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Marzocchi 888 VF 170, Technical Instructions

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Marzocchi 888 VF 170 Technical Instructions Download Page 3

Spare part list - 888 VF 170

 

 

Rif.

Code

Description

Q.ty in the 
model

2

528154 

O-RING

2

8

810060/R 

PRELOAD PLUG UNIT 888VF 05

2

9

501510LA 

UPPER CROWN- 888 04

1

11

7051171/R 
(replaces 7051171) 

LOWER CROWN+STEEL STEM 888 '04

1

12

533167 

DUST SEAL DIA.35

2

13

523236 

STOP RING

2

14

528034>B 

OIL SEAL DIA.35

2

16

538038>A 

UPPER BUSHING DIA.35

2

17

529194 

SLEEVE

2

18

538124 

LOWER BUSHING

2

19

522406 

WASHER

2

20

547624 

RH+LH LABELS 888 VF 2005

1

21

520341 

SCREW

1

22

5321153>A 

CABLE GUIDE

1

23

850956/C 
(replaces R5127LA) 

AXLE+SCREW KIT-66/888

1

24

520349LA 

AXLE SCREW -QR 20

1

25

5181299 

PRELOAD SLEEVE

2

26

5141293/C 

SPRINGS KIT K=3.2

1

32

528260 

O-RING

2

35

5321193RS/R>A 

MONOLITE D.35- GLOSS ECO BLACK

1

35

5321193RR/R>A 

MONOLITE D.35-FLAT BLACK

1

36

520344PN 

SCREW

7

37

507665/C 

888 STANCHION

2

38

528051 

O-RING

2

39

520178PN 

SCREW

4

40

8031212/C 

PUMPING ROD 888 RT '04

2

41

524180 

PISTON RING DIA.35

2

42

5141294/C 

REBOUND SPRINGS KIT K=2.5

1

43

522415 

WASHER

2

44

5141303 

SPRING

2

45

516107 

VALVE 20,3 DIA.35

2

46

509135 

FERRULE

2

47

523078 

STOP RING

2

48

512101 

FOOT BUFFER

2

50

5181304 

SLEEVE 30MM

2

51

531072 

RUBBER

2

52

526145AA 

BUSHING

4

53

502559LA 

LOWER CROWN 888-04

1

54

508998CD/C 

STEEL STEM

1

55

850760/C 

FENDER UNIT

1

56

526143RX 

FENDER BUSHINGS

2

57

520342AR 

FENDER SCREW

2

59

5321199 

FOOT NUT UNIT

2

60

520178PN 

SCREW

7

61

505084LA 

RH CLAMP -888

1

62

505085LA 

LH CLAMP -888

1

© Marzocchi Suspension

2005

 - 

888 VF

Summary of Contents for 888 VF 170

Page 1: ...2005 888 VF Technical instructions Marzocchi Suspension 2005 888 VF ...

Page 2: ...344PN 7 37 507665 C 2 38 528051 2 39 520178PN 4 40 8031212 C 2 41 524180 2 42 5141294 C 1 43 522415 2 44 5141303 2 45 516107 2 46 509135 2 47 523078 2 48 512101 2 50 5181304 2 51 531072 2 52 526145AA 4 53 502559LA 1 54 508998CD C 1 55 850760 C 1 56 526143RX 2 57 520342AR 2 59 5321199 2 60 520178PN 7 61 505084LA 1 62 505085LA 1 63 505083LA 1 64 526157KR 1 65 526158KR 1 66 850881 C 1 888 VF 170 Oil ...

Page 3: ... SPRINGS KIT K 3 2 1 32 528260 O RING 2 35 5321193RS R A MONOLITE D 35 GLOSS ECO BLACK 1 35 5321193RR R A MONOLITE D 35 FLAT BLACK 1 36 520344PN SCREW 7 37 507665 C 888 STANCHION 2 38 528051 O RING 2 39 520178PN SCREW 4 40 8031212 C PUMPING ROD 888 RT 04 2 41 524180 PISTON RING DIA 35 2 42 5141294 C REBOUND SPRINGS KIT K 2 5 1 43 522415 WASHER 2 44 5141303 SPRING 2 45 516107 VALVE 20 3 DIA 35 2 46...

Page 4: ...63 505083LA LOWER HANDLEBAR CLAMP 888 1 64 526157KR BUSHING 1 65 526158KR BUSHING 1 66 850881 C HANDLEBAR CLAMP KIT 888 04 1 Marzocchi Suspension 2005 888 VF ...

Page 5: ...36 520344PN 7 37 507665 C 2 38 528051 2 39 520178PN 4 40 8031212 C 2 41 524180 2 42 5141294 C 1 43 522415 2 44 5141303 2 45 516107 2 46 509135 2 47 523078 2 48 512101 2 51 531072 2 52 526145AA 4 53 502559LA 1 54 508998CD C 1 55 850760 C 1 56 526143RX 2 57 520342AR 2 59 5321199 2 60 520178PN 7 61 505084LA 1 62 505085LA 1 63 505083LA 1 64 526157KR 1 65 526158KR 1 66 850881 C 1 888 VF 200 Oil levels ...

Page 6: ...INGS KIT K 3 2 1 32 528260 O RING 2 35 5321193RS R A MONOLITE D 35 GLOSS ECO BLACK 1 35 5321193RR R A MONOLITE D 35 FLAT BLACK 1 36 520344PN SCREW 7 37 507665 C 888 STANCHION 2 38 528051 O RING 2 39 520178PN SCREW 4 40 8031212 C PUMPING ROD 888 RT 04 2 41 524180 PISTON RING DIA 35 2 42 5141294 C REBOUND SPRINGS KIT K 2 5 1 43 522415 WASHER 2 44 5141303 SPRING 2 45 516107 VALVE 20 3 DIA 35 2 46 509...

Page 7: ...64 526157KR BUSHING 1 65 526158KR BUSHING 1 66 850881 C HANDLEBAR CLAMP KIT 888 04 1 Marzocchi Suspension 2005 888 VF ...

Page 8: ...de of magnesium alloy cast and CNC machined for lighter weight and more stiffness Sliding bushings made of friction free and wear free material Springs constant pitch Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents foam and keeps the viscosity unchanged while offering high performance free from static friction Dropout type m...

Page 9: ... with the fork s oil Always collect and keep any lubricants solvents or detergents which are not completely biodegradable in the environment These materials should be kept in appropriate containers and disposed of according to local laws 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 m...

Page 10: ...proper mounting A The brake cable must never touch the crown and stanchions Warnings Assembling the fender The fender can be supplied with the fork or purchased separately Fender 1 must be assembled by placing the small support bush 2 between the screw and the fender as shown and by tightening screws 3 with an 8mm fixed spanner to the recommended tightening torque 6 Nm 1 Warnings Assembling the wh...

Page 11: ...t 1 onto the top crown so that the fixing holes match With a 4mm Allen wrench lock the handlebar mount tightening screws 2 to the recommended tightening torque 6 Nm 1 Fit the handlebar right in the middle of the mount Lock the handlebar in position with the special U bolts 3 With a 4mm Allen wrench tighten screws 4 to the recommended tightening torque 6 Nm 1 On request special adapters 5 are avail...

Page 12: ... 3 Dismantling Draining the oil Remove the preload tube 1 and spring 2 from both legs Free the fork from the vice and tip it into a container of a suitable size to drain the oil compress the fork a few times to help the oil flow out Do not pour used oils on the ground Dismantling Breaking down the steering crown unit arch slider assembly Turn the arch slider assembly upside down Marzocchi Suspensi...

Page 13: ... 3 off the arch slider assembly 4 Dismantling Breaking down the pumping element Remove bushing 4 valve 5 the conical spring 11 and the three point ring 6 from the piston rod Using the special round nose pliers remove the internal stop ring 12 Dismantling Dismantling the pumping element and valve Remove the bottom pad 1 Marzocchi Suspension 2005 888 VF ...

Page 14: ...Remove the preload tube 9 only for models with 170mm travel Remove the rebound spring 7 If the piston segment 8 is damaged you can prize it off with a small flat tip screwdriver Dismantling Removing the seals Prize the dust seal 1 off its seat with a small flat tip screwdriver Take great care not to damage the internal surfaces of the one piece assembly while removing the dust seal Marzocchi Suspe...

Page 15: ... great care not to damage the internal surfaces of the one piece assembly while removing the sealing ring Remove the spring cup 4 The old sealing rings and dust seals must not be used again Dismantling Removing the guide bushes Knock the top end of the one piece assembly against a wooden surface and remove the top guide bush 1 spacer 2 and the bottom guide bush 3 Do this operation with extreme cau...

Page 16: ... Marzocchi Suspension 2005 888 VF ...

Page 17: ...nsert 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 Using a small flat tip screwdriver fit the stop ring 2 and check that it fits perfectly into its groove Take great care not to damage the internal surfaces of the one piece assembly when fitting the stop ring The dust seals shall be r...

Page 18: ...in this order bushing 4 valve 5 conical spring 11 three point ring 6 and check that the parts are oriented as shown Insert the pre assembled valve in the piston rod from the three point ring side as shown Insert the valve and the pumping element 3 into the stanchion Take great care not to damage the segment and if necessary use a small flat tip screwdriver to help the piston of the pumping element...

Page 19: ...s use other tools Fit both dust seals 11 to the stanchions Insert the crown stanchion unit 3 in the arch slider assembly 4 With the 15mm socket spanner tighten the bottom nut 1 complete with O ring 2 of both legs to the recommended tightening torque 10 Nm 1 Using introducer A insert the dust seals 11 in their seats Marzocchi Suspension 2005 888 VF ...

Page 20: ...eg see table Pour roughly 1 3 of the oil required into each stanchion then pump the fork a few times to eliminate any traces of air Pour the rest of oil in A lower or higher volume or a type of oil other than the one recommended can change the behaviour of the fork in every phase Lift the crown stanchion unit on the arch slider assembly Insert spring 2 and the preload tube 1 in both legs Marzocchi...

Page 21: ...ounting the top caps Put the fork in the vice in vertical position fixing it by the dropouts Using the 28mm fixed spanner tighten cap 1 to the recommended tightening torque 10 Nm 1 Marzocchi Suspension 2005 888 VF ...

Page 22: ... 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 Once the correct setting has been f...

Page 23: ...rews 6 1 Pumping element cartridge bottom nuts 10 1 Top crown fixing screws 6 1 Wheel axle Allen screws 6 1 Wheel axle screws 15 1 User weight Air pressure kg lb bar psi 0 110 0 242 0 1 00 0 00 1 450 00 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 220 Left fork leg SAE 7 5 550013 220 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 220 Left fork leg SAE 7 5 550013 220 Mar...

Page 24: ...ork is too soft but the sag is the one recommended Compression damping is not enough Increase compression damping by changing oil volumes Fork is too soft needs more than the maximum preload Oil is too fluid Check oil levels Fork is too soft needs more than the maximum preload Spring rate too soft Change to stiffer spring rate Fork is too soft needs more than the maximum preload Spring rate too so...

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