Marzocchi MXC+ECC Air Instructions Manual
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Marzocchi MXC+ECC Air Instructions Manual

Marzocchi MXC+ECC Air Instructions Manual

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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
MXC
in contact with each other using silicone
+
fat spray or a specific oil for seals.
5. Always grease the lip seal rings before
reassembling.
ECC
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 MXC+ECC 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

    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 Maintenance

    RECOMMENDATIONS INSTALLATION MAINTENANCE DISC BRAKE SYSTEM ASSEMBLY Installing the fork on a bicycle is a very If a disc brake system is installed, brake delicate operation that should be carried forks are based on advanced ARZOCCHI supports fixing pins can be replaced with out with extreme care.

  • Page 4: Fork Leg Pressurization

    ADJUSTMENTS NOTE: in case of air leakages when adapter REBOUND LIMITER FORK LEG PRESSURIZATION fitting (D) is fitted, ensure that the O-ring (only left leg) Blow pressurized air through the valves to set (D1) is not damaged. In case of hard uphill path, fork leg rebound COMPRESSION damping.
  • Page 5 REBOUND ADJUSTMENT VIA INNER PUMPING ROD The adjuster controlling REBOUND damp- ing adjustment is accommodated inside the pumping element (32) inside the r.h. fork leg. To access the adjuster, unscrew the top cap (8) and push the stanchions fully down (see section DISASSEMBLY Fig.

  • Page 6: 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 7 STANCHION TUBE CAP FIG. 2 FIG. 3 (only left leg) FIG. 1 (only left leg) Depressurize each fork leg (see section Lock the check nut (34) and remove the cap Loosen screw (3) and remove rebound ADJUSTMENT). (6) from hydraulic cartridge end (11). limiting knob (4).
  • Page 8 FIG. 4 HYDRAULIC CARTRIDGE CHANGE FIG. 6 (only left leg) Push the stanchions (1) into the sliders (18) AND PUMPING ROD CHANGE Remove the hydraulic cartridge (11) com- and let all the oil drain out from the fork legs. FIG. 5 plete with rebound spring (9) and foot Pump the stanchions several times to help Turn the fork leg upside-down and unscrew...
  • Page 9 SEAL ASSEMBLY AND PILOT FIG. 8 FIG. 9 BUSHING CHANGE Remove the dust seal (13) from the top of Remove the stop ring (14) from the sliders FIG. 7 the sliders using a small screwdriver. by placing the screwdriver bit in one of the Withdraw the crown and stanchions as- three openings on the stop ring.
  • Page 10 FIG. 10 FIG. 11 FIG. 12 Fit the slider protector (A) onto the slider Remove the upper washer (16) from the Fit the bit of a small screwdriver into upper and remove the oil seal (15) with the help slider. edge slot of the pilot bushing (17) and lift of a large screwdriver.
  • Page 11 PUMPING ROD CHANGE VALVE ASSEMBLY CHANGE REPLACING AIR VALVE FIG. 13 FIG. 14 (only right leg) FIG. 15 Remove the foot buffer (26) with the o-ring To check that the valve assembly is operat- This operation can be performed when fork (25) from the pumping rod (32) end.
  • Page 12 REASSEMBLY CAUTION: before reassembling, all metal FIG. 17 FIG. 18 components should be washed carefully Fit the upper washer (16) into the slider so Lubricate the oil seal (15) 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 13 FIG. 19 FIG. 20 VALVE AND PUMPING ROD Insert the stop ring (14) into the slider Lubricate the dust seals (13) and fit them ASSEMBLY (only right leg) making sure it is properly seated into place. into the stanchions from the spring end. FIG.
  • Page 14 FIG. 22 FIG. 23 CROWN AND STANCHIONS Lubricate O-rings(30) and (25) and reas- Fit this assembly into the stanchion tube and ASSEMBLY semble the foot buffer (26) onto the end properly seat the valve assembly (F). FIG. 24 Fit the crown and stanchions assembly (1) part of pumping rod (32).
  • Page 15 HYDRAULIC CARTRIDGE FIG. 26 HOW TO FILL WITH OIL RE-ASSEMBLY (left leg) Lubricate O-Rings (19) on the foot nuts FIG. 27 FIG. 25 (20) and screw them onto the pumping rod Pour oil little by little when the stanchions Push the stanchions up to slider bottom. (32) and cartridge (11) threaded end.
  • Page 16 FIG. 28 (onlyleft leg) FIG. 29 FIG. 30 (left leg only) Screw the cap (6) on hydraulic cartridge Lubricate O-rings (5) in caps. Then lift Set rebound limiting knob (4) on RH leg end (11) unti it rests against the rod. stanchions and fit caps (6) and (8) by adjuster and tighten screw (3) to the torque Lock check nut (34) on cap to the specified...

  • Page 17: Specific Marzocchi Tools

    SPECIFIC MARZOCCHI TOOLS Ref. Item. Description and use R 5089 AB Slider protector: to remove the oil seal from the slider R 5090 Oil seal press: to press oil seal into the slider R 4008/C Inflating pump 5321038 Adapter fitting...

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