Marzocchi X-Fly Manual de usuario

X-Fly

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.

X-Fly

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

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

Adjuster position does not affect fork opera-

tion

1. Dirt inside legs

2. RH fork cartridge faulty

1. Clean carefully and change oil

2. Replace hydraulic cartridge

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

X-Fly

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

WARNING: If a disc brake system

is installed, it is absolutely forbidden

to loosen and remove original brake sup-

ports fixing pins. In fact, apart from retain-

ing Cantilever or V-brake levers, they also

play an important role in securing slider

bottom to slider-arch monolith. If needed,

replace these pins with screws (part no.

532979QF) available as spare parts.

Tighten the above screws to 10 Nm.

IMPORTANT: screw and pin threading is

treated to ensure hydraulic seal. Never

reuse screws and pins which have been

removed.

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.

X-Fly

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 ADJUSTMENT

(only right leg)

The right fork leg is equipped with an

adjuster screw (A) for REBOUND damp-

ing. Turning this adjuster clockwise into the

cartridge rod, changes the hydraulic set-

ting of the inner valves. In short, the amount

of adjustment applied on the piston in the

fluid determines the rate of damping.

To adjust, always start from the minimum

damping setting, i.e. unscrew completely

counterclockwise. About 8 turns - abt. 4 mm

of the adjustment - are possible.

X-Fly

LOCK

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

X-Fly

▲

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

FORK OIL CHANGE

STANCHION TUBE CAP FIG. 1/2/3

AIR VALVE CHANGE

FIG. 13

FOOT NUTS FIG. 5

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

CARWON AND STANCHIONS ASSEMBLY

FIG. 7

DUST SEAL FIG. 8

STOP RING FIG. 9

OIL SEAL FIG. 10

UPPER WASHER FIG. 11

PILOT BUSHING FIG. 12

HYDRAULIC CARTRIDGES,

REBOUND SPRING AND WASHER FIG. 6

HYDRAULIC CARTRIDGES CHANGE

X-Fly

11-12

STANCHION PLUG

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 (7) with a 21 mm socket

wrench.

FIG. 3

Lock the check nut (26) and remove the cap

(7) from hydraulic cartridges ends (12)

and (11).

X-Fly

118

12 11

6-9

Sx.Dx.

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. 22 to Fig. 24.

HYDRAULIC CARTRIDGE 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

Pull the hydraulic cartridge (12) and (11)

complete with rebound spring.

IMPORTANT: cartridges fitted to forks

with a travel of 100 feature a rebound

spring (9) that is the same fitted in both fork

legs.

Rebound springs in forks with a travel of

80 are different: rebound spring (9) is in

the LH fork leg, while rebound spring (6) is

in the RH fork leg.

Remove the bottom washers (23, see ex-

ploded view) from inside the stanchions.

NOTE: the hydraulic cartridge is supplied

with gaskets and lock nut (26).

These parts can be also ordered separately

(see exploded view).

Replace the whole hydraulic cartridges.

X-Fly

REPLACING SEALING UNIT AND

GUIDE BUSHES

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.

X-Fly

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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