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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
MXR
in contact with each other using silicone
fat spray or a specific oil for seals.
Coil
5. Always grease the lip seal rings before
reassembling.
ext.
6. Use wrenches with metric size only.
Wrenches with inch size might damage
Preload
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
special tools only.
ARZOCCHI
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Summary of Contents for Marzocchi MXR Coil ext. Preload
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing the M special tools only. ARZOCCHI 2. On reassembling the suspension system, always use new seals. 3. Clean all metal parts with a special, preferably biodegradable solvent, such as trichloroethane or trichloroethylene.
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Page 2: Failures, Causes And Remedies
FAILURES, CAUSES AND REMEDIES This paragraph reports some failures that may occur when using the fork. It also indicates possible causes and suggests a remedy. Always refer to this table before doing any repair work. FAILURES CAUSES REMEDIES Oil leaking though the top of slider 1. -
Page 3: Recommendations For Maintenance
RECOMMENDATIONS FOR INSTALLATION MAINTENANCE Installing the fork on a bicycle is a very DISC BRAKE SYSTEM ASSEMBLY delicate operation that should be carried forks are based on advanced WARNING: If a disc brake system ARZOCCHI out with extreme care. The installation should technology, supported by year-long experi- is installed, it is possible to replace always be checked by one of our Technical... -
Page 4: Spring Preload
ADJUSTMENT SPRING PRELOAD REBOUND ADJUSTMENT Spring preload determines COMPRESSION (only left leg) damping and is adjusted by turning the Each fork leg is equipped with an adjuster adjustment knob (3) on the top of the fork screw (C) for REBOUND damping at slider legs. -
Page 5: Disassembly Diagram
DISASSEMBLY GENERAL – The reference numbers given in this section relate to the components shown in the fork exploded view. – Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence. Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to remove first. - Page 6 SPRING CHANGE FIG. 2 PILOT BUSHING AND SEAL FIG. 1 Push the stanchions into the sliders and ASSEMBLY CHANGE Unscrew the caps (4) with a 21 mm socket remove the lower washer (11) and the FIG. 3 (only left leg) wrench.
- Page 7 FIG. 4 FIG. 5 FIG. 6 Remove foot nuts (26) and (29) with a Withdraw the crown and stanchions as- Remove the dust seal (19) from the top of socket wrench. sembly (1) from the sliders. the sliders using a small screwdriver. Coil ext.
- Page 8 FIG. 7 FIG. 8 FIG. 9 Remove the stop ring (20) from the sliders Fit the slider protector (A) onto the slider Remove the upper washer (22) from the by placing the screwdriver bit in one of the and remove the oil seal (21) with the help slider.
- Page 9 FIG. 10 REPLACING PUMPING ELEMENT FIG. 12 Fit the bit of a small screwdriver into upper SEALS Withdraw the pumping elements (14) and edge slot of the pilot bushing (23) and lift FIG. 11 (12) and the rebound springs (15) from gently.
- Page 10 FIG. 13 (only left leg) VALVE ASSEMBLY CHANGE Remove the stop ring (33) from pumping (only left leg) element bottom (14) with a small flat screw- FIG. 14 driver. To check that the valve assembly is operat- Mark stop ring seat into inner rod for proper ing correctly, it is necessary to work on the fitting.
- Page 11 REASSEMBLY CAUTION: before reassembling, all metal FIG. 16 FIG. 17 components should be washed carefully Fit the upper washer (22) into the slider so Lubricate the oil seal (21) and place it onto with inflammable, preferably biodegrad- that it touches the pilot bushing. the seal press (B) with the hollow side able, solvent and dried with compressed air.
- Page 12 FIG. 18 FIG. 19 PUMPING ROD ASSEMBLY Insert the stop ring (20) into the slider Lubricate the dust seals (19) and fit them FIG. 20 (only left leg) making sure it is properly seated into place. into the stanchions from the spring end. Lubricate the O-ring (27) and fit inner rod Use buffer (B) to properly seat the ring into threaded end into pumping element (14).
- Page 13 VALVE AND PUMPING ROD FIG. 22 FIG. 23 (only left leg) ASSEMBLY Lubricate the O-rings (24) and (25) and Insert the LH pumping element you have just FIG. 21 (LH pumping element only) reassemble the foot buffer (18) onto pump- assembled into the stanchion tube and After having overhauled or replaced the ing element end (14) and foot buffer (44)
- Page 14 FIG. 24 (only right leg) CROWN AND STANCHIONS AS- FIG. 26 Fit the RH pumping element (12) from SEMBLY Screw the foot nuts (26) and (29) on the stanchion top with only one rebound spring FIG. 25 threaded elements of pumping elements (15) on forks with a travel of 100, and Fit the crown and stanchions assembly (1) (14) and (12).
- Page 15 FIG. 27 (only left leg) HOW TO FILL WITH OIL SPRING AND CAP Fit the retainer (D) into the slider (E) to FIG. 28 FIG. 29 reassemly the adjuster unit (28). Pour oil little by little when the stanchions Fit the springs (30) into each stanchion are fully down and then pump with the tube.
- Page 16 FIG. 30 Lubricate the O-ring (5) on the cap (4). Turn the preload adjuster (9, see exploded view) counterclockwise until it is at its minimum setting and install the lower wash- er (11). Start the caps with the O-ring (5) in place into the stanchion tube threads by hand.
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