Marzocchi MX Comp ETA 2005, Technical Instructions

Page 1: ...2005 MX Comp ETA Technical instructions Marzocchi Suspension 2005 MX Comp ETA ...

Page 2: ... 1 19 5321182SR R A 1 20 547605 1 21 547640 1 21 547637 1 21 547636 1 22 528046 2 23 5321130 B 2 28 509097 A 1 29 5141131 C 1 31 523270 1 32 512098 C 1 33 524127 A 1 34 8031186 C 1 35 522069 1 36 516104 1 39 528243 1 42 5321106 1 43 5321158 A 1 44 5321114 2 45 5321115QF 2 46 521142IW A 1 47 529178 1 48 5141116 C 1 49 703699KM C 1 MX Comp ETA 85 Oil levels Position Oil type Quantity cc Right fork l...

Page 3: ... UNIT 04 1 19 5321182SS R A MAGNUM GREY GLOSS MONOL UNIT 1 19 5321182SR R A SILVER DUST MONOLITE UNIT 1 20 547605 LH RH LABELS MX CONP 05 1 21 547640 ETA 2005 EXTERNAL LABEL 1 21 547637 ETA 2005 LABELS TOP 1 21 547636 replaces 547585 REBOUND ADJUSTER STICKER 05 1 22 528046 O RING 2 23 5321130 B FOOT NUT UNIT 2 28 509097 A replaces 509097 FERRULE 1 29 5141131 C replaces 850272 C REBOUND SPRING KIT ...

Page 4: ... 1 19 5321182SR R A 1 20 547605 1 21 547640 1 21 547637 1 21 547636 1 22 528046 2 23 5321130 B 2 28 509097 A 1 29 5141131 C 1 31 523270 1 32 512098 C 1 33 524127 A 1 34 8031185 C 1 35 522069 1 36 516104 1 39 528243 1 42 5321106 1 43 5321158 A 1 44 5321114 2 45 5321115QF 2 46 521142IW A 1 47 529179 1 48 5141275 C 1 49 703698KM C 1 MX Comp ETA 105 Oil levels Position Oil type Quantity cc Right fork ...

Page 5: ...04 1 19 5321182SS R A MAGNUM GREY GLOSS MONOL UNIT 1 19 5321182SR R A SILVER DUST MONOLITE UNIT 1 20 547605 LH RH LABELS MX CONP 05 1 21 547640 ETA 2005 EXTERNAL LABEL 1 21 547637 ETA 2005 LABELS TOP 1 21 547636 replaces 547585 REBOUND ADJUSTER STICKER 05 1 22 528046 O RING 2 23 5321130 B FOOT NUT UNIT 2 28 509097 A replaces 509097 FERRULE 1 29 5141131 C replaces 850272 C REBOUND SPRING KIT 1 31 5...

Page 6: ...SS R A 1 19 5321182SR R A 1 20 547605 1 21 547640 1 21 547637 1 21 547636 1 22 528046 2 23 5321130 B 2 28 509097 A 1 29 5141131 C 1 31 523270 1 32 512098 C 1 33 524127 A 1 34 8031185 C 1 35 522069 1 36 516104 1 39 528243 1 42 5321106 1 43 5321158 A 1 44 5321114 2 45 5321115QF 2 46 521142IW A 1 48 5141276 C 1 49 703682KM C 1 MX Comp ETA 120 Oil levels Position Oil type Quantity cc Right fork leg SA...

Page 7: ...ONOLITE UNIT 04 1 19 5321182SS R A MAGNUM GREY GLOSS MONOL UNIT 1 19 5321182SR R A SILVER DUST MONOLITE UNIT 1 20 547605 LH RH LABELS MX CONP 05 1 21 547640 ETA 2005 EXTERNAL LABEL 1 21 547637 ETA 2005 LABELS TOP 1 21 547636 replaces 547585 REBOUND ADJUSTER STICKER 05 1 22 528046 O RING 2 23 5321130 B FOOT NUT UNIT 2 28 509097 A replaces 509097 FERRULE 1 29 5141131 C replaces 850272 C REBOUND SPRI...

Page 8: ...ptional aluminium 1 1 8 threadless 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 form...

Page 9: ...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 10: ... 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 11: ...all pin screwdriver blow the air off the fork leg pushing on the air valve Fully unscrew lock cap 2 with a 21mm socket spanner Remove lock cap 2 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 Fully unscrew lock cap 2 using a 21mm socket spanner Lift out lock cap 2 Marzocchi Suspension 2005 MX Comp ETA ...

Page 12: ...help the oil flow out Do not pour used oils on the ground Dismantling Breaking down the steering crown unit arch slider assembly Use the special spanner to remove the bottom nuts Do not use other tools Turn the arch slider assembly upside down Using the special 12mm spanner A loosen the bottom nuts 1 of both legs Pull the bottom nuts 1 complete with O rings 2 out of both legs Pull the complete ETA...

Page 13: ...sembly 4 Dismantling Dismantling the right pumping element and valve Remove the bottom pad 1 Using the special round nose pliers remove stop ring 2 Pull out the pumping element 3 complete with rebound spring and valve Marzocchi Suspension 2005 MX Comp ETA ...

Page 14: ...e Loosen and remove nut 1 with a 10mm fixed spanner Be very careful during this operation as the preloaded spring 2 could eject with violence the parts located on the top nut 1 washer 3 and preload tube 7 To avoid dangerous situations slightly preload the spring pressing down washer 3 so that it can counteract the action of the spring Also avoid to direct the fork assembly side towards people or a...

Page 15: ...s of the one piece assembly 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 ...

Page 16: ...xed 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 guide bush I...

Page 17: ... Marzocchi Suspension 2005 MX Comp ETA ...

Page 18: ... 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 Smear the dust seal and the sealing ring with some grease Insert the sealing ring 3 in its seat with the special introduce...

Page 19: ...g During the assembly of the pumping unit strictly obey 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 Assembling Assembling the right pumping element and valve Replace the segment 8 of the pumping element if necessary Insert the preload tube 9 only for models with ...

Page 20: ...ose pliers mount the stop ring 2 and check it fits perfectly into its groove Fit the bottom pad 1 to the pumping element rod Assembling Assembling the ETA cartridge Insert spring 2 the preload tube 7 and washer 3 in the ETA cartridge rod Screw down nut 1 without tightening During this operation it might be necessary to slightly preload the spring pressing down washer 3 so that it can counteract th...

Page 21: ...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 ETA cartridge 9 in the left leg Using the special 12mm spanner A tighten the bottom nuts 1 complete with O rings 2 of both legs to the recommended tightening torque 10 Nm 1 Marzocchi Suspension 2005 MX Comp ETA ...

Page 22: ...t 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 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 Marzocch...

Page 23: ...ghtening torque 10 Nm 1 Restore the correct air pressure see settings Fit the protection cap 1 Assembling Assembling the top right cap 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 tightening torque 10 Nm 1 Restore the correct air pressure see settings Marzocchi Suspension 2005...

Page 24: ...e 10mm and 21mm spanners tighten locknut 6 on cap 2 to the recommended tightening torque 6 Nm 1 With the 21mm socket spanner tighten the lock cap 2 on the steering crown to the recommended tightening torque 10 Nm 1 Fit the ETA control knob 5 and screw 4 Using a 2mm Allen wrench tighten the knob fixing screw 4 to the recommended tightening torque 2 Nm 0 5 Marzocchi Suspension 2005 MX Comp ETA ...

Page 25: ... Marzocchi Suspension 2005 MX Comp ETA ...

Page 26: ...amage 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 these simp...

Page 27: ...remove the protection cap A Fit the hexagonal rod B supplied into the hole of the adjustment screw C in the stanchion tube Turning the adjustment screw counter clockwise increases the hydraulic damping and the fork will be slower during the rebound phase Turning the adjustment screw clockwise decreases the hydraulic damping and the fork will be more reactive during the rebound phase Once the setti...

Page 28: ...TA cartridge NEVER use the LOCK position when riding on steep downhills 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 Marzocchi Suspension 2005 MX Comp ETA ...

Page 29: ...80 154 176 2 40 3 10 3 480 00 4 495 00 80 95 176 209 2 90 3 80 4 205 00 5 510 00 95 110 209 242 3 60 4 50 5 220 00 6 525 00 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 135 Left fork leg SAE 7 5 550013 135 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 135 Left fork leg SAE 7 5 550013 135 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 135 Left fork leg SAE ...

Page 30: ... Marzocchi Suspension 2005 MX Comp ETA ...