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Summary of Contents for Marzocchi DJ Urban 2006
- Page 1 © Marzocchi Suspension 2006 - DJ Urban 2006 - DJ Urban Technical instructions...
- Page 2 © Marzocchi Suspension 2006 - DJ Urban Exploded view - DJ Urban - 110 TA Rif. Code Quantity 1 524177 2 8031405/C 3 523011 4 528223 5 5081001/C 6 5141420/C 7 520178PN 8 512105 9 547801-TW 9 547803-TW 9 547800-TW...
- Page 3 © Marzocchi Suspension 2006 - DJ Urban Spare part list - DJ Urban - 110 TA Q.ty in the Rif. Code Description model 524177 PISTON RING 8031405/C PISTON ROD Z1 '06 TRAVEL 130 523011 STOP RING 528223 O-RING 5081001/C REINFORCED ALLOY STEM 1 1/8 5141420/C REB.SPRINGS 15MM KIT K=4.5...
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Page 4: Cable Guide
© Marzocchi Suspension 2006 - DJ Urban 5321153>A CABLE GUIDE... - Page 5 © Marzocchi Suspension 2006 - DJ Urban Technical characteristics: Technical characteristics Single-crown fork with ø 32mm legs. Available travels: 110 mm. Right fork leg damping element: spring (air pre-load). Left fork leg damping element: air. Right fork leg damping system: VF2 pumping element with external rebound adjustment.
- Page 6 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 7 © Marzocchi Suspension 2006 - DJ Urban The brake cable must never touch the crown and stanchions. 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 8 © Marzocchi Suspension 2006 - DJ Urban Dismantling: Removing the top caps Put the fork in the vice in 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 air valve.
- Page 9 © Marzocchi Suspension 2006 - DJ Urban Use the special spanner to remove the bottom nuts. Do not use other tools. Turn the arch-slider assembly upside down. With a 2mm Allen wrench loosen the screw (5) fixing the rebound adjustment knob (6) from the right leg.
- Page 10 © Marzocchi Suspension 2006 - DJ Urban Pull out the pumping element (3), the rebound spring (7) and the preload tube (9) ( only on models with 130mm travel If the piston segment (8) is damaged, you can prize it off with a small flat-tip screwdriver.
- Page 11 © Marzocchi Suspension 2006 - DJ Urban removing the dust seal. With the same screwdriver, prize off the metal stop ring (2). Take great care not to damage the internal surfaces of the one-piece assembly while removing the stop ring.
- Page 12 © Marzocchi Suspension 2006 - DJ Urban Fit the extraction washer keeping the blunt side towards the threaded grubscrew (C) fixed crosswise on to the main rod as shown. The slot in the rod lets the extraction washer swing inside the rod itself.
- Page 13 © Marzocchi Suspension 2006 - DJ Urban 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 2006 - DJ Urban 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 2006 - DJ Urban Fit the bottom pad (1) to the pumping element rod. Assembling: Assembling the left pumping element Insert the rebound spring (7) and the preload tube (9) ( only for models with 130mm travel ) into the piston rod (3).
- Page 16 © Marzocchi Suspension 2006 - DJ Urban Insert the crown-stanchion unit (3) in the arch-slider assembly (4). With the special 12mm spanner (A), tighten the right bottom nut (7) complete with O-ring (8) to the recommended tightening torque (10 Nm ± 1).
- Page 17 © Marzocchi Suspension 2006 - DJ Urban Using introducer (A) insert the dust seals (11) in their seats. Assembling: Filling with oil Block the fork in the vice, in perfectly vertical position. Lower the crown-stanchion unit on the arch-slider assembly.
- Page 18 © Marzocchi Suspension 2006 - DJ Urban Insert spring (2) in the right leg. Assembling: Mounting the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. Check that O-ring is not damaged. Using the 21mm socket spanner, tighten cap (2) to the recommended tightening torque (10 Nm ± 1).
- Page 19 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 20 Positive air is the elastic element of air damped forks. 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.
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Page 21: Tightening Torques
© Marzocchi Suspension 2006 - DJ Urban Tightening torques Components Tightening torque (Nm) Adjuster locking screws 2±0,5 Fork leg top caps 10±1 Pumping element/cartridge bottom nuts 10±1 Wheel axle Allen screws 6±1 Wheel axle screws 15±1 Air pressures Positive air pressure... - Page 22 © Marzocchi Suspension 2006 - DJ Urban 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 Change to softer spring rate...
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