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Marzocchi Dirt Jumper 1 QR20, Instructions Manual

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Marzocchi Dirt Jumper 1 QR20 Instructions Manual Download Page 14

Z1

Drop-Off

QR20

VALVE AND PUMPING ROD
ASSEMBLY
FIG. 20

After having overhauled or replaced the
valve unit and after having cleaned the
inside of the tube, reassemble. Assemble
valve components, in correct sequence:
washer 

(16)

, rebound spring 

(37)

, valve

(38) 

and pocket 

(39)

.

Then fit pumping rod 

(14) 

with seal ring

(13) 

and rebound spring 

(15) 

into the

valve assembly 

(16)

.

14

15

13

16

37

38

39

FIG. 21

Lubricate O-rings

(25-26)

 and reassemble

the foot buffer 

(18) 

onto the end part of

pumping rod 

(14)

.

26

18

14

25

FIG. 22

Fit this assembly into the stanchion tube and
properly seat the valve assembly 

(C)

.

Insert the stop ring 

(17)

.

17

C

Summary of Contents for Dirt Jumper 1 QR20

Page 1: ...ts 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...

Page 2: ...eals 3 Clean the oil seal seat and replace oil seal FAILURES CAUSES REMEDIES Oil leaking through the bottom of slider O rings at pumping element bottom and adjusting rod 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 Excessive play of stanchio...

Page 3: ...anchion 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 cleaned ...

Page 4: ...ders Lock the quick release lever B and make sure the bushings A are properly seated in the sliders Fit bolt end C in suitable slider groove and tighten the screw D to specified torque WARNING These sliders are spe cifically designed to fit this type of hub Do not use any hub design other than that specified here as this would not ensure proper fastening of the wheel and may lead to breakdown of t...

Page 5: ...ning the ad justment knob clockwise the preload is increased up to the maximum value equal to 15 mm spring preload This adjustment is essential in order to have the right fork response for the rider s weight and riding style REBOUND ADJUSTMENT Each fork leg is equipped with an adjuster screw C for REBOUND damping at slider bottom To adjust always start from the minimum damping setting i e with the...

Page 6: ...rrows to determine which other parts you need to remove first DISASSEMBLY DIAGRAM FORK LEG OIL CHANGE CHANGING PUMPING ELEMENT SEALS FOOT NUT FIG 4 SPRING FIG 2 DUST SEAL FIG 6 STOP RING 7 OIL SEAL FIG 8 PUMPING ROD FIG 11 REBOUND SPRING FIG 11 VALVE ASSEMBLY CHANGE PILOT BUSHING AND SEAL ASSEMBLY CHANGE STANCHION TUBE CAP FIG 1 FOOT BUFFER FIG 11 CROWN AND STANCHIONS ASSEMBLY FIG 5 SPRING CHANGE ...

Page 7: ...nd the spring 12 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 dureasdescribedinsection REASSEMBLY from Fig 26 to Fig 28 4 5 32 PILOT BUSHING AND SEAL ASSEMBLY CHANGE FIG 3 Turn fork legs upside down and press adjuster retainer 32 with a small screw driver to release it Remove adjuster assem bly 32 fr...

Page 8: ...ff QR20 FIG 4 Removefootnuts 30 withasocketwrench 30 FIG 5 Withdraw the crown and stanchions as sembly 1 from the sliders 1 FIG 6 Remove the dust seal 19 from the top of the sliders using a small screwdriver 19 ...

Page 9: ...hen removing the stop ring make sure not to damage its seat 20 FIG 8 Fit the slider protector A onto the slider and remove the oil seal 21 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 21 A FIG 9 Remove the upper washer 22 from the slider 22 ...

Page 10: ...rod 14 end Withdraw the pumping element 14 and the rebound spring 15 from the stanchion tube top Replace the seal ring 13 if damaged or worn out 13 15 18 26 14 FIG 12 Remove the stop ring 35 from pumping element bottom 14 with a small flat screwdriver Mark stop ring seat into inner rod for proper fitting Use the same screwdriver to remove the ring A and screw inner rod until adjuster threaded end ...

Page 11: ...sembly 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 valve assembly out of the tube with one finger in this sequence pocket 39 valve 38 reboundspring 37 andwasher 16 17 39 38 37 16 ...

Page 12: ...G 14 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 23 FIG 15 Fit the upper washer 22 into the slider so that it touches the pilot bushing 22 FIG 16 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 using the a...

Page 13: ...ust seals 19 and fit them into the stanchions from the spring end 19 PUMPING ROD ASSEMBLY FIG 19 Lubricate the O ring 29 and fit inner rod threaded end into pumping element 14 Turn inner rod clockwise so that threaded end can be seen the into pumping element and stop ring seat 35 marked during disassembly Fit stop ring 35 into inner rod seat and ring A into pumping element seat 35 14 A 29 ...

Page 14: ... sequence washer 16 rebound spring 37 valve 38 and pocket 39 Then fit pumping rod 14 with seal ring 13 and rebound spring 15 into the valve assembly 16 14 15 13 16 37 38 39 FIG 21 Lubricate O rings 25 26 and reassemble the foot buffer 18 onto the end part of pumping rod 14 26 18 14 25 FIG 22 Fit this assembly into the stanchion tube and properly seat the valve assembly C Insert the stop ring 17 17...

Page 15: ...ee that the stanchions slide unre stricted 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 1 19 19 FIG 24 Screw the foot nut 30 on the pumping rod...

Page 16: ...5 mm from the top of the stanchion tube in both legs 65 SPRING AND CAP FIG 27 Fit the springs 12 into each stanchion tube 12 FIG 28 Lubricate the O ring 5 on the cap 4 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 5 in place into the stanchion tube threads by hand Tighten caps 4 to 20 Nm 4 5 Nm 20 ...

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