Marzocchi Drop-Off SL 2006, Technical Instructions

Page 1: ...2006 Drop Off SL Technical instructions Technical characteristics Technical characteristics Marzocchi Suspension 2006 Drop Off SL ...

Page 2: ...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 offering high perform...

Page 3: ...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 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...

Page 4: ...forks with standard drop out Install the wheel following the instructions of the manufacturer For a correct operation of the fork install the wheel and proceed with the following checks Check the correct fork wheel alignment by fully compressing the fork a few times The wheel should not come into contact with any parts of the fork Lift the front wheel above the ground turn the wheel a few times to...

Page 5: ...lly unscrew lock cap 2 with a 21mm socket spanner Remove lock cap 2 Dismantling Draining the oil Remove spring 2 from the right leg 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 Marzocchi Susp...

Page 6: ...ut of both legs Pull the crown stanchion unit 3 off the arch slider assembly 4 Dismantling Removing the right pumping element Remove the bottom pad 1 Pull out the pumping element 3 the preload tube 9 only for models with 110 130mm travel and the rebound spring 7 If the piston segment 8 is damaged you can prize it off with a small flat tip screwdriver Dismantling Removing the left pumping element M...

Page 7: ... while removing the dust seal 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 sealing ring 3 Remove the sealing ring 3 Take great care not to damage the internal surfaces of the one piece a...

Page 8: ...bscrew 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 extractor rod will let the washer pass underneath the bush to be extracted Pull the extractor rod so that the upper face of the washer stops against the lower face of the g...

Page 9: ... Marzocchi Suspension 2006 Drop Off SL ...

Page 10: ...er 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 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 Insert the spring cup 4 in its seat Marzocchi Suspension 2006 Drop Off SL ...

Page 11: ...y 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 The pumping element operating the hydraulic rebound braking that can be recognised by the segment must be installed in the right leg Assembling Assembling the right pumping element Replace the piston segment 8 if nece...

Page 12: ...iston rod 3 Insert the pumping element into the stanchion and check it fits perfectly into its seat Fit the bottom pad 1 to the pumping element rod 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 Marzocchi Suspension 2006 Drop Off SL ...

Page 13: ... complete with O rings 2 of both legs to the recommended tightening torque 10 Nm 1 Using introducer A insert the dust seals 11 in their seats Assembling Filling with oil Block the fork in the vice in perfectly vertical position Lower the crown stanchion unit on the arch slider assembly Marzocchi Suspension 2006 Drop Off SL ...

Page 14: ...e 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 spring 2 in the right leg Assembling Mounting the top caps Put the fork in the vice in vertical position fixing it by the dropouts Check that O ring is not damaged Using the 21mm socket spanner tighten cap 2 to the recommended tighte...

Page 15: ...Restore the correct air pressure see settings Fit the protection cap 1 Marzocchi Suspension 2006 Drop Off SL ...

Page 16: ...n or damage to the fork resulting 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 thes...

Page 17: ...trol the return speed of the fork after compression The right rebound speed setting makes the bike stable letting it follow the variations in the terrain and any obstacles If the fork setting is too reactive this will make the rear suspension instable and the mountain bike will have a tendency to snake A too slow setting however will cause problems when dealing with multiple obstacles where the su...

Page 18: ...Do not force the adjuster beyond its limit of travel Marzocchi Suspension 2006 Drop Off SL ...

Page 19: ... top caps 10 1 Pumping element cartridge bottom nuts 10 1 Wheel axle Allen screws 6 1 Wheel axle screws 15 1 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 150 Left fork leg SAE 7 5 550013 150 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 150 Left fork leg SAE 7 5 550013 150 Marzocchi Suspension 2006 Drop Off SL ...

Page 20: ...is too soft needs more than the maximum preload 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...