Marzocchi 66 SL 150, Technical Instructions

Page 1: ...2006 66 SL Technical instructions Marzocchi Suspension 2006 66 SL ...

Page 2: ...31 522472 1 33 522429 1 34 523295 1 35 5181433 R 1 36 521142IW A 1 42 703747LA C 1 43 523011 1 44 547717 1 44 547665 1 44 547687 1 47 533167 2 48 523236 2 49 528034 B 2 50 538038 A 2 51 538128 A 2 52 5321369RS C 1 52 5321369RR C 1 52 5321369TK C 1 52 5321369TI C 1 52 5321369TH C 1 53 520341 1 54 5321153 A 1 55 547708 1 56 850956 C 1 57 520349LA 1 58 528051 2 60 528030 2 61 549090KR B 1 62 522244AA...

Page 3: ...RING 1 19 528174 O RING 1 20 538075 BUSHING 1 21 522428 SPACER 1 22 528271 SEAL 1 23 547705 ALLOY STEM LABELS 1 23 547706 DOUBLE AIR LABEL 1 23 547713 EXT REBOUND ADJ MTB 06 LABEL 1 23 547711 RC2 LABEL 1 25 523272BZ STOP RING 1 26 536103 SPRING GUIDE 1 27 5141237 REBOUND SPRING 1 28 309763 R AIR SHAFT 66SL 06 1 29 524176 PISTON RING 1 30 528272 OIL SEAL 1 31 522472 66 PLUG SPACER 1 33 522429 WASHE...

Page 4: ...A CABLE GUIDE 1 55 547708 EXTER COMPRESS ADJUST LABEL 1 56 850956 C replaces R5127LA AXLE SCREW KIT 66 888 1 57 520349LA AXLE SCREW QR 20 1 58 528051 O RING 2 60 528030 O RING 2 61 549090KR B replaces 549090KR A COMPRESSION ALUM KNOB 1 62 522244AA WASHER 1 63 520278 SCREW 1 64 520178PN SCREW 4 65 526145 A BUSHING 2 66 5321387 NUT UNIT 66 888 FORK 06 2 69 531063 A AIR CUP 1 70 526143RX FENDER BUSHI...

Page 5: ...um alloy forged and CNC machined Stanchions anodised aluminium One piece assembly made of magnesium alloy cast and CNC machined for lighter weight and more stiffness Sliding bushings made of friction free and wear free material Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents foam and keeps the viscosity unchanged while offer...

Page 6: ...nts avoid scratching or cutting the components with the screwdriver tip Do not carry out any maintenance and or adjustment operations that are not explained in this manual Only use original Marzocchi spare parts Before servicing the fork we recommend washing the fork thoroughly Work in a clean organized and well lit place If possible avoid servicing your forks outdoors Carefully check to see that ...

Page 7: ... wheel and the left dropout With the 6mm Allen wrench act on cap 2 and tighten the wheel axle to the recommended tightening torque 15 Nm 1 Check for the proper fork wheel alignment To do this begin by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Then lift the front of the bicycle and spin the wheel a few times to verify the ...

Page 8: ...g 4 loosen and remove the central cap 5 and free the protection cap 1 Remove the protection cap 1 Using a small pin screwdriver blow the air off the fork leg pushing on the air valve Fully unscrew lock cap 2 with the Shimano TL LR10 lockring tool Remove lock cap 2 being careful not to damage O ring 3 Dismantling Removing the top left cap Remove the protection cap 1 Marzocchi Suspension 2006 66 SL ...

Page 9: ...right leg cap 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 Do not pour used oils on the ground Dismantling Breaking down the steering crown unit arch slider assembly Use the special spanner to remove the bottom nuts Do not use other tools Turn the arch slider assembly upside ...

Page 10: ... 1 Pull out the right bottom nut 1 complete with O ring 2 Pull the complete RC2 cartridge 9 off the right leg Using the special 15mm spanner loosen the left bottom nut 1 Pull out the left bottom nut 1 complete with O ring 2 Pull the complete DOPPIO AIR cartridge 9 off the left leg Marzocchi Suspension 2006 66 SL ...

Page 11: ... a 10mm fixed spanner The hydraulic 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 Dismantling the DOPPIO AIR cartridge Click here to view the video instructions Dismantling Removing the seals Marzocchi Suspension 2006 66 SL ...

Page 12: ...prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the one piece assembly while removing the stop ring With the same screwdriver prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the one piece assembly while removing the stop ring Protect the upper part of the slider with the special tool A With a screwdriver prize off the se...

Page 13: ...e remove the non used washer from the extractor Remove first the top bushes then the bottom bushes Fit the extraction washer keeping the blunt side towards the threaded grubscrew C fixed crosswise on to the main rod as shown The slot in the rod lets the extraction washer swing inside the rod itself Insert the extractor in the arch slider assembly from the side of washer B as shown The slot in the ...

Page 14: ...he sealing ring While holding the main rod in position the aluminium bush will drive the guide bushes during extraction Using striker D knock out and extract the guide bush 1 Remove the guide bush 1 from the extractor Repeat the steps above to remove the bottom guide bush Pull the extractor rod so that the upper face of the washer stops against the lower face of the guide bush Insert the aluminium...

Page 15: ... Marzocchi Suspension 2006 66 SL ...

Page 16: ...the top bushes Using the long introducer A fit the bottom bush 1 Using a hammer knock the introducer A into the arch slider assembly Using the short introducer B fit the top bush 2 Using a hammer knock the introducer B into the arch slider assembly Assembling Assembling the seals Smear the dust seal and the sealing ring with some grease Insert the sealing ring 3 in its seat with the special introd...

Page 17: ... assembly of the pumping unit strictly obey the instructions below Do not at any times reverse the position of the pumping elements in the fork legs if you are unsure about anything please refer to the relevant exploded view Assembling Assembling the RC2 cartridge Screw down nut 1 without tightening Assembling Assembling the DOPPIO AIR cartridge Click here to view the video instructions Assembling...

Page 18: ...ert the complete RC2 cartridge 9 in the right leg With the special 12mm spanner tighten the right bottom nut 1 complete with O ring 2 to the recommended tightening torque 10 Nm 1 Insert the complete DOPPIO AIR cartridge 9 in the left leg Marzocchi Suspension 2006 66 SL ...

Page 19: ...with oil Block the fork in the vice in perfectly vertical position Lower the crown stanchion unit on the arch slider assembly In a graduated recipient 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 eliminate any traces of air Pour the rest of oil in Marzocchi Suspension 2006 66 SL ...

Page 20: ... fork in the vice in vertical position fixing it by the dropouts Assembling Assembling the top right cap Check that O ring 3 is not damaged Using the Shimano TR RL10 lockring tool tighten lock cap 2 to the recommended tightening torque 10 Nm 1 Restore the correct air pressure see settings Fit the protection cap 1 By turning ring 4 screw down the central cap 5 and block the protection cap 1 Marzocc...

Page 21: ...Check that O ring 3 is not damaged Using the Shimano TR RL10 lockring tool tighten lock cap 2 to the recommended tightening torque 10 Nm 1 Restore the correct air pressure see settings Fit the protection cap 1 Marzocchi Suspension 2006 66 SL ...

Page 22: ...ing in an accident personal injury or death Once the correct setting has been found we recommend noting the number of clicks or turns of the adjuster with respect to the fully closed position adjuster fully clockwise for a faster re setting of your fork in case of need Setting SAG SAG means the fork bottoming under the biker s weight How to measure the SAG Follow these simple steps to measure the ...

Page 23: ...sing inadequate tools may lead to a wrong inflation and result in a malfunctioning or damage to the fork If you need to reduce the leg pressure simply push the valve pin down with a pointed tool such as a small pin extractor Left fork leg To increase the pressure in the fork leg Loosen and remove the protection cap Screw the pump adapter down on the internal valve and inflate till reaching the req...

Page 24: ...een one obstacle and the next Turning adjuster A clockwise increases the hydraulic damping making the fork slower during the rebound phase Turning adjuster A counter clockwise decreases the hydraulic damping making the fork more reactive during the rebound phase Do not force the adjuster beyond its limit of travel Setting Compression adjustment Right fork leg With the compression adjuster you can ...

Page 25: ...heel axle screws 15 1 User weight Air pressure kg lb bar psi 0 110 0 242 5 00 15 00 7 250 00 21 750 00 User weight Air pressure kg lb bar psi 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 95 110 209 242 3 60 4 50 5 220 00 6 525 00 User weight Air pressure kg lb bar psi 0 110 0 242 0 1 00 0 00 1 450 00 Position Oil type...

Page 26: ...too soft needs more than the maximum preload Oil is too fluid Check oil levels Fork is too soft needs more than the maximum preload Spring rate too soft Change to stiffer spring rate Fork is too soft needs more than the maximum preload Spring rate too soft Increase air pressure Fork reaches travel end too easily Compression damping is not enough Increase compression damping at travel end with the ...