Marzocchi QR20 Plus, Owner'S Manual

Page 1: ...MODEL YEAR 2004 ...

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Page 3: ...al may compromise the structural integrity of the suspension system and significantly reduce its lifespan Please have your bicycle regularly inspected by a qualified mechanic for any oil leaks cracks deformation or other signs of fatigue The frequency of inspection depends on many factors check with your authorized Marzocchi representative to select a schedule that is best for you If the inspectio...

Page 4: ...eight XC forks must only be used with tires specifically designed for cross country riding or disk rim or linear pull brakes Free Ride FR This riding style is for skilled riders and involves aggressive slopes large obstacles and moderate jumps Free Ride forks should be used only with disk brakes as well as frames wheels and other components specifically designed for Free Riding The disk brakes mus...

Page 5: ...ht on puts forces on your fork it was not designed to absorb Landing improperly after a jump or drop also puts forces on your fork it was not designed to absorb You should only perform jumps or drops when a transition or down ramp is available to help your bicycle absorb the impact forces generated during the landing and both wheels should smoothly make contact with the transition or down ramp at ...

Page 6: ...9 11 REMEMBER Even forks made out of solid metal will fail if they are misused abused or improperly used Extreme use can eventually wear out and break even the strongest components Ride fast yet ride Smart ...

Page 7: ...MZ010 Use and maintenance instruction manual English ...

Page 8: ...leaning the fork legs and the dust seals 92 5 Adjustments 93 5 1 Preload 94 5 1 1 Spring preload with external adjustment 94 5 1 2 Spring preload with internal adjustment 95 5 1 3 Air preload 96 5 2 Rebound adjustment with external adjustable pumping rod 97 5 3 Rebound adjustment with internal adjustable pumping rod 97 5 4 ECC 98 6 Tables 99 7 Warranty 100 TABLES INDEX Table 1 Use application of t...

Page 9: ...ycle the wheel the steering set or any other component directly or indirectly associated with the fork that are not actually a part of the fork MARZOCCHI reserves the right to make changes to the products at any time and without prior notice to improve the products or to meet any productive or commercial requirements The user is the only person responsible for the correct application of the assemb...

Page 10: ...ferent from the one provided by the manufacturer For further information concerning the specific fork s use please refer to the Safety regulations for the user Table 1 Use application of the MY 2004 PREMIUM SUSPENSION forks Drop Off Comp Drop Off Triple EXR Comp EXR Pro Air EXR Pro Coil TXC EXR Supra MZ Comp MZ Race TXC ECC M A R A T H O N C R O S S C O U N T R Y F R E E R I D E D I R T J U M P E ...

Page 11: ...ounted to the underside of the crown helps protecting the rider against debris from the front tire 2 1 2 Wheel axle securing system The system for securing the wheel axle to the fork sliders can be standard with traditional dropouts or with the QR20 Plus system Forks using this system must have a suitable hub with 110 mm width spacing and a 20 mm wheel axle The MARZOCCHI QR20 Plus system it is the...

Page 12: ...ons indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 177 ø 30 80 100 130 18 ø 30 248 A C Max 340 353 Max 60 A max A min TRAVEL C mm mm mm Disk brake mounts Brake type Cantilever or V Brake Drop out type Standard QR 20 Plus Accessories XC International Standard for 6 disk Integrated MZ Series current option not availab...

Page 13: ...dicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 177 ø 30 80 100 130 18 ø 30 248 A C Max 340 353 Max 60 A max A min TRAVEL C mm mm mm 478 373 105 458 373 85 493 373 120 Disk brake mounts Brake type Cantilever or V Brake Drop out type Standard QR 20 Plus Accessories XC International Standard for 6 disk EXR Series current...

Page 14: ...ns indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 181 Max 68 ø 30 100 130 18 ø 32 A C Max 345 352 A max A min TRAVEL C mm mm mm Disk brake mounts Brake type Cantilever or V Brake Drop out type Standard QR 20 Plus Accessories XC International Standard for 6 disk Integrated fender Drop Off Comp Series current option n...

Page 15: ... the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information ø 32 C 110 130 ø 30 Max 345 352 181 Max 68 18 A A max A min TRAVEL C mm mm mm Disk brake mounts Brake type Cantilever or V Brake Drop out type Standard QR 20 Plus Accessories XC International Standard for 6 disk Drop Off Triple current option not available 538 388 150 Integrated fe...

Page 16: ...The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information ø 28 C A 10 3 100 108 151 79 280 A max A min TRAVEL C mm mm mm Disk brake mounts Brake type Cantilever or V Brake Drop out type Standard QR 20 Plus Accessories XC International Standard for 6 disk Integrated TXC Series current option not available 60 80 4...

Page 17: ...liders arch monolith by two teflon coated bushings free from static friction The seal system prevents oil or grease leaks and contamination from particles entering the fork It uses a special dual lip oil seal and a dust seal at the top of each slider You will find here below the different fork damping systems ECC the Extension Control Cartridge offers on the fly adjustment of the rebound damping S...

Page 18: ...ried out by one of our service centers only using the required tools ATTENTION In case of improper installation of the steer tube into the crown the rider might lose control of his her bicycle thus jeopardizing his her safety ATTENTION On the DropOff Triple model the lower crown is clamped to the stanchions through some bolts During installing you will have to verify that keeping the fork s legs f...

Page 19: ...he fork s specifications considering that On the MZ and TXC forks the V Brake system adapters are integrated into the monolith casting On Ø 32 mm stanchions forks you can exclusively assemble disk brake systems The EXR forks can be previously provided with disk brake assembling accessories or with Cantilever or V Brake systems assembling accessories Specialized personnel only can change one brake ...

Page 20: ...he release lever B For threaded cap hubs unscrew the cap C as much as needed to insert the wheel axle through the fork wheel axle clamp Insert the wheel axle D through the fork wheel axle clamp Make sure that the wheel axle supporting bushings E are centered in the sliders seat If the wheel axle is provided with quick release system lock the wheel with the quick release lever B otherwise tighten t...

Page 21: ...ain proper sag Spring rate too soft or fork oil too fluid Check oil height Get stiffer springs Increase air pressure Fork does not get full travel Spring rate too stiff or fork oil too high Check oil height Get softer spring Decrease air pressure Fork extends too quickly harsh top out after impacts Not enough rebound damping Increase rebound damping Replace oil SAE 7 5 with a higher viscosity Fork...

Page 22: ... is sticky fork does not perform as new Oil seals are contaminated fork needs to be serviced Replace all seals Oil leakage from the bottom Loose bottom nut screw Tighten bottom nut screw O ring damaged Replace O ring Loss of sensitivity Worn sliding bushings Replace sliding bushings Old oil Change oil General maintenance operation Use Intense Normal Check screws tightening up to required torque Be...

Page 23: ...but can damage the bolts and make it impossible to unscrew them Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws When using a screwdriver to assemble or disassemble metal stop rings o rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Do not carry out any maintenance and or adjustment operations that are no...

Page 24: ...driver pry the dust seal B off the slider C avoiding scratching the stanchion tube Slide the dust seal along the stanchion tube and clean inside the dust seal and its seat on the slider with a jet of compressed air NOTE It is advisable to tip the fork s leg to make the pouring of any particles easier ATTENTION Never use metal tools to clean any particles of dirt Compress the fork legs slightly and...

Page 25: ...load Internal Preload PLe External Preload External Preload A Positive Air Preload Positive Air Preload PRe External rebound register External rebound register PRi Internal rebound register Internal rebound register ECC Extension control cartridge Extension control cartridge Fork PLi PRi PRe ECC PLe A See paragraph 5 1 1 5 3 5 2 5 4 5 1 2 5 1 3 Drop Off Comp Drop Off Triple EXR Comp EXR Pro Air EX...

Page 26: ...ving air preload 5 1 1 Spring preload with external adjustment NOTE The fork is set to the minimum preload by the manufacturer i e the knob is completely turned counterclockwise However the spring is slightly preloaded to help counteractining static load By turning the knob A on the top of the fork s leg you can modify the spring preload to adjust the initial setting according to the rider s weigh...

Page 27: ...ng according to the rider s weight and needs you will have to remove the plastic protection cap A and turn the adjuster B using a 4 mm Allen key By turning the adjsuter clockwise the preload spring can be increased up to the maximum value By turning the adjuster counterclockwise you will reduce the preload spring down to the minimum value Once the adjustment completed put the plastic protection ca...

Page 28: ...s of a pointed object Apply the same preload pressure on both legs By pressurizing air through the valve A you can adjust the damping of the forces generated during the COMPRESSION phase If you increase the pressure inside the fork s leg you increase the preload To do so you need to remove the dust cap B fully tighten the threaded pump adapter inflate air up to the required pressure refit the dust...

Page 29: ... more responsive during the rebound phase ATTENTION Do not force the adjustment knob D past its limits 5 3 Rebound adjustment with internal adjustable pumping rod You will find some damping rods where the rebound adjustment is located inside the stanchion tube To adjust these forks you will need to remove the dust cap A located on the top of the fork s leg insert the supplied hexagon rod B into th...

Page 30: ...ter impacts any other impact will make lower the fork s geometry further This position is only suitable for hard steep climbs Position UNLOCK By turning the lever A counterclockwise you will re establish the normal fork s function and deactivate the ECC cartridge function ATTENTION Do not use the LOCK position for any reason while riding hard downhill as the fork could not react safely enough when...

Page 31: ...ixing bolts 6 1 Fender fixing bolts 6 1 Handlebar clamp fixing bolts 10 1 ECC knobs fixing bolts 2 0 5 Pumping rods and cartridges fixing foot nuts screws 11 1 Cantilever bolts fixing screws 11 1 Pumping rods knobs fixing screws with lower external adjustment 2 0 5 Air pressure 0 15 psi 0 1 bar Rider s weight Air pressure 120 155 lbs 55 70 kg 30 40 psi 2 0 2 75 bar 155 180 lbs 70 80 kg 35 45 psi 2...

Page 32: ...ll commence on the date of purchase and shall continue for a period of two 2 years from the date of the original purchase is worth the invoice date or the ticket that must be kept 4 PROCEDURE In event of a defect covered by this warranty the purchaser should contact an authorized dealer or a Marzocchi Service Centre 5 ENTIRE AGREEMENT This warranty supersedes any and all oral or express warranties...

Page 33: ...ank you for the purchase of this Marzocchi Suspension System If any defect covered under the warranty appears with the agreed terms send the Marzocchi Suspension System postage prepaid to an authorized dealer or to a Marzocchi Service Center including a copy of the invoice or the ticket When doing so please state your full name address date of purchase and explain the problem of defect The policy ...

Page 34: ...MZ009 181 MARZOCCHI distributors and service centers ...

Page 35: ... 322 2231 info duellbike fi www duellbike fi FRANCE PHILAMY S A 1384 Parc Industriel Saint Maurice F 04100 Manosque France Contact Derrick Coetzer Tel 33 0 4 92 70 97 00 Fax 33 0 4 92 72 60 70 Info philamy com www philamy com GERMANY COSMIC SPORTS GmbH Ipsheimerstr 15 17 D 90431 NÜRNBERG Germany Tel 49 911 31 07 55 0 Fax 49 911 3107 55 55 Info cosmicsports de www cosmicsports de ITALY LARM SPA Via...

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Page 37: ... Fax 82 0 31 719 6519 Fours1 yahoo co kr SINGAPORE CAPPA TRADING PTE LTD 85 Kaki Bukit Avenue Shun Li Industrial Park SINGAPORE 417955 Singapore Tel 65 8415151 Fax 65 8425133 cappa pacific net sg OFFICIAL DISTRIBUTOR ALSO FOR MALAYSIA INDONESIA BRUNEI THAILAND USA SOUTH AMERICA MARZOCCHI USA 25213 Anza Drive VALENCIA CA 91355 USA Tel 1 661 257 6630 Fax 1 661 257 6636 Marzmail marzocchiusa com www ...

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Page 39: ...Cod 900910 Aprile 2003 Edizione 00 MARZOCCHI S p A Via Grazia 2 40069 Lavino di Zola Predosa Bologna ITALY Telefono 39 0 51 61 68 711 Telefax 39 0 51 75 88 57 ...