Marzocchi MXC+ECC Air Manual de usuario

MXC

ECC

Air

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system us-

ing the M

ARZOCCHI

special tools only.

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

in contact with each other using silicone

fat spray or a specific oil for seals.

5. Always grease the lip seal rings before

reassembling.

6. 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.

MXC

ECC

Air

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

Adjuster position does not affect fork

operation

1. Dirt inside legs

2. Pumping element of r.h. leg does not

work properly.

1. Clean carefully and change oil

2. Replace pumping element.

Oil leaking through the bottom of slider O-ring on the pumping rod or on cartridge

securing nut bottom damaged

Replace the O-ring

Oil leaking through the top of the slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on slider oil seal

1. Replace oil seal

2. Replace crown/stanchions assembly, oil

seals and dust seals

3. Clean the oil seal seat and replace oil seal

Fork has not been used for some time and

is locked out

Oil seals and dust seals tend to stick to

stanchions

Raise dust seal and lubricate stanchion

tube, dust seal and oil seal

Pressure drop Cap valve damaged Replace cap and/or valve

Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings

Fork rebounds too fast in any adjuster

position

Dirt inside fork legs Clean carefully and change oil

Fork does not react to rebound lock LH fork cartridge faulty Replace hydraulic cartridge

MXC

ECC

Air

RECOMMENDATIONS FOR

MAINTENANCE

ARZOCCHI

forks are based on advanced

technology, supported by year-long experi-

ence in the field of professional mountain

biking. In order to achieve best results, we

recommend to check and clean the area

below the dust seal and the stanchion tube

after each use and lubricate with silicone

oil.

In general, M

ARZOCCHI

forks can offer top

performance from the start. However, in

some cases a short running-in period is

required (5-10 hours) for inner adjustments.

This running-in period will make fork life

longer and ensure fork top performance

over time.

IMPORTANT: change oil at least every

100 working hours and check pressure at

least every 10 working hours.

Polished forks should be cleaned with

bodywork polish at regular intervals in

order to preserve their original finish.

INSTALLATION

Installing the fork on a bicycle is a very

delicate operation that should be carried

out with extreme care. The installation should

always be checked by one of our Technical

Service Centers.

WARNING: Steer tube/headset

mounting and adjustment must be

carried out in compliance with the headset

manufacturer’s instructions. Improper in-

stallation may jeopardize the safety of the

rider.

To replace it, contact one of our Technical

Service Centers with the required tools.

WARNING: In case of improper

installation of the steer tube into the

crown, the rider might lose control of his/

her bicycle, thus jeopardizing his/her safety.

DISC BRAKE SYSTEM ASSEMBLY

If a disc brake system is installed, brake

supports fixing pins can be replaced with

screws (part no. 532979QF) available as

spare parts.

Tighten the above screws to 10 Nm.

Assembling the brake caliper onto the slider

is a very delicate operation that should be

carried out with extreme care.

Improper assembly might overstress the

caliper supports which might break.

When installing the disc brake system, be

sure to properly follow the instructions given

by the manufacturer.

MXC

ECC

Air

LOCK

ADJUSTMENTS

FORK LEG PRESSURIZATION

Blow pressurized air through the valves to set

COMPRESSION damping. To change the

pressure inside the fork legs, remove the

protection cap (2) and depressurize each

leg by pushing lightly on valve pin with a bit.

Fully tighten adapter fitting (D), supplied

with the fork, on M

ARZOCCHI

pump (C).

Screw fitting end –with O-ring (D1) on

valve, and pressurize until the required value

is reached. Unscrew the fitting/pump as-

sembly and refit the cap (2).

IMPORTANT: inflate using special

ARZOCCHI

pump with pressure gauge.

Use of improper tools or other procedures

than specified ones might lead to improper

inflating.

NOTE: in case of air leakages when adapter

fitting (D) is fitted, ensure that the O-ring

(D1) is not damaged.

REBOUND LIMITER

(only left leg)

In case of hard uphill path, fork leg rebound

can be locked for improved behavior.

Position the knob (4) on l.h. fork leg top to

“LOCK” to lock rebound limit in this posi-

tion; this also allows to decrease fork leg

height for optimal attitude uphill, thus sup-

porting suspension compression operation.

Reposition the knob to its original position

so that the fork will rebound and restart to

work as before.

WARNING: do not position to

“LOCK” when riding downhill as

available travel might not be enough, thus

jeopardizing rider’s safety

MXC

ECC

Air

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. 2).

Fit the supplied hexagon rod (E) into the

stanchion tube and into the adjuster inner

hole. Rotate the adjuster clockwise for harder

damping, counterclockwise to soften it.

Refit the cap (8) and tighten it to the

specified torque (see section REASSEMBLY,

Fig. 29).

MXC

ECC

Air

▲

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.

DISASSEMBLY DIAGRAM

▲

FOOT NUT FIG. 5

SEAL ASSEMBLY AND

PILOT BUSHING CHANGE

CROWN AND STANCHIONS

ASSEMBLY FIG. 7

STOP RING FIG. 9

OIL SEAL FIG. 10

UPPER WASHER FIG. 11

PILOT BUSHING FIG. 12

HYDRAULIC CARTRIDGE, REBOUND

SPRING AND WASHER FIG. 6

HYDRAULIC CARTRIDGE CHANGE

(l.h. fork leg)

FORK OIL CHANGE

STANCHION TUBE CAP FIG. 1/2/3

AIR VALVE CHANGE

FIG. 15

REPLACING PUMPING ELEMENT

(r.h. fork leg)

REPLACING VALVE ASSEMBLY

REBOUND BUMPER,

PUMPING ROD,

REBOUND SPRING FIG. 13

STOP RING, VALVE ASSEMBLY

FIG. 14

DUST SEAL FIG. 8

MXC

ECC

Air

STANCHION TUBE CAP

FIG. 1 (only left leg)

Loosen screw (3) and remove rebound

limiting knob (4).

FIG. 2

Depressurize each fork leg (see section

ADJUSTMENT).

Unscrew the caps (8) and (6) with a 21 mm

socket wrench.

Remove the caps complete with O-ring (5)

from the stanchion tubes.

FIG. 3 (only left leg)

Lock the check nut (34) and remove the cap

(6) from hydraulic cartridge end (11).

MXC

ECC

Air

118

FIG. 4

Push the stanchions (1) into the sliders (18)

and let all the oil drain out from the fork legs.

Pump the stanchions several times to help

oil drain off.

WARNING: Remember to always

recycle any used oil.

To change the fork leg oil follow the proce-

dure as described in section “REASSEMBLY”

from Fig. 27 to Fig. 30.

HYDRAULIC CARTRIDGE CHANGE

AND PUMPING ROD CHANGE

FIG. 5

Turn the fork leg upside-down and unscrew

the foot nuts (20) by the use of a 15 mm

socket wrench complete with O-Rings (19).

FIG. 6 (only left leg)

Remove the hydraulic cartridge (11) com-

plete with rebound spring (9) and foot

washer (23, see exploded view) from the

l.h. stanchion.

Replace the whole hydraulic cartridge.

MXC

ECC

Air

13 14

SEAL ASSEMBLY AND PILOT

BUSHING CHANGE

FIG. 7

Withdraw the crown and stanchions as-

sembly (1) from the sliders (18).

FIG. 8

Remove the dust seal (13) from the top of

the sliders using a small screwdriver.

FIG. 9

Remove the stop ring (14) from the sliders

by placing the screwdriver bit in one of the

three openings on the stop ring.

IMPORTANT: when removing the stop

ring, make sure not to damage its seat.

MXC

ECC

Air

FIG. 10

Fit the slider protector (A) onto the slider

and remove the oil seal (15) with the help

of a large screwdriver.

IMPORTANT: when removing the oil seal,

make sure not to damage its seat. Once

removed the oil seals should not be used

again.

FIG. 11

Remove the upper washer (16) from the

slider.

FIG. 12

Fit the bit of a small screwdriver into upper

edge slot of the pilot bushing (17) and lift

gently. Pull the bushing out of the slider and

make all necessary changes.

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