Table of Contents
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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
in contact with each other using silicone
fat spray or a specific oil for seals.
5. Always grease the lip seal rings before
MXR
reassembling.
6. Use wrenches with metric size only.
Wrenches with inch size might damage
Air
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 Air
- 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.
- Page 2 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 through the top of the slider 1.
- Page 3 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, brake supports fixing always be checked by one of our Technical...
- Page 4 ADJUSTMENTS FORK LEG PRESSURIZATION REBOUND ADJUSTMENT Blow pressurized air through the valves (5) Each fork leg is equipped with an adjuster on the stanchion caps to set COMPRES- screw (D) for REBOUND damping at slider SION damping. To change the pressure bottom.
- Page 5 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 FIG. 1 FIG. 2 PILOT BUSHING AND SEAL Depressurize each fork leg (see section Push the stanchions (1) into the sliders (11) ASSEMBLY CHANGE ADJUSTMENT). and let all the oil drain out from the fork legs. FIG. 3 (only left leg) Unscrew the caps (5) with a 21 mm socket Pump the stanchions several times to help Turn fork legs upside down and press...
- Page 7 FIG. 4 FIG. 5 FIG. 6 Remove foot nuts (26) and (7) by the use Withdraw the crown and stanchions as- Remove the dust seal (19) from the top of of a 15 mm socket wrench. sembly (1) from the sliders (11). the sliders using a small screwdriver.
- 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. 12 FIG. 10 REPLACING PUMPING ELEMENT Withdraw the pumping elements (14) and Fit the bit of a small screwdriver into upper SEALS (12) and the rebound spring (15) from the edge slot of the pilot bushing (23) and lift FIG.
- Page 10 FIG. 13 (only left leg) VALVE ASSEMBLY CHANGE Remove the stop ring (4) from pumping FIG. 14 (only left leg) element bottom (14) with a small flat screw- To check that the valve assembly is operat- driver. ing correctly, it is necessary to work on the Mark stop ring seat into inner rod for proper inside of the stanchion tube.
- 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 toward the slider.
- 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 (3) 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 (only left leg) Lubricate the O-rings (24) and (25) and Fit this LH assembly into the stanchion tube FIG. 21 reassemble the foot buffers (18) and (32) and properly seat the valve assembly (E). After having overhauled or replaced the onto pumping element ends (14) and (12).
- Page 14 FIG. 24 (only right leg) CROWN AND STANCHIONS FIG. 26 Fit pumping element (12) and rebound ASSEMBLY Screw the foot nuts (26) and (7) on the spring (15) from the stanchion tube top. FIG. 25 threaded elements of pumping elements Fit the crown and stanchions assembly (1) (14) and (12).
- Page 15 FIG. 27 HOW TO FILL WITH OIL FIG. 29 Fit the retainer (D) into the slider (E) to FIG. 28 Lubricate the O-ring (6) on the cap (5). reassemly the adjuster unit (28). Pour oil little by little when the stanchions Lift the crown (1) and fit start caps (5) onto are fully down and then pump with the stanchion threads by hand.
- Page 16 FIG. 30 Tighten the caps (5) to 20 Nm. Pressurize as shown in section ADJUST- ING.
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