Table of Contents
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Features
TECHNICAL CHARACTERISTICS
Fork with Ø30 mm legs with spring and
hydraulic rebound damping.
Adjustment of the hydraulic rebound
braking through the adjuster in the right leg.
Adjustment of the air preload on both legs.
The stanchion tubes are pressed into the
crown with a cryogenic process.
New sliding system to improve the stiffness
and operation.
Magnesium alloy cast one-piece assembly,
CNC machined for lighter weight and more
stiffness.
Components subjected to friction are
lubricated and cooled by means of a
special oil.
Steer tube: steel or (optional) aluminium,
1-1/8", threadless.
Crown: BAM® aluminium alloy forged and
CNC machined.
Stanchions: anodised aluminium.
Springs: constant pitch.
Sliding bushes: made of friction free and
wear free material.
1/45
MX Comp + ETA
Seals: computer designed oil seals that
guarantee the maximum seal in any
condition.
Oil: special formulated oil that prevents
foam and keeps the viscosity unchanged
while offering high performance; free from
static friction.
Dropout type: Standard.
Disk brake mount: XC International
Standard for 6" disk.
V-Brake fit.
BAM®: Bomber Aerospace Material:
special alloy coming from the aerospace
industry.
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Summary of Contents for Marzocchi MAX COMP + ETA - 105
- Page 1 Features MX Comp + ETA TECHNICAL CHARACTERISTICS Seals: computer designed oil seals that guarantee the maximum seal in any Fork with Ø30 mm legs with spring and condition. hydraulic rebound damping. Oil: special formulated oil that prevents Adjustment of the hydraulic rebound foam and keeps the viscosity unchanged braking through the adjuster in the right leg.
- Page 2 Features MX Comp + ETA 2/45...
- Page 3 Warning MX Comp + ETA INSTRUCTIONS FOR USE GENERAL REGULATIONS FITTING THE FORK ONTO THE FRAME INSTALLING THE DISK BRAKE SYSTEM INSTALLING THE V-BRAKE SYSTEM ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS 3/45...
- Page 4 Warning MX Comp + ETA INSTRUCTIONS FOR USE MARZOCCHI forks are based on an advanced technology coming from the company’s years long experience in the professional mountain bike industry. For the best results, it is advisable to inspect and clean the area below the dust...
- Page 5 GENERAL REGULATIONS damage the bolts and screws making it impossible to unscrew them. · After a complete breakdown, always use new MARZOCCHI seals when · Use the right size and sort of screwdriver reassembling. to unscrew slotted or crosshead screws.
- Page 6 A wrong installation can be dangerous for the rider. Marzocchi does not guarantee the assembly and accepts no liability for damage and/or accidents arising from a wrong installation. The steer tube must be pressed into the crown;...
- Page 7 INSTALLING THE DISK BRAKE SYSTEM Installing the brake system is a very delicate operation that must be carried out at our specialised service centres only. Marzocchi does not guarantee the installation and accepts no liability for damage and/or accidents arising from a wrong installation...
- Page 8 INSTALLING THE V-BRAKE SYSTEM Installing the brake system is a very delicate operation that must be carried out at our specialised service centres only. Marzocchi does not guarantee the installation and accepts no liability for damage and/or accidents arising from a wrong installation.
- Page 9 Warning MX Comp + ETA ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS Install the wheel following the instructions of the bike’s manufacturer. A good and reliable operation of the fork and all of the parts linked to it mainly depend on the correct fixing of the front wheel.
- Page 10 Diagnostic MX Comp + ETA 10/45...
- Page 11 Disassembling MX Comp + ETA REMOVING THE TOP CAP – RIGHT LEG REMOVING THE TOP CAP – LEFT LEG DRAINING THE OIL BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY BREAKING DOWN PUMPING ELEMENT AND VALVE – RIGHT LEG REMOVING THE ETA CARTRIDGE - LEFT LEG REMOVING THE SEALS REMOVING THE GUIDE BUSHES 11/45...
- Page 12 Disassembling MX Comp + ETA REMOVING THE TOP CAP - RIGHT LEG · Put the fork in the vice in a vertical position, fixing it by the dropouts. · Remove the protection cap (1). · Using a small pin screwdriver, blow the air off the fork leg pushing on the preload valve.
- Page 13 Disassembling MX Comp + ETA REMOVING THE TOP CAP – LEFT LEG · With a 2mm Allen wrench loosen screw (1 · Remove first the screw (1), then the ETA control knob (3). · Fully unscrew the lock cap (4) using a 21mm socket spanner.
- Page 14 Disassembling MX Comp + ETA · Holding locknut (5) with the 10mm spanner, use the 21mm spanner to unscrew the lock cap (4) completely. · Remove the lock cap (4). 14/45...
- Page 15 Disassembling MX Comp + ETA DRAINING THE OIL · Free the fork from the vice and tip it into a container of a suitable size to drain the oil; compress the fork a few times to help the oil flow out. Do not pour used oils on the ground.
- Page 16 Disassembling MX Comp + ETA BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY Use the special spanner to remove the bottom nuts. Do not use other tools. Using the special 12mm spanner (A), loosen the two bottom nuts (1). Remove the bottom nuts (1) and the O-rings (2).
- Page 17 Disassembling MX Comp + ETA · Pull the crown-stanchion unit (3) off the arch-slider assembly (4). 17/45...
- Page 18 Disassembling MX Comp + ETA BREAKING DOWN PUMPING ELEMENT AND VALVE – RIGHT LEG · Remove the bottom pad (1). · Using the round-nose pliers remove the stop ring (2). 18/45...
- Page 19 Disassembling MX Comp + ETA · Pull out the pumping element (3) complete with rebound spring and valve. · Remove bushing (4), valve (5), three-point ring (6) and rebound spring (7) from the pumping element. · Pull out the preload tube (9) (only for models with 105mm travel).
- Page 20 Disassembling MX Comp + ETA REMOVING THE ETA CARTRIDGE - LEFT LEG · Loosen and remove nut (1) with a 10mm spanner with fixed jaws. 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)].
- Page 21 Disassembling MX Comp + ETA · Remove washer (3), the preload tube (7) and spring (2). The ETA cartridge (5) has been sealed through machining and cannot be overhauled. In the case of faults or a malfunctioning, this cartridge must be replaced.
- Page 22 Disassembling MX Comp + ETA REMOVING THE SEALS · Remove the dust seal (1) from its seat, using a small flat-tip screwdriver. · With the same screwdriver prize off the metal stop ring (2). Take great care not to damage the internal surfaces of the arch-slider assembly when removing the dust seal and the stop ring.
- Page 23 Disassembling MX Comp + ETA Protect the upper part of the slider with the special tool (A). With a screwdriver prize the sealing ring (3) off. Remove the sealing ring (3). Take great care not to damage the internal surfaces of the arch-slider assembly when removing the sealing ring.
- Page 24 Disassembling MX Comp + ETA REMOVING THE GUIDE BUSHES Use the special extractor to remove the guide bushes. Do not use other tools. Fit the aluminium bush (A) to the extractor keeping the small diameter side towards the edge opposite to the striker. Fit the extraction washer (B) with a white finish to the extractor.
- Page 25 Disassembling MX Comp + ETA 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. While holding the main rod in position, the aluminium bush drives the guide bushes during extraction.
- Page 26 Assembling MX Comp + ETA ASSEMBLING THE GUIDE BUSHES 26/45...
- Page 27 Assembling MX Comp + ETA 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 black finish). Do not use other tools. Fit first the bottom bushes, then the top bushes.
- Page 28 Assembling MX Comp + ETA Using the short introducer (B) fit the bottom bush (2). Using a hammer knock the introducer (B) into the arch-slider assembly. 28/45...
- Page 29 Assembling MX Comp + ETA ASSEMBLING THE SEALS · Smear the dust seal and the sealing ring with some grease. · Refit the sealing ring (3) using the special introducer (A). · Using a hammer knock in the introducer (A ) and drive the sealing ring home into the arch-slider assembly.
- Page 30 Assembling MX Comp + ETA ASSEMBLING PUMPING ELEMENT AND VALVE – RIGHT LEG · Replace the piston segment (8) if necessary. · Insert the preload tube (9) (only for models with 105mm travel) and the rebound spring ( 7) in the piston rod. ·...
- Page 31 Assembling MX Comp + ETA · Insert the pre-assembled valve in the piston rod from the three-point ring side as shown. · Insert the valve and the pumping element ( 3) into the stanchion. Take great care not to damage the segment and if necessary use a small flat-tip screwdriver to help the piston of the pumping element into the stanchion.
- Page 32 Assembling MX Comp + ETA · Fit the bottom pad (1) to the pumping element rod. 32/45...
- Page 33 Assembling MX Comp + ETA MOUNTING THE ETA CARTRIDGE - LEFT LEG · 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 the action of the spring.
- Page 34 Assembling MX Comp + ETA ASSEMBLING THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY A special spanner shall be used to assemble the bottom nut. Do not use other tools. · Fit the dust seals (11) to the stanchions. · Insert the crown-stanchion unit (3) in the arch-slider assembly (4).
- Page 35 Assembling MX Comp + ETA · Fit the complete ETA cartridge (9) in the left leg. · With the special 12mm spanner (A), tighten the bottom nut (1) with O-ring (2) of both legs to the recommended tightening torque (11 Nm±1). 35/45...
- Page 36 Assembling MX Comp + ETA · Re-assemble the dust seals (11) in their seats using the special introducer (A). 36/45...
- Page 37 Assembling MX Comp + ETA FILLING WITH OIL · Put the fork in the vice in vertical position. · Lower the crown-stanchion unit on the arch-slider assembly. · Prepare the quantity of oil to pour into the fork leg (see table). ·...
- Page 38 Assembling MX Comp + ETA · Lift the crown-stanchion unit on the arch-slider assembly. 38/45...
- Page 39 Assembling MX Comp + ETA MOUNTING THE TOP CAP - RIGHT LEGT · Put the fork in the vice in vertical position, fixing it by the dropouts. · With the 21mm socket spanner, tighten the lock cap (2) to the recommended tightening torque (20 Nm±1).
- Page 40 Assembling MX Comp + ETA MOUNTING THE TOP CAP – LEFT LEG · Screw the lock cap (4) down on the ETA cartridge rod without tightening being very careful not to damage the O-ring. · Using the 10mm and 21mm spanners, tighten locknut (5) on cap (4) to the recommended tightening torque (6 Nm±1).
- Page 41 Assembling MX Comp + ETA · With the 21mm socket spanner, tighten the lock cap (4) on the steering crown to the recommended tightening torque (20 Nm ±1). · Fit the ETA control lever (3) and screw (1). · Using the 2mm Allen wrench, tighten screw (1) to the recommended tightening torque (2 Nm ±...
- Page 42 Settings MX Comp + ETA AIR PRELOAD REBOUND ADJUSTMENT ETA (TRAVEL LIMITING DEVICE) 42/45...
- Page 43 Settings MX Comp + ETA AIR PRELOAD Use the MARZOCCHI pump with pressure gauge to inflate the fork legs. Using inadequate tools may lead to a wrong inflation and result in a malfunctioning or damage to the fork. To reduce the leg’s pressure, simply push the valve pin down with a pointed tool such as a small pin extractor.
- Page 44 Settings MX Comp + ETA REBOUND ADJUSTMENT · With the 21mm socket spanner, loosen the lock cap (A). · Remove the lock cap (A). · Insert the hexagon rod (B) provided in the stanchion being careful to center the notch of the adjusting screw (C).
- Page 45 Settings MX Comp + ETA ETA (TRAVEL LIMITING DEVICE) The ETA cartridge fitted to the left leg, allows reducing the fork rebound limiting the fork travel to 30 mm. Turning the control (A) clockwise activates the ETA cartridge function. Turning the control (A) counter-clockwise brings the fork back to normal function and deactivates the limiting device.
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