Marzocchi Jr. T, Manual

Page 1: ...Jr T Q R 2 0 yyy yyy 45 37 9 12 13 18 17 16 15 14 28 34 11 4 2 10 8 6 20 39 40 3 26 32 31 31A 31B 33 21 22 7 8A 25 24 1 35 36 36 36 19 29 30 38 23 27 44 41 42 43 ...

Page 2: ... cooled and lubricated by a specially formulated oil Brake caliper adapter available fits onto LH slider Steer tube in CrMo steel with variable butting Several lengths available in non threaded 1 1 8 diameters EASTON aluminum steer tubes available for 1 1 8 threadless Crown Forged and CNC machined BAM aluminum alloy Upper plate CNC machined T6 6082 alloy Arch CNC machined ERGAL alloy Stanchions An...

Page 3: ...iswelltightened thentighten the second screw and then go back to the first one and screw it tighter 4 Clean all metal parts with a special preferablybiodegradablesolvent such as trichloroethane or trichloroethylene 5 Before reassembling lubricate all parts in contact with each other using sili cone fat spray or a specific oil for oil seals 6 Always grease the conic seal rings before reassembling 7...

Page 4: ...ing seal Excessive oil build up on stanchions 1 Oil seal is worn out 2 Stanchion tube is scored 3 Excessive dirt on oil seal 1 Replace oil seal 2 Replace oil seal and stanchion tube 3 Clean the oil seal seat and replace oil seal Fork has not been used for some time and is locked out Oil seals and dust seals tend to stick to stanchion tube Raise dust seal and lubricate stanchion tube dust seal and ...

Page 5: ... factory It will need to be cut to the required length for a proper fit Always have the installation checked at one of our Technical Service Centers WARNING A Head Set head set Steering tube mounting and adjustment must be carried out in compli ance with the headset manufacturer s in structions Improper installation may jeop ardize the safety of the rider Have steer tube replaced at an authorized ...

Page 6: ...per plate 35 If fork legs overprotrude fit some spacers D to the plate close to the steer tube 35 D 13 FIG D Fit the handlebar support and the A Head Set plug over the upper plate 35 and then adjust the steering Now finally tighten the 3 bolts 36 on the upper plate to 9 Nm IMPORTANT Loosenthe3screws 36 on the upper plate before ad justing the steering Tighten the above bolts to the specified torqu...

Page 7: ...e of bolts fastening stan chion tube onto lower crown and up per plate proper torque of bolts fastening brake arch onto slider 11 Nm 28 13 Nm 11 FIG E If the crown 34 position with respect to thestanchiontubes 13 hasbeenchanged for any reason adjust the original dis tance Distance H between crown and tyre edge when inflated should not be lower than total travel 130 mm 3 mm WARNING If steering crow...

Page 8: ... designed to fit this type of hub Do not use any hub design other than that specified here as this would not ensure proper fastening of the wheel and may lead to breakdown of the assembly components DISC BRAKE SYSTEM ASSEMBLY FIG H Assembling the brake caliper onto the slider is a very delicate operation that should be carried out with extreme care Improper assembly might overstress the caliper su...

Page 9: ...e the right Jr T response in accordance with the rider s weight and riding style 2 REBOUND DAMPING ADJUSTMENT FIG L The adjuster controlling REBOUND damp ing adjustment is accommodated inside cartridge rod 11 inside each fork leg To access the adjuster unscrew the top caps 37 and push the stanchion tubes fully down see Fig 1 Slide out the pre load sleeve 1 Fit the supplied hexagon rod C into the s...

Page 10: ...s the quickest procedure and the exact disassembling sequence Start from the part to be disassembled and then follow the arrows to remove the other parts DISASSEMBLY DIAGRAM SPRING FIG 2 FOOT BUFFER FIG 10 CARTRIDGE ROD FIG 10 FOOT NUT FIG 3 STANCHION TUBE CAP FIG 1 DUST SEAL FIG 5 STOP RING FIG 6 OIL SEAL FIG 7 CARTRIDGE ROD CHANGE VALVE ASSEMBLY CHANGE STOP RING FIG 11 VALVE ASSEMBLY FIG 11 GUID...

Page 11: ...ube into the slider and removetheupperwasher 27 thepreload sleeve 1 and the spring 9 Make all necessary changes GUIDE BUSHING AND SEAL ASSEMBLY CHANGE FIG 3 Let all the oil drain out WARNING Remember to always recycle any used oil To change the fork leg oil follow the procedure as described in section REASSEMBLY from Fig 22 to Fig 25 Turn the fork leg upside down and un screw the foot nut 22 compl...

Page 12: ...5 FIG 5 Remove the dust seal 14 from the top of slider using a small screwdriver FIG 6 Remove the stop ring 15 from the slider by placing the screwdriver bit in one of the three openings on the stop ring IMPORTANT when removing the stop ring make sure not to damage its seat ...

Page 13: ...RTANT when removing the oil seal make sure not to damage its seat Do not reuse any oil seals you have removed 16 A 17 18 FIG 8 Remove the upper washer 17 from the slider FIG 9 Fit the bit of a small screwdriver into upper edge slot of the guide bushing 18 and lift gently Pull the bushing out of the slider and make all necessary changes ...

Page 14: ... the stanchion tube opposite side Replace the seal ring 26 if damaged or worn out 26 12 33 11 32 31 VALVE UNIT CHANGE FIG 11 To check that the valve unit is operating correctly it is necessary to work on the inside of the stanchion tube Slip off the stop ring 32 using pointed pliers Put the valve unit 31 out of the tube in the same sequence as in the figure ...

Page 15: ...s or dirt lodged be tween slider and bushing Insert the guide bushing 18 into the slider making sure it becomes properly seated against slider walls 18 17 16 B FIG 13 Fit the upper washer 17 into the slider so that it comes in contact with the guide bushing FIG 14 Lubricate the oil seal 16 and fit it onto the seal press B its hollow side toward the slider Press the oil seal until it touches the lo...

Page 16: ...ROD ASSEMBLY FIG 16 After having overhauled or replaced the valve unit and after having cleaned the inside of the tube reassemble Assemble valve unit components 31 in correct sequence Then fit cartridge rod 11 seal ring 26 and rebound spring 12 into the valve unit 31 FIG 17 Reassemble the foot buffer 33 onto the end part of cartridge rod 11 ...

Page 17: ...it the stanchion tube 13 gently into the oil seal 16 Rotate the stanchion tube while inserting it into the seal to reduce the chance of damaging the seals Turn the slider over and check that car tridge rod thread 11 is sticking out through the slider hole If not so press on hexagon rod to push out cartridge rod FIG 20 Lubricate the dust seal 14 and seat it into the stanchion ...

Page 18: ...lidesproperlythrough the stroke 22 21 Nm 12 95 9 HOW TO FILL WITH OIL FIG 22 Pour the oil little by little when the stan chion tube is fully down and then pump stanchion tube up and down so as to have a better filling Check that the oil level is 95 mm 3 74 in from the top of the stanchion tube in both legs SPRING AND PRELOAD CAP FIG 23 Fit the spring 9 into the stanchion tube ...

Page 19: ...g 6 on the cap 5 Turn the plunger 7 inside the cap counterclockwise until it is at its minimum setting Start the complete cap assembly onto stanchion tube thread by hand Tighten to 12 Nm Fit the brake arch to the fork leg and then install fork legs into crown and upper plate as specified in section INSTALLA TION Nm 12 5 6 ...

Page 20: ...IFIC TOOLS Ref Item Description and use A 536003 AB Slider protector to remove the oil seal from the slider B R 5068 Oil seal press to press oil seal into the slider C R 5084 Hexagon wrench to set rebound adjuster B C A ...