Marzocchi DIRT JUMPER 2 Instructions Manual Download

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EXR

Coil

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.

Oil leaking through the bottom of slider

O-ring on pumping rod nut damaged

Replace the O-ring

Oil leaking though the top of slider

1. Oil seal is worn out
2. Stanchion tube is scored
3. Excessive dirt on 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

FAILURES

CAUSES

REMEDIES

Excessive play of stanchions in the sliders

Pilot bushings are worn

Replace pilot bushings

Summary of Contents for DIRT JUMPER 2

Page 1: ...ith 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 ...

Page 2: ...king though the top of slider 1 Oil seal is worn out 2 Stanchion tube is scored 3 Excessive dirt on oil seal 1 Replace oil seal 2 Replacecrown stanchionsassembly 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...

Page 3: ...rried outwithextremecare Theinstallationshould 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 i...

Page 4: ...r responds to 0 preload turn in as many turns as the preload you want Each turn corresponds to 1 25 mm When supplied the fork is set to the mini mum preload However spring is slightly preloaded to counteract static loads By turning the adjustment screw clockwise the preload is increased up to the maximum value equal to 15 mm s of spring preload This adjustment is essential in order to have the rig...

Page 5: ...ce 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 PUMPING ROD CHANGE FOOT NUT FIG 3 SPRING FIG 2 DUST SEAL FIG 5 STOP RING 6 OIL SEAL FIG 7 PUMPING ROD FIG 8 REBOUND SPRING FIG 8 VALVE ASSEMBLY CHANGE SEAL ASSEMBLY CHANGE STANCHION TUBE CAP FIG 1 CROWN AND STANCHIONS ASSEM BLY...

Page 6: ...wer washer 7 and the spring 8 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 17 to Fig 19 SEAL ASSEMBLY CHANGE FIG 3 Turn the fork leg upside down and unscrew the foot nuts 20 complete with O ring 19 by the use of a 15 mm socket wrench 5 6 8 7 20 19 ...

Page 7: ... 5 Remove the dust seal 15 from the top of the sliders using a small screwdriver FIG 6 Remove the stop ring 16 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 1 18 15 16 ...

Page 8: ...umping elements 10 and the rebound spring 11 from the stanchion tube top Replace the seal ring 9 if dam aged or worn out VALVE ASSEMBLY CHANGE FIG 9 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 22 using pointed pliers Pull the valve assembly out of the tube with one finger in the same sequence as in the ...

Page 9: ... oil seal 17 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 above seal press FIG 11 Insert the stop ring 16 into the slider making sure it is properly seated into place Use buffer B to properly seat the ring into the slider 17 B 16 FIG 12 Lubricate the dust seals 15 and fit them into the stanchions from th...

Page 10: ... 1 with the dust seals in place gently into the sliders seals WARNING to avoid any dam ages to sealing surfaces keep the stanchions duly lubricated and squared into the sliders Press the crown and stanchions assembly fully down and check that threaded ends of pumping elements 10 are coming out through the bottom of the sliders Check to see that the stanchions slide unre stricted by cycling the for...

Page 11: ... the stroke by pumping them up and down several times HOW TO FILL WITH OIL FIG 17 Pour oil little by little when the stanchions are fully down and then pump with the crown so as to have a better filling Check that the oil level H is as required in both legs SPRING AND CAP FIG 18 Fit the spring 8 and washer 7 into each stanchion tube 20 19 Nm 11 H Travel mm H mm 80 47 100 47 8 7 ...

Page 12: ...rn the preload adjuster 4 inside the cap until setting minimum preload see section ADJUSTMENT Start the complete cap assembly into the stanchion tube thread by hand Tighten the cap 5 to 20 Nm Set spring preload as specified in section ADJUSTMENT Nm 20 5 6 ...

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Marzocchi DIRT JUMPER 2, Instructions Manual

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