Marzocchi XC700 owners manual

2
INDEX		Page
GENERAL .....................................................................................................................		3
OWNER'S INFORMATION ...........................................................................................		4
GENERAL RULES ........................................................................................................		6
SPECIFIC TOOLS ........................................................................................................		6
FAILURES, CAUSES AND REMEDIES .......................................................................		7
RECOMMENDATIONS FOR MAINTENANCE .............................................................		7
INSTALLATION ............................................................................................................		8
DISASSEMBLY ...........................................................................................................		10
REASSEMBLY ............................................................................................................		11
INDICE		Pagina
GENERALITÀ .............................................................................................................		14
INFORMAZIONI PER IL PROPRIETARIO DELLA BICICLETTA ...............................		15
REGOLE GENERALI ..................................................................................................		17
ATTREZZATURA SPECIFICA ....................................................................................		17
INCONVENIENTI, CAUSE E RIMEDI ........................................................................		18
RACCOMANDAZIONI PER L’USO ............................................................................		18
INSTALLAZIONE ........................................................................................................		19
SCOMPOSIZIONE ......................................................................................................		21
RICOMPOSIZIONE ....................................................................................................		22
INDEX		Page
INFORMATIONS GENERALES .................................................................................		25
INFORMATIONS POUR LE PROPRIETAIRE DE LA BICYCLETTE .........................		26
REGLES GÉNÉRALES ..............................................................................................		28
OUTILLAGE SPECIFIQUE .........................................................................................		28
INCONVÉNIENTS, CAUSES ET REMÈDES .............................................................		29
CONSEILS POUR L’UTILISATION ............................................................................		29
INSTALLATION ..........................................................................................................		30
DÉCOMPOSITION .....................................................................................................		32
RECOMPOSITION .....................................................................................................		33
INHALTSVERZEICHNIS		Seite
ALLGEMEINES ...........................................................................................................		36
INFORMATIONEN FÜR DEN FAHRRADBESITZER .................................................		37
ALLGEMEINE NORMEN ............................................................................................		39
SPEZIFISCHE AUSRÜSTUNG ..................................................................................		39
MÄNGEL, URSACHEN UND ABHILFEN ...................................................................		40
ANWENDUNGSEMPFEHLUNGEN ............................................................................		40
EINBAU .......................................................................................................................		41
AUSBAU .....................................................................................................................		43
WIEDERZUSAMMENBAU ..........................................................................................		44

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GENERAL

Fully hydraulic air sprung/oil dampened multi-valve design. Air pressure regulation by “Schraeder” valve.

On the fly damping adjustment via external knob on each fork leg at 6 positions.

Position 6 effects fork lock-out.

In this condition, there is no damping effect at all, so it is suitable for riding uphill.

Weight: 3.15 lbs. o 1430 grams.

Standard air pressure : 3.5 Bar (51 psi).

Steer tube: High strength steel with variable wall thickness available in different lengths: 1” - 1 1/8" - 1 1/4".

Crown: Forged T6-6082 offset alloy, externally machined for reduced weight.

Arch: Forged T6-6082 alloy, CNC machined for reduced weight. Stanchions: Hard chromed chromoly steel - Ø1.023 in. o Ø 26 mm Sliders: Forged T6-6082 alloy, CNC externally machined for reduced weight.

Bushings: Low stiction, long life hard steel internal upper bushing units. Lower stanchion tube bushing is made of stiction free nylon.

Travel: 2 inches o 50 mm.

Seals: Computer designed oil seals guarantee the best seal. The exclusive Marzocchi design offers the greatest seal reliability.

Oil: Specially formulated Marzocchi oil eliminates foaming and viscosity breakdown while providing stiction free performance. SAE 20 (Item 52.51).

The following is accompanying the fork:

–Warranty

–Instruction manual

–Technical descriptions

–Brake cable clamp

–Adaptor.

DH3	DOWN - HILL
XC 700	CROSS - COUNTRY
XCR	CROSS - COUNTRY
ZOKES-PRO	NO COMPETITIONS
ZOKES 2 / ZOKES TREKKING	NO COMPETITIONS

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OWNER'S INFORMATION

IMPORTANT: Installing a Marzocchi suspension system is a very delicate operation that must be carried out with extreme care. These installation and maintenance instructions are designed for experienced bicycle mechanics and must be followed exactly as written and specified. Failure to precisely follow these instructions could cause damage to one or more components of the Marzocchi suspension system. This damage may not be readily visible or apparent and could lead to unexpected failure on one or more components of your suspension to such extent that the rider may loose control of the bicycle and suffer severe injury.

The responsibility of the owner

1)The Marzocchi suspension system is designed to absorb the shocks of an uneven road surface in order to give the rider more control over this bicycle. It is not designed to absorb the forces generated by jumps or other acrobatic maneuvers. If you subject the Marzocchi suspension system to repeated jumps

or other acrobatic maneuvers, you could cause one or more of the components of the suspension system to unexpectedly break, resulting in a loss of bicycle control and serious injury to the rider.

2)Some of the parts of the bicycle, such as the brakes, steering, tires, wheel assembly and shifters may not have been adjusted at the time the Marzocchi

suspension system was installed on the bicycle. Before you ride the bicycle, be sure all the parts of the bicycle were properly adjusted and functioning properly.

3) All of the components of the suspension system must be correctly assembled and tightened exactly to the specified torque values. Periodically check the torque of these components to insure that they are correct. Failure to properly assemble and tighten the components could cause one or more of the components to unexpectedly break, resulting in a loss of bicycle control and serious injury to the rider.

4) There are obvious risks associated with mountain biking and other types of bicycle riding. Despite the use of all safety equipment for the bicycle and the rider, either injuries or damages may occur. This is the responsibility of the rider. To reduce the risk of injury, all activities must be under proper supervision and only after proper training and experience. Good physical condition of the rider and the good state of the bicycle are essential to be a safe and successful rider.

5) Be sure to read and follow all the instructions and warnings which originally accompanied your bicycle. In addition, it is recommended for added safety and protection while riding that a good quality bicycle helmet be worn and that other safety devices such as lights, reflectors, or reflective clothing be used. Some cities and states may require the use of a helmet and other safety equipment. Follow all traffic rules and all other laws about safety equipment and use your bicycle where you are permitted to ride.

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6) For any further information you might need, please call or write to the addresses on page 47-48.

It is your responsibility to make sure the assembly instructions in this book are precisely followed.

Always ride safely and carefully.

Always respect Nature when riding !

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GENERAL RULES

1.Where specified, assemble and disassemble the shock absorption system only using the LARM or MARZOCCHI special tools, as shown in the table below.

2.On reassembling the suspension system, always use new seals.

3.If two screws are close one to the other, always tighten using a 1-2-1 sequence. In short, screw the first screw just up to the point it is well tightened, then tighten the second screw and then go back to the first one and screw it tighter.

4.Clean all metal parts with a special, preferably biodegradable solvent, such as trichloroethane or trichloroethylene.

5.Before reassembling, lubricate all parts in contact with each other using silicone fat spray.

6.Always grease the conic seal rings before reassembling.

7.Use wrenches with metric size only. Wrenches with inch size might damage the fastening devices even when their size is similar to that of the wrenches in metric size.

SPECIFIC TOOLS

	Item	Item
Ref.	MARZOCCHI	LARM	Description	Use
A	104	60.32	Plug extracting tool	To remove the plug from the stanchion tube
				(XC 400 - 500 - 600 - 700 / XCR / DH3)
B	R5043	60.21	Pointed pliers	To remove the oil seal retaining ring
				(XC 400 - 500 - 600 - 700 / XCR / DH3)
C	R5047	60.34	Tool for seal ring	To insert the oil seal into the slider
			Ø 26 mm assembly	(XC 600 - 700 / XCR / DH3)

If you do not have this equipment, contact the “MARZOCCHI Technical Service Centers.

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FAILURES, CAUSES AND REMEDIES

This paragraph reports some troubles 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
Fluid escapes through the	1)	Oil seal is worn out	1)	Replace oil seal
oil seal	2)	Stanchion tube is scored	2)	Replace oil seal and
	3)	Exceeding dirt on oil		stanchion tube
		seal	3)	Replace oil seal
Pressure leakage	1)	Valve of inflating plug is	1)	Tighten plug or replace
		loosened		air valve
	2)	Plug O-ring is damaged	2)	Replace O-ring and
				check that O-ring seat
				on the plug is in good
				conditions. Replace plug
				body
Fork has not been used for	Oil seal and dust seal tend		Raise dust seal and
some time and tends to	to stick to stanchion tube		lubricate oil seal and dust
lock out during initial travel			seal with oil
Damping is no longer as	Exhausted oil		Change oil
steady as in the beginning
Fork bottoms or tops out	1)	Pressure is too low	1)	Check pressure
too easily	2)	Low oil level	2)	Refill oil
Even at low pressure, fork	Oil level is too high		Reduce oil level
is too progressive
Fork rebounds too fast	Dirt inside, valves do not		Clean carefully and replace
	close perfectly		oil

RECOMMENDATIONS FOR MAINTENANCE

MARZOCCHI forks are based on advanced technology, supported by year-long experience in the field of professional mountain biking. In order to achieve best results, we recommend to check and clean the area below the oil seal and the stanchion tube after each use and lubricate with silicone oil.

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All components of the suspension system and the whole bike should be regularly checked. The frequency of these checks depends on the bike use. For further information, read the table below. Check any fastening device to check that it is either too tight or to loose. Remove any clearance or loosening of either the system components or the bike. Check that no component of both the system and the bike is broken, bended, improperly misaligned or not properly working. Should some problem occur, do not ride the bike until it is detected and removed by a specialised technician. Failure to properly check the suspension system and the bike could cause one ore more of the components to unexpectedly break, resulting in a loss of bicycle control and serious injury to the rider.

RIDERS CLASS	CHECK FREQUENCY
Chance and keen riders	each 50 hours
Determined riders who often
ride on difficult tracks;
Riders who ride under extreme	each 20 hours
conditions (mud, rain, storms,
low temperatures and so on)
or who trains with his own bike
Professional riders or athletes	after each ride

INSTALLATION (see figures on the folded leaflet enclosed to this manual)

IMPORTANT: Installing the MARZOCCHI fork on a frame is a very delicate operation that should be carried out with extreme care following the instructions given below. Once installed, have it checked at one of our Technical Service Centres.

–Distance “H” between crown and tyre edge (when inflated) should not be lower than total travel + 3 mm (see Fig. a).

For instance: fork XC700 has a total travel of 50 mm; mounting minimum distance shall be H=50+3=53 mm.

–Fit the steer tube into the crown and tighten fastening screws (Ref. 9, see Fig. b) by means of a proper wrench at 11 Nm torque (7.5 lb.ft.).

WARNING: Steering tube/headset mounting and adjustment must be carried out in compliance with the headset manufacturer’s instructions either when a threaded steering tube or an “A-Head Set” steering tube is installed. Improper installation may

jeopardize the safety of the rider.

–Check the torque of the screws (Ref. 3, see Fig. c) fastening stanchions to crown and (Ref. 10, see Fig. c) stiffening arch to sliders.

				US	UK	9
For prescribed tightening torque, see the table below.
Thread diameter		Tightening torque
		Nm			lb ft
M5		9			6.6
M6		11			7.5

–The eccentric fastening of the control wires for the brake pads must be positioned so that the two angles (“α”, Fig. d) to the tube axis are equal and symmetric. The brake cable must also be kept straight for at least 50 mm (2 in.) to get to a correct bending during the whole fork stroke. Only by following these instructions you will reach a correct

brake cable-cam function.

To reroute the front brake to right-hand lever, proceed as follows:

–Undo and remove screw (1) and cam (2) positioned as shown in Fig. d.

–Turn the cam and fasten it at 9 Nm (6.6 lb.ft.) by means of the screw as shown in Fig. e.

–Cut cable to size so as to have a straight section at least 50 mm long. NOTE: Use brake cable only.

–Insert the short cable (4) into the left cantilever and lock it with the original fastener.

–With the cam still positioned as in Fig. e, secure the cable (4) to the cam with screw 85) and plate (6).

–Install clamp (8) (supplied with the fork) and lock it over the control cable (7) as shown in figure (“α” angles should be identical and symmetrical to steering tube axis). NOTE: Clamp screw should be tightened over the cable to 5 Nm (3.7 lb.ft.)

CAUTION: should the clamp work itself loose, the braking effect on front wheel will be lost.

– Adjust brakes as recommended by brake manufacturer.

ATTENTION: Once installed on the frame, the fork should be left in a vertical position, set at adjuster position “1”, for at least 3-4 hours. This to let the oil fill all internal ducts, after fork was transported in a horizontal position. This is the only way to ensure your

fork’s efficiency.

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DISASSEMBLY (see figures on the folded leaflet enclosed to this manual)

The reference numbers given in this section relate to the components shown in the fork exploded drawing on the folded leaflet enclosed to this manual.

FIG. 1

Loosen the screws (10) which block the brake arch (305) to the sliders.

FIG. 2

Remove the fork legs from the crown by loosening the screws (3) on the locking clamps.

FIG. 3

Slide the top of the stanchion tubes out of the crown.

FIG. 4

Before carrying out any maintenance or replacement work, remove the protection caps (303) and release the air pressure in the fork legs through the valves.

FIG. 5

Screw the special tool A (MARZOCCHI Item 104 - LARM Item 60.32) onto the plug threaded projection.

Push the upper plug assembly (17) into the stanchion tube (19) deep enough to be able to get at the stop ring. Loosen and remove the tool.

FIG. 6

Take out the upper stop ring (38H) by means of a screw driver.

FIG. 7

Mount tool A (MARZOCCHI Item 104 - LARM Item 60.32) and pull out the upper plug assembly (17) from the stanchion tube. Pull hard to overcome the resistance made by the OR oil seal (4).

FIG.8

Drain the oil contained in the fork leg by pushing the slider up and down to let all the oil come out.

WARNING: Do not waste the exhausted oil in the environment!

FIG. 9

Remove the dust seal (20) from the top of the slider by exerting an upward pressure with a screwdriver.

FIG. 10

By means of pointed pliers B (MARZOCCHI Item R 5043 - LARM Item 60.21) remove the lower stop ring (38).

FIG. 11

Temporarily fit the upper plug assembly (17) into the stanchion tube in order to block the tube in a vice with protective jaws without ovalizing it. Pull hard from the slider, with alternating motions, until stanchion tube comes out (19).

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FIG. 12

Remove the oil seal (22), the lower retaining cup (139), the pilot support (141) complete with bushing from the stanchion tube. Check the wear of the removed parts.

FIG. 13

Using a screw driver as a lever, push on the edge of the adjuster knob (311) to take out the foot valve set (301) from the slider. To make this operation easier, hit the slider with a mallet a few times.

FIG. 14

The valve set consists of various components and should only be disassembled when necessary. To remove the adjuster knob (311), stop the inner cylinder, which is integral with the knob, from spinning by means of a flat-head screw driver.

Vice the screwdriver and unscrew the the fastening screw of the adjusting knob by means of a 3 mm Allen wrench. Remove the screw, the first spring washer, the knob and the second spring washer.

The body of the foot valve has an O-ring (312) and a lip seal (313) that should be replaced after every overhaul.

REASSEMBLY (see figures on the folded leaflet enclosed to this manual)

IMPORTANT: before reassembling, all components should be washed carefully and dried with compressed air. The foot valve should be cleaned with special care.

FIG. 1

Fit a new O- ring (312) into the seat of the valve body. Fit a new conic seal ring (313) from the opposite side. These seals should be duly greased. Take special care when fitting the conic seal ring: the widest side must face the bottom of the valve body.

FIG. 2

Fit a spring washer on either side of the adjuster knob (311) and fit the fastening screw from the knurled side. Insert the adjuster knob onto the cylinder and line up reference “1” with the open oil hole with larger diameter.

FIG. 3

Hold the inner cylinder with the same screw driver you used for disassembling and, at the same time, tighten the fastening screw of the adjuster knob.

FIG. 4

Having the knob on “1” and lined up with the larger open hole, fit the foot valve set (301) into the slider until it reaches the bottom. Line up its reference “1” with the arrow on the slider.

FIG. 5

Lubricate the pilot boss support (141) complete with bushing and mount them on the stanchion tube (19).

Fit this assembly into the slider up to the bottom.

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FIG. 6

Fit the lower retaining cup (139) into the stanchion tube with its rounded part facing outward.

FIG. 7

Lubricate the oil seal (22) and slip it onto the proper buffer C (MARZOCCHI Item R 5047 - LARM Item 60.34). Hit the buffer to fit the retaining ring into the slider.

FIG. 8

Fit the stop ring (38) into the proper retaining groove in the slider and for its proper fitting by pushing it in different directions.

FIG. 9

Lubricate the dust seal (20) and carefully fit it into the stanchion tube.

FIG. 10

Pour “MARZOCCHI oil Item 52.51” into the stanchion tube. Pump several times up and down so that the oil fills the whole inner volume. Make sure that the stanchion tube is at the slider bottom and check that the oil is 35 mm from the top.

FIG. 11

Tighten tool A (MARZOCCHI Item 104 - LARM Item 60.32) on the plug threaded projection. Grease the O-ring (4) and fit the upper plug assembly (17) inside the stanchion tube. Push it beyond the seat of the stop ring.

FIG. 12

Mount the upper stop ring (38H) and inflate (standard air pressure: 3.5 Bar / 51 psi). Fit the protection plug (303) and proceed with the assembly following the instrucions of chapter “INSTALLATION”.

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Description of exploded view components shown on the folded leaflet enclosed to this manual.

REF DESCRIPTION

3SCREW

4O-RING

9SCREW

10SCREW

14STEER TUBE

15CROWN

16CROWN + STEER TUBE

17UPPER PLUG ASSEMBLY

19STANCHION TUBE

20DUST SEAL

22OIL SEAL

24RIGHT SLIDER

25LEFT SLIDER

38STOP RING 38H STOP RING

56UPPER BUSHING

84	VALVE
91	BOOT
139	RETAINING CUP

141BUSHING UNIT

142PILOT BOSS SUPPORT

143WASHER

200 OVERHAUL KIT

301 CLICKER

303PROTECTION PLUG

304GUIDE PIN

305ARCH

311KNOB

312O-RING

313CONIC SEAL RING

316	CAM
322	CAM SCREW

504LEFT DECAL

505RIGHT DECAL

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GENERALITÀ

Ammortizzata ad aria/olio con sistema multi-valvole. Regolazione pressione aria per mezzo di valvola “Schraeder”.

Facile e immediata regolazione per mezzo di un pomello esterno su ogni gamba forcella a 6 posizioni.

Nella posizione 6 si ha il lock-out della forcella.

In questa condizione viene a mancare completamente l'effetto ammortizzante ed è quindi indicata per affrontare tratti pianeggianti e salite.

Peso: 1430 grammi (3.15 lbs).

Pressione aria standard: 3,5 Bar (51 psi).

Cannotto: acciaio ad alta resistenza con spessore parete variabile disponibile in varie lunghezze nelle versioni da 1" - 1 1/8" - 1 1/4".

Base: Offset in lega T6-6082 stampata, lavorata esternamente per ridurre il peso.

Archetto: Lega T6-6082 stampata, lavorazione meccanica per riduzione del peso.

Tubi portanti: in acciaio al cromomolibdeno speciale ad alta resistenza, cromati duri - Ø26 mm.

Gambe: Lega T6-6082 stampata, lavorate esternamente per riduzione peso.

Boccole di scorrimento: basso attrito di primo distacco, boccole superiori interne in acciaio duro di lunga durata. La boccola del tubo portante inferiore

è di nylon esente da attrito di primo distacco.

Corsa: 50 mm (2 pollici)

Guarnizioni: anelli di tenuta progettati al computer assicurano la massima tenuta. Il design dei componenti è esclusivo Marzocchi ed offre la massima affidabilità.

Olio: Olio a formula speciale elimina la formazione di schiuma e mantiene inalterate le caratteristiche di viscosità mentre è in grado di fornire elevate prestazioni; esente da attrito di primo distacco. SAE 20 (Art. 52.51).

La forcella è corredata da:

– Garanzia

– Libretto istruzioni

– Descrizioni tecniche

– Morsetto per attacco cavo freno

– Adaptor.

DH3	DOWN - HILL
XC 700	CROSS - COUNTRY
XCR	CROSS - COUNTRY
ZOKES-PRO	NON COMPETIZIONE
ZOKES 2 / ZOKES TREKKING	NON COMPETIZIONE

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INFORMAZIONI PER IL PROPRIETARIO DELLA BICICLETTA

IMPORTANTE: Installare un sistema di sospensione Marzocchi rappresenta un’operazione estremamente delicata che deve essere eseguita con estrema attenzione. Le presenti istruzioni per l’installazione e la manutenzione sono destinate a meccanici per biciclette esperti e dovranno essere scrupolosamente osservate alla lettera. La non osservanza di tali istruzioni secondo le indicazioni fornite, potrà provocare danni ad uno o più componenti del sistema di sospensione Marzocchi. Tale danno potrebbe non risultare visibile immediatamente o evidente a prima vista e causare l’imprevista rottura di uno o più componenti del sistema di sospensione, di entità tale da pregiudicare il controllo della bicicletta e comportare gravi danni fisici per il ciclista.

La responsabilità del proprietario della bicicletta

1)Il sistema di sospensione Marzocchi è progettato in maniera tale da ammortizzare gli urti o gli effetti di un fondo stradale non uniforme, al fine di assicurare

al ciclista un maggiore controllo della propria bicicletta.

Questo sistema non è stato progettato per assorbire le forze generate da salti o altre manovre acrobatiche eseguite in sella alla propria bici. Se il sistema di sospensione Marzocchi viene ripetutamente messo a dura prova da salti o esercizi acrobatici, uno o più componenti del medesimo potrebbero andare incontro ad impreviste rotture che comporterebbero la perdita del controllo del mezzo e gravi lesioni al ciclista.

2) Alcune parti costitutive della bicicletta, quali freni, sterzo, pneumatici, gruppo ruota e leva del cambio, potrebbero non essere stati regolati nel momento in cui è stata eseguita l’installazione del sistema di sospensione Marzocchi sulla bicicletta. Prima di montare in sella alla bici, verificare che tutte le parti siano state correttamente regolate e funzionino in maniera appropriata.

3)Tutti i componenti del sistema di sospensione dovranno essere assemblati correttamente e serrati saldamente ai valori di coppia specificati. Controllare

periodicamente la coppia di questi componenti per accertarne la correttezza. La mancata esecuzione di un corretto assemblaggio e di un idoneo serraggio dei componenti potrebbe provocare l’imprevista rottura di uno o più elementi che pregiudicherebbero il controllo del mezzo e comporterebbero gravi lesioni al ciclista.

4) Alle mountain bike e ad altri tipi di bicicletta sono ovviamente associati dei rischi. Nonostante l’impiego di tutti i dispositivi di sicurezza sia per la bicicletta sia per il ciclista che vi monta in sella, possono verificarsi danni per entrambi. Ciò rientra nell’ambito delle responsabilità del ciclista. Per ridurre il rischio di incidenti, tutte le attività dovranno essere svolte sotto un’attenta supervisione e soltanto dopo un periodo di training e un’esperienza appropriati. La buona forma fisica del ciclista e l’ottimo stato della bicicletta sono elementi essenziali per assicurare un controllo sicuro del mezzo.

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5)Avere cura di leggere e seguire tutte le istruzioni e gli avvertimenti che vengono originariamente forniti insieme alla bicicletta. Si raccomanda inoltre, per

garantire una maggiore sicurezza e protezione, di indossare un casco protettivo di buona qualità e di installare altri dispositivi di sicurezza quali luci, riflettori o indossare un abbigliamento appropriato, realizzato in materiale rifrangente. In alcune città e stati è prescritto obbligatoriamente l’uso di un casco protettivo abbinato all’uso di altri dispositivi di sicurezza. Attenersi a tutte le disposizioni che regolano la circolazione stradale nonché a tutte le altre norme relative ai dispositivi di sicurezza, avendo cura di usare la bicicletta soltanto nei luoghi in cui ne è consentita la circolazione.

6)In caso di quesiti da sottoporre alla nostra attenzione, vi preghiamo di telefonare o scrivere agli indirizzi riportati a pag. 47-48.

Vi riterremo responsabili della corretta applicazione delle istruzioni di assemblaggio contenute nel presente libretto.

Guidare sempre nel pieno rispetto delle norme di sicurezza e prestando sempre la massima attenzione.

In ogni Vostro spostamento rispettate sempre la Natura!