Marzocchi Marathon SL, Manual

Page 1: ...C 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 Sliding bushes made of friction free and wear free material Seals computer designed oil seals that guarantee the maximum seal in any condition Oil s...

Page 2: ...Marathon SL 2 48 Features ...

Page 3: ...on SL 3 48 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 ...

Page 4: ...ter every use and to lubricate the parts with some silicone oil MARZOCCHI forks usually offer the best performances since the very first rides Notwithstanding this a short running in period may be necessary 5 10 hours to adjust the internal couplings This precaution will lengthen your fork s life and guarantee its best performances Changing the oil every 100 hours is recommended The forks with a p...

Page 5: ...e not completely biodegradable in the environment these must be collected and kept in the relevant special containers then disposed of in accordance with the regulations in force Always grease the seal lips before reassembling Use only metric spanners and not imperial Imperial spanners may have similar sizes to metric ones but they can damage the bolts and screws making it impossible to unscrew th...

Page 6: ... tube must be carried out following the instructions of the steering set manufacturer 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 its replacement must be carried out by one of our service centres using the adequate to...

Page 7: ...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 Improper installation can be dangerous for the rider Use only brake systems in accordance with the fork s specifications If the fork comes standard with V brake mounts remove such mounts and install the cable gui...

Page 8: ...of the brake system manufacturer Improper installation can be dangerous for the rider Use only brake systems in accordance with the fork s specifications If the fork does not come standard with V brake mounts after removing the cable guide A and the disk brake mount cap B install the adapter A and the bolt D on both legs check that the adapter is correctly oriented as shown and tighten the bolt to...

Page 9: ...tion of the fork and all of the parts linked to it mainly depend on the correct fixing of the front wheel For a correct operation of the fork install the wheel as explained below Check the correct fork wheel alignment by fully compressing the fork a few times Lift the front wheel above the ground turn the wheel a few times to verify the correct alignment with the disk brake ...

Page 10: ...Marathon SL 10 48 Diagnostic ...

Page 11: ... 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 REMOVING THE SEALS REMOVING THE GUIDE BUSHES ...

Page 12: ...g 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 Remove the ECC5 control knob 3 Remove pin 4 and spring 5 ...

Page 13: ...Marathon SL 13 48 Disassembling 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 ...

Page 14: ...sen and remove the protection cap 6 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 Now you can remove the caps from the cartridge rods It is however recommended to do this operation after having removed the cartridge from the arch slider assembly ...

Page 15: ...NING 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 Do not pour used oils on the ground ...

Page 16: ...NCHION 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 Pull the complete cartridges 10 off both fork legs ...

Page 17: ...Marathon SL 17 48 Disassembling Pull the crown stanchion unit 3 off the arch slider assembly 4 ...

Page 18: ...ssembling REMOVING THE CARTRIDGE RIGHT LEG 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: ...ng 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 On the thread of cap 4 a special anti unscrewing treatment has been applied Do not re use removed caps as they loose such treatment ...

Page 20: ...Marathon SL 20 48 Disassembling 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 ...

Page 21: ...Marathon SL 21 48 Disassembling Separate the cap from the rebound spring 6 If the segment 8 or the O rings 9 are worn out prize them off with a small flat tip screwdriver ...

Page 22: ...emove 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: ... 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 The old sealing rings and dust seals must not be used again ...

Page 24: ...o the extractor During use 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 ...

Page 25: ...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 With 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 ...

Page 26: ...Marathon SL 26 48 Assembling ASSEMBLING THE GUIDE BUSHES ...

Page 27: ...pecial 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 Using the long introducer A fit the bottom bush 1 Using a hammer knock the introducer A into the arch slider assembly ...

Page 28: ...Marathon SL 28 48 Assembling Using the short introducer B fit the bottom bush 2 Using a hammer knock the introducer B into the arch slider assembly ...

Page 29: ...ck in the introducer A and drive the sealing ring home into the arch slider assembly With a small tip screwdriver mount the stop ring 2 and check it fits perfectly into its groove Take great care not to damage the internal surfaces of the arch slider assembly when fitting the stop ring The dust seals shall be refitted when reassembling the crown stanchion unit arch slider assembly ...

Page 30: ...Marathon SL 30 48 Assembling MOUNTING THE CARTRIDGE RIGHT LEG Fit the lock cap 1 Insert the stop ring 8 and check it fits perfectly into its groove ...

Page 31: ...RTRIDGE 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 Do not re use the removed caps as they loose such treatment ...

Page 32: ...Marathon SL 32 48 Assembling 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 ...

Page 33: ...Marathon SL 33 48 Assembling Insert the cartridge rod 5 complete with plug 4 inside the liner Holding liner 3 firmly tighten cap 4 with a 19mm hexagonal wrench ...

Page 34: ...Marathon SL 34 48 Assembling 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 ...

Page 35: ...LING 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: ...rathon SL 36 48 Assembling 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 ...

Page 37: ...Marathon SL 37 48 Assembling Re assemble the dust seals 11 in their seats using the special introducer A ...

Page 38: ...nchion 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 Pour the rest of the oil in Lower again the crown stanchion unit on the arch slider assembly ...

Page 39: ... air properly and avoid to alter the reached values lower the lock caps on the fork crown as much as possible For the recommended air volumes consult our website www marzocchi com A lower or higher volume of air or a type of oil other than the recommended type can change the behaviour of the fork in every phase Lift the stanchions on the sliders ...

Page 40: ...ng 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 Insert spring 5 and pin 4 ...

Page 41: ...1 48 Assembling 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: ...ut 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 Restore the positive and negative air pressure see settings Hand tighten the protection cap 6 ...

Page 43: ...Marathon SL 43 48 Settings POSITIVE AIR NEGATIVE AIR ECC5 ...

Page 44: ...ge 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 Apply the same preload pressure to both fork legs Drawing in compressed air through the positive air valves A changes the damping of the forces resulting from the COMPRESSION of the fork legs For this adjustment fit the special pump adapter which comes standard with the fork...

Page 45: ... knob B Fit and tighten the pump adapter C on the valve Inflate till reaching the pressure you wish see table Refit knob B With a 2 5mm Allen wrench tighten screw A to the recommended tightening torque 2 Nm 0 5 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 ...

Page 46: ...on 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 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 ...

Page 47: ...r Drawing in compressed air through the negative air valve B changes the damping of the forces resulting from the REBOUND of the fork legs Install the pump adapter provided with the fork Loosen and remove the protection cap A on the left leg Screw the pump adapter C down on the central valve A Inflate till reaching the pressure you wish see table Refit and tighten the protection cap B The pressure...

Page 48: ... ll get the maximum rebound damping In this position the fork legs stay down when hitting an obstacle any other impact will lower the bike s geometry further This position is suitable for steep uphills Pos 2 3 4 Turning the knob counter clockwise reduces the rebound resistance Pos 5 MINIMUM REBOUND DAMPING Turning the knob fully counter clockwise you ll reach the minimum rebound damping and the ma...