Marzocchi Dirt Jam Comp 2005 Technical Instructions
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Marzocchi Dirt Jam Comp 2005 Technical Instructions

Marzocchi Dirt Jam Comp 2005 Technical Instructions

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© Marzocchi Suspension
2005 - Dirt Jam Comp
2005 - Dirt Jam Comp
Technical instructions

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Summary of Contents for Marzocchi Dirt Jam Comp 2005

  • Page 1 © Marzocchi Suspension 2005 - Dirt Jam Comp 2005 - Dirt Jam Comp Technical instructions...
  • Page 2 © Marzocchi Suspension 2005 - Dirt Jam Comp Exploded view - Dirt Jam Comp 100 Rif. Code Quantity 1 EXR FLC106-024 5 EXR FKE022-02 7 EXR FEE262 8 EXR FEP171 10 520341 11 5321153>A 12 533297 13 523261 14 528230>A...
  • Page 3 © Marzocchi Suspension 2005 - Dirt Jam Comp Spare part list - Dirt Jam Comp 100 Q.ty in the Rif. Code Description model EXR FLC106-024 CROWN+STANCH+STEM DJ COMP 2005 EXR FKE022-02 PLUG EXR FEE262 SPRING GUIDE EXR FEP171 ELASTOMER 520341 SCREW 5321153>A...
  • Page 4 © Marzocchi Suspension 2005 - Dirt Jam Comp Exploded view - Dirt Jam Comp 120 Rif. Code Quantity 1 EXR FLC106-024 5 EXR FKE022-02 7 EXR FEE262 8 EXR FEP171 10 520341 11 5321153>A 12 533297 13 523261 14 528230>A...
  • Page 5 © Marzocchi Suspension 2005 - Dirt Jam Comp Spare part list - Dirt Jam Comp 120 Q.ty in the Rif. Code Description model EXR FLC106-024 CROWN+STANCH+STEM DJ COMP 2005 EXR FKE022-02 PLUG EXR FEE262 SPRING GUIDE EXR FEP171 ELASTOMER 520341 SCREW 5321153>A...
  • Page 6 © Marzocchi Suspension 2005 - Dirt Jam Comp Technical characteristics: Technical characteristics Single-crown fork with ø 32mm legs. Available travels: 100 mm, 120 mm. Right fork leg damping element: spring with preload mechanical adjustment. Left fork leg damping element: spring with preload mechanical adjustment.
  • Page 7 Always grease the seal lips before reassembling. All of the components of Marzocchi forks require the use of metric tools. Use only metric tools. Imperial (US) tools may have similar sizes, but can damage the bolts, making them impossible to loosen or tighten.
  • Page 8 © Marzocchi Suspension 2005 - Dirt Jam Comp Warnings: Assembling the wheel on forks with ø20mm through-axle For a correct operation of the fork, install the wheel as explained below: Align the center of the wheel with each wheel axle clamp.
  • Page 9 © Marzocchi Suspension 2005 - Dirt Jam Comp Dismantling: Removing the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. Fully unscrew lock cap (2) with the special spanner. Remove lock cap (2).
  • Page 10 © Marzocchi Suspension 2005 - Dirt Jam Comp Dismantling: Breaking down the pumping element Remove the bottom pad (1) from the pumping element rod. Pull the pumping element (3), spacer (7) ( only for models with 100mm travel ), the rebound spring (4), bush (5) and the bottom washer (13) off the top of the fork.
  • Page 11 © Marzocchi Suspension 2005 - Dirt Jam Comp 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 assembly while removing the sealing ring.
  • Page 12 © Marzocchi Suspension 2005 - Dirt Jam Comp Pull the extractor rod so that the upper face of the washer stops against the lower face of the guide bush. Insert the aluminium bush (A) in the seat of the sealing ring.
  • Page 13 © Marzocchi Suspension 2005 - Dirt Jam Comp Assembling: Assembling the guide bushes Insert the guide bushes using the special introducers (short type for the top bush and long type for the bottom bush, both with a white finish). Do not use other tools.
  • Page 14 © Marzocchi Suspension 2005 - Dirt Jam Comp Smear the dust seal and the sealing ring with some grease. Insert the sealing ring (3) in its seat with the special introducer (A). Using a hammer, knock in introducer (A) and drive the sealing ring home into the arch-slider assembly.
  • Page 15 © Marzocchi Suspension 2005 - Dirt Jam Comp Fit the bottom pad (1) to the end of 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.
  • Page 16 © Marzocchi Suspension 2005 - Dirt Jam Comp Assembling: Assembling spring and elastomer Block the fork in the vice, in perfectly vertical position. Smear both springs with the recommended grease. Lift the crown-stanchion unit on the arch-slider assembly. Insert the bottom spring cup (4), spring (3),elastomer (2) and the top spring cup (1) in both legs.
  • Page 17 During setting don't force the adjusters beyond their limit of travel and don't exceed the max recommended air pressure. To keep the pressure inside the fork’s legs, only use the special MARZOCCHI pump with pressure gauge. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.
  • Page 18 © Marzocchi Suspension 2005 - Dirt Jam Comp Do not force the adjuster beyond its limit of travel.
  • Page 19 © Marzocchi Suspension 2005 - Dirt Jam Comp Tightening torques Components Tightening torque (Nm) Fork leg top caps 10±1 Pumping element locking bottom nuts 10±1 Wheel axle Allen screws 6±1 Wheel axle screws 15±1 Dirt Jam Comp 100 - Oil levels...
  • Page 20 © Marzocchi Suspension 2005 - Dirt Jam Comp Diagnostics Finding the problem Finding the possible cause Possible solutions proposed Fork doesn't get full travel Oil level too high Check oil levels Fork doesn't get full travel Spring rate too stiff...

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