Marzocchi Marathon XC 2005, Technical Instructions

Page 1: ...2005 Marathon XC Technical instructions Marzocchi Suspension 2005 Marathon XC ...

Page 2: ...A 1 31 5321264 1 32 520220KV 1 33 5141137 A 1 34 525007 1 37 528239 A 1 39 528224 1 40 521209 1 41 528243 1 42 703715LA C 1 43 522446 1 44 5141276 C 1 54 523295 1 56 533301 2 57 523261 2 58 528172NOK B 2 59 538113 2 60 538112 2 62 850779 C 1 63 5321182RS R A 1 63 5321182RR R A 1 63 5321182SS R A 1 63 5321182SR R A 1 64 5321115QF 2 65 5321114 2 66 5321106 2 67 547603 1 68 528046 2 69 5321270 1 70 5...

Page 3: ...4 5321295 TST NUT 1 15 523294 STOP RING 1 16 522447 WASHER 1 17 528278 SEAL 1 20 528018 O RING 2 21 522244AA WASHER 1 22 703722 C TST CARTRIDGE MARATHON SL 05 1 23 524189 PISTON RING 1 24 524185 PISTON RING 1 25 309727 R TST PISTON SHAFT 1 26 804094 R TST BUSHING UNIT 1 27 5321265 INNER ROD 1 28 528193 O RING 1 29 528223 O RING 1 30 521142IW A NUT 1 31 5321264 BOTTOM PLUG 1 32 520220KV ALLEN BOLT ...

Page 4: ...63 5321182SR R A SILVER DUST MONOLITE UNIT 1 64 5321115QF CANTILEVER PIN 2 65 5321114 PIN ADAPTOR 2 66 5321106 RUBBER 2 67 547603 LH RH LABELS MARATH XC COIL 05 1 68 528046 O RING 2 69 5321270 NUT UNIT 1 70 549085AQ ADJUSTER KNOB 2 71 520278 SCREW 2 72 5321262 TAS NUT UNIT 1 73 528030 O RING 1 74 5181345 R TST BODY 1 75 5321158 A CABLE GUIDE 1 76 528005 O RING 2081 1 Marzocchi Suspension 2005 Mara...

Page 5: ...hreadless Crown BAM aluminium 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 Springs constant pitch Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents ...

Page 6: ...ching 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 your work area ...

Page 7: ... 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 the recommended tightening torque 9 Nm 1 On the thread of bolts D a special anti unscrewing treatment has been applied as a result the removed bolts cannot be re used as they lose such treatment Warnings Assembling the wheel Install the w...

Page 8: ...2 of the TST control knob Remove the TST control knob 3 Remove pin 4 and spring 5 Using a small pin screwdriver blow the air off the fork leg pushing on the air valve Fully unscrew lock cap 1 with the 21mm socket spanner Dismantling Removing the top left cap With a 2mm Allen wrench loosen screw 4 Remove first the screw 4 then the ETA control knob 5 Marzocchi Suspension 2005 Marathon XC ...

Page 9: ...o you can reach locknut 6 with the 10mm spanner Holding locknut 6 with the 10mm spanner use the 21mm spanner to fully unscrew lock cap 2 Remove lock cap 2 Dismantling Draining the oil Remove washer 1 and spring 2 from the left leg Lift the right leg cap 1 from the crown unit Marzocchi Suspension 2005 Marathon XC ...

Page 10: ...o not use other tools Turn the arch slider assembly upside down With a 2mm Allen wrench loosen the screw 5 fixing the rebound adjustment knob 6 from the right leg Remove the rebound adjustment knob 6 Using the special 12mm spanner A loosen the right bottom nut 7 Pull out the bottom nut 7 complete with O ring 8 Take great care not to damage the O ring on the pumping element rod With a 2mm Allen wre...

Page 11: ...at care not to damage the O ring on the pumping element rod Pull the crown stanchion unit 3 off the arch slider assembly 4 Dismantling Dismantling the TST cartridge Click here to view the video instructions Dismantling Dismantling the TAS cartridge TAS Click here to view the video instructions ETA Click here to view the video instructions Marzocchi Suspension 2005 Marathon XC ...

Page 12: ... Marzocchi Suspension 2005 Marathon XC ...

Page 13: ...DOPPIO AIR cartridge Click here to view the video instructions 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 Insert the crown stanchion unit 3 in the arch slider assembly 4 Insert the complete TST cartridge 10 in the right leg With the spec...

Page 14: ...ue 2 Nm 0 5 Using the special 12mm key A tighten the bottom nut of the right leg 7 complete with O ring 8 to the recommended torque 10 Nm 1 Fit the TAS adjustment knob 16 to the left leg Be careful not to damage the O ring at the end of the pumping rod Tighten the fixing screw of knob 16 to the recommended torque 2 Nm 0 5 Using introducer A insert the dust seals 11 in their seats Marzocchi Suspens...

Page 15: ...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 A lower or higher volume or a type of oil other than the one recommended can change the behaviour of the fork in every phase Lift the crown stanchion unit on the arch slider assembly Insert washer 2 and spring 1 in the left leg Marzocchi Suspe...

Page 16: ... Using the 21mm socket spanner tighten cap 2 to the recommended tightening torque 10 Nm 1 Insert spring 5 and pin 4 Fit the TST control knob 3 Using the 2mm Allen wrench tighten screw 2 of the TST control knob to the recommended tightening torque 2 Nm 0 5 Restore the correct air pressure see settings Assembling Assembling the top left cap Marzocchi Suspension 2005 Marathon XC ...

Page 17: ...n cap 1 Screw the lock cap 2 down on the rod of the ETA cartridge without tightening being very careful not to damage the O ring Push washer 7 and the preload tube 8 downwards so you can reach locknut 6 with a 10mm spanner Using the 10mm and 21mm spanners tighten locknut 6 on cap 2 to the recommended tightening torque 6 Nm 1 Fit the control knob 5 washer 3 and screw 4 Using a 2mm Allen key tighten...

Page 18: ...Fit the ETA control knob 5 washer 3 and screw 4 Using a 2mm Allen key tighten the knob fixing screw 4 to the recommended tightening torque 2 Nm 0 5 Marzocchi Suspension 2005 Marathon XC ...

Page 19: ... 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 SAG On the leg portion of t...

Page 20: ... 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 TAS Left fork leg The TAS cartridge lets you adjust the maximum travel and length to adapt the fork to th...

Page 21: ...ownhills 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 Setting TST Right fork leg The TST system lets you set the fork damping With the 5 position control the biker can select the best setting in relation to the track condition DS best downhill set...

Page 22: ...t knob fixing screws 2 0 5 TAS knob fixing screws 2 0 5 Top caps on fork cartridge 6 1 TST knob locking screws 2 0 5 V brake locking pins 9 1 User weight Air pressure kg lb bar psi 55 70 121 154 2 00 2 900 00 70 80 154 176 2 00 2 75 2 900 00 3 987 50 80 95 176 209 2 75 3 40 3 987 50 4 930 00 95 110 209 242 4 20 6 090 00 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 40 Left fork leg S...

Page 23: ...d Oil is too fluid Check oil levels Fork stays down or packs up during multiple impacts Rebound damping is too high Decrease rebound damping with the relevant register Front wheel tends to tuck under while turning left or right Rebound damping is too high Decrease rebound damping with the relevant register Heavy amount of oil on stanchions oil dripping down legs Sealing rings damaged Renew all sea...