider assembly.

Wait for a few minutes and check thevolume of the air (h); if necessary refill tothe right level.

A lower or higher volume of air, or atype of oil other than the recommendedtype can change the behaviour of the

fork in every phase.

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Assembling

Lift the crown-stanchion unit on thearch-slider assembly.

Insert spring (2) and the preload tube (1).

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Assembling

MOUNTING THE TOP CAPS

Put the fork in the vice in vertical position,fixing it by the dropouts.

With the 21mm socket spanner, tightenthe lock cap (2) to the recommendedtightening torque (20 Nm1).

Restore the preload pressure (see

settings).

Fit the protection cap (1).

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Settings

AIR PRELOAD

REBOUND ADJUSTMENT

MX C C ilS i

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Settings

AIR PRELOAD

Use the MARZOCCHI pump with pressuregauge to inflate the fork legs.

Using inadequate tools may lead to awrong inflation and result in amalfunctioning or damage to the fork.

To reduce the legs pressure, simply push

the valve pin down with a pointed tool suchas a small pin extractor.

Apply the same preload pressure toboth fork legs.

Drawing in compressed air through valve (A) changes the damping of the forces

resulting from the COMPRESSION of thefork legs.

Adjusting the legs pressure increases thepreload.

To increase the pressure in the fork leg:

Remove the protection cap (B).

Tighten the threaded adapter on the pump.

Inflate till reaching the pressure you wish(see table).

Refit the protection cap (B).

The pressure values in the table are given

as a mere example and can be changed tomeet the bikers riding style and the track

condition.

MX C C ilS tti

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Settings

REBOUND ADJUSTMENT

With the 21mm socket spanner, loosenthe lock cap (A).

Remove the lock cap (A).

Insert the hexagon rod (B) provided in thestanchion being careful to center the notchof the adjusting screw (C).

Turning the adjusting screwcounter-clockwise increases the hydraulicdamping making the fork slower during therebound phase.

Turning the adjusting screw clockwisedecreases the hydraulic damping making

the fork more responsive during therebound phase.

Do not force the adjusting screw (C)beyond its limit stops.