Marzocchi Dirt Jumper 1,5 QR20 Instructions Manual Download Page 6

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Dirt

Jumper

1,5

QR20

▲

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

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 LEG OIL CHANGE

CHANGING PUMPING

ELEMENT SEALS

SPRING FIG. 2

DUST SEAL FIG. 5

STOP RING. 6

OIL SEAL FIG. 7

PUMPING ROD FIG. 11

REBOUND SPRING FIG. 11

VALVE ASSEMBLY CHANGE

(only right leg)

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 10

CROWN AND STANCHIONS

ASSEMBLY FIG. 4

SPRING CHANGE

FOOT NUT FIG. 3

STOP RING FIG. 12

UPPER WASHER FIG. 8

PILOT BUSHING FIG. 9

VALVE ASSEMBLY FIG. 12

Summary of Contents for Dirt Jumper 1,5 QR20

Page 1: ...arts 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 simil...

Page 2: ...lace oil seal 2 Replacecrown stanchionsassembly oil seals and dust seals 3 Clean the oil seal seat and replace oil seal Oil leaking through the bottom of slider O rings at pumping rod bottom damaged Replace the O rings 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 Exces...

Page 3: ...stanchion tube after each use and lubricate with silicone oil In general MARZOCCHI 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 Polished forks should be cleane...

Page 4: ...NG 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 herbicycle thusjeopa...

Page 5: ... in order to have the right fork response for the rider s weight and riding style REBOUND ADJUSTMENT VIA INNER PUMPING ROD only right leg The adjuster controlling REBOUND damp ing adjustment is accommodated inside pumping rod 14 inside each fork leg To access the adjuster unscrew the top cap 5 and push the stanchions fully down see section DISASSEMBLY Fig 1 Fit the supplied hexagon rod C into the ...

Page 6: ...e 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 LEG OIL CHANGE CHANGING PUMPING ELEMENT SEALS SPRING FIG 2 DUST SEAL FIG 5 STOP RING 6 OIL SEAL FIG 7 PUMPING ROD FIG 11 REBOUND SPRING FIG 11 VALVE ASSEMBLY CHANGE only right leg STANCHION TUBE CAP FIG 1 FOOT BUFFER FIG 10 CROWN AND STANCHIONS ASSEM...

Page 7: ...he stanchions into the sliders and remove the lower washer 11 and the spring 34 from each fork leg Drain all oil from the fork legs WARNING Remember to always recycle any used oil To change the fork leg oil follow the proce dure as described in section REASSEM BLY from Fig 24 to Fig 26 PILOT BUSHING AND SEAL ASSEMBLY CHANGE FIG 3 Remove foot nuts 29 with a socket wrench ...

Page 8: ...he sliders 30 FIG 5 Remove the dust seal 19 from the top of the sliders using a small screwdriver FIG 6 Remove the stop ring 20 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 ...

Page 9: ...ver IMPORTANT when removing the oil seal make sure not to damage its seat Once removed the oil seals should not be used again FIG 8 Remove the upper washer 22 from the slider FIG 9 Fit the bit of a small screwdriver into upper edge slot of the pilot bushing 23 and lift gently Pull the bushing out of the slider and make all necessary changes ...

Page 10: ...p CAUTION model with a travel of 110 fit two rebound springs 15 for every pumping element Replace the seal ring 13 placed only on RH fork leg pumping element if damaged or worn out VALVE ASSEMBLY CHANGE only right leg FIG 12 To check that the valve assembly is operat ing correctly it is necessary to work on the inside of the stanchion tube Slip off the stop ring 17 using pointed pliers Pull the va...

Page 11: ...L ASSEMBLY FIG 13 Check that no dirt or debris is between slider and bushing Insert the pilot bushing 23 into place so that it adheres to the slider FIG 14 Fit the upper washer 22 into the slider so that it touches the pilot bushing FIG 15 Lubricate the oil seal 21 and place it onto the seal press B with the hollow side toward the slider Press the oil seal until it touches the lower washer by usin...

Page 12: ...LVE AND PUMPING ROD ASSEMBLY FIG 18 right pumping element only After having overhauled or replaced the valve unit and after having cleaned the inside of the tube reassemble Assemble valve components in correct se quence washer 16 reboundspring 35 valve 39 and pocket 40 Then fit seal ring 13 on pumping element 14 In pumping element fitted to forks with a travel of 130 only fit one rebound spring 15...

Page 13: ...d 14 and foot buffer 42 on pumping element top 12 FIG 20 only right leg Insert the RH pumping element you have just assembled into the stanchion tube and properly seat the valve assembly D Insert the stop ring 17 FIG 21 only left leg Fit pumping element 12 from stanchion top with only one rebound spring 15 on forks with a travel of 130 and two rebound springs 15 for a travel of 110 ...

Page 14: ...ed by cycling the fork up and down several times The tube should slide freely inside the seal assembly without any side play In the event it is too hard or too soft repeat the previous steps described above and check compo nents to ensure they are not damaged Seat the dust seals 19 on top of the sliders FIG 23 Screw the foot nuts 29 on the threaded elements of pumping elements 14 and 12 Tighten to...

Page 15: ...each stanchion tube FIG 26 Lubricate the O ring 6 on the cap 5 Turn the preload adjuster 9 counterclock wise until it is at its minimum setting and install the lower washer 11 Start the caps with the O ring 6 in place into the stanchion tube threads by hand Tighten caps 5 to 20 Nm ...

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Marzocchi Dirt Jumper 1,5 QR20, Instructions Manual

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