User manual MARZOCCHI 2003 EXR

[. . . ] Never use a fork that is damaged in any way during an accident (oil leakage, bent or cracked components, etc). The fork must be regularly maintained throughout the use of the fork. The fork must be repaired and overhauled by authorized technicians only. Take your fork to the shop where you bought it so they can send it to the Marzocchi Authorized Service Center in your country; this will protect your own safety and original spare parts only. [. . . ] Use the fast rebound position for downhilling, the 3 middle positions for race start sprints and rough climbing and the fully closed ECC position for steep dirt switchback climbs or Marathon style road climbs. ETA: the new Extension Travel Adjustment locks down the rebound damping like the standard ECC, but still allows 25 - 30mm of travel. HSCV: the High-Speed Compression Valve (HSCV) allows lighter damping for better trail sensitivity but still resists bottoming. It is the best way to provide a controlled damping environment for consistent and perfect damping. The moving valve on the shaft controls rebound and low-speed compression damping. The special valve in the bottom of the cartridge (HSCV), takes the edge of any hard hit to maintain control. SSV: the Speed Sensitive Valve (SSV) uses 5 valve circuits to control damping rates based on the fork's compression and rebound speed as well as the fork's position in the travel. MZ001 SSVF: The latest version of our Speed Sensitive Valve has a new Floating valve and spring design. It incorporates a spring-loaded valve, which is more responsive and uses an external rebound adjuster. Technical information 47 Fork Marathon SL Marathon S Marathon SL 29' MX Pro W/ETA MX Pro Air MX Pro Coil MX Pro W/ETA 29' MX Comp W/ETA MX Comp Air MX Comp Coil MX Comp Coil 29' Z1 FR SL Z1 FR Z1 Drop Off Dirt Jumper I Dirt Jumper II Dirt Jumper III Junior T Super T Pro Shiver SC Shiver DC Damping system Right leg ECC5 hydraulic cartridge HSCV cartridge ECC5 hydraulic cartridge SSVF pumping rod with floating valve and external adjustment SSVF pumping rod with floating valve and external adjustment SSVF pumping rod with floating valve and external adjustment SSVF pumping rod with floating valve and external adjustment SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment ECC5 hydraulic cartridge HSCV cartridge SSVF pumping rod with floating valve and external adjustment SSVF pumping rod with floating valve and external adjustment SSV pumping rod with internal adjustment Non-adjustable SSV pumping rod ETA cartridge Pneumatic cartridge, negative air ETA cartridge / / ETA Cartridge ETA Cartridge SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment Pneumatic cartridge, negative air ETA cartridge ETA cartridge / SSV pumping rod with internal adjustment Non-adjustable SSV pumping rod English Left leg Pneumatic cartridge, negative air SSV pumping rod with floating valve and SSV pumping rod with floating valve and internal adjustment internal adjustment HSCV cartridge HSCV cartridge HSCV cartridge HSCV cartridge ETA cartridge HSCV cartridge MZ001 48 Installation INSTALLATION Installation on the frame 3 3. 1 The fork is supplied with "A-Head Set" (threadless) steer tube to be cut according to frame size it will be used on. Installing a MARZOCCHI fork on the bicycle frame is a very delicate operation that must be carried out by specialized personnel. The assembling on the frame and the steer tube adjustment must be carried out in compliance with the manufacturer's instructions. Improper installation may jeopardize the safety of the rider. Marzocchi does not guarantee the installation and refuses all responsibility for damages and/or accidents that may be caused by an incorrect installation. The steer tube must be pressed into the crown; its replacement must be carried out by one of our service centers only, using the required tools. 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. · Tighten to the required torque (see Table 1 ­ Tightening Torques) the bolts (C) positioned on both dropouts. MZ001021 A 6 mm MZ001022 B 5 mm C MZ001 MZ001023 English 52 Maintenance MAINTENANCE Problems ­ Diagnosis ­ Solutions 4 4. 1 This paragraph indicates some of the problems that may arise during the fork's use, as well as the possible causes of these problems and the suggested solutions. Always check this table before working on the fork. Operations inside the grey box must be carried out by authorized service centers. Problem Fork has too much sag Diagnosis Spring rate too soft Solution Add spring preload Change to stiffer spring rate Check oil height Fork bottoms too easily; needs Spring rate too soft or fork oil too more than maximum preload to Get stiffer springs low attain proper sag Increase air pressure Forks bottoms too easily, but it Not enough compression has the recommended sag damping Fork does not get full travel Increase compression damping by changing oil level English Check oil height Spring rate too stiff or fork oil too Get softer spring high Decrease air pressure Increase rebound damping Replace oil (SAE 7, 5) with a higher viscosity Decrease the rebound damping Increase spring rate Decrease rebound damping Decrease rebound damping Replace all seals (repair the fork before using it again) Replace all seals and have the stanchions inspected (repair the fork before using it again) Fork extends too quickly; harsh Not enough rebound damping top-out after impacts Front wheel wants to tuck under while cornering Too much rebound damping; spring rate too soft Fork "packs up" or stays down Too much rebound damping in travel during multiple impacts Knocking sound during rebound, but no harsh top-out Oil "ring" on stanchions Heavy amount of oil on stanchions; oil dripping down legs Fork is sticky; fork does not perform as new Oil leakage from the bottom Loss of sensitivity Too much rebound damping Oil seals are contaminated Seals are damaged, stanchions could be damaged Oil seals are contaminated; fork Replace all seals (repair the fork before using it again) needs to be serviced Loose bottom nut Bottom nut o-ring damaged Worn sliding bushings Old oil Tighten bottom nut Replace bottom nut o-ring Replace sliding bushings Change oil MZ001 Maintenance 4. 2 Periodical maintenance table Use Intense After every ride Before every ride 50 hours 100 hours 10 hours 100 hours 200 hours Normal 53 General maintenance operation Stanchion and dust seal cleaning Air pressure control Oil change Oil seals replacement 4. 3 General safety regulations After a complete breakdown, always use new seals when reassembling. To tighten two bolts or nuts that are near each other, always follow the sequence 1-2-1 using the required tightening torque (see Table 1 ­ Tightening Torques). Never use flammable or corrosive solvents to clean the parts, as these could damage the seals. If necessary use specific detergents that are not corrosive, not flammable or have a high flash point, compatible with the seals materials and preferably biodegradable. If you are planning not to use your fork for a long time, always lubricate the forks components that are in contact with some fork's oil. Never pour lubricants, solvents or detergents which are not completely biodegradable in the environment; these must be collected and kept in the relevant special containers, then disposed of according to the regulations in force. Use only metric spanners, not imperial spanners, which may have similar sizes, but can damage the bolts and make it impossible to unscrew them. Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws. 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