2006 - DJ Urban
Technical instructions
© Marzocchi Suspension
2006
-
DJ Urban
Page 1: ...2006 DJ Urban Technical instructions Marzocchi Suspension 2006 DJ Urban ...
Page 2: ...1 523261 2 22 528230 A 2 23 522403 A 2 24 538115 2 25 538114 2 26 5321261RS R A 1 26 5321261RR R A 1 26 5321261ST R A 1 26 5321261TI R A 1 26 5321261SR R A 1 27 523300 2 28 5321130 B 1 29 805021 1 30 850777 C 1 31 5141558 TW 1 32 520349LA 1 33 549072AD 2 34 EXR FAA148 2 35 507649 C 2 37 509150 1 40 520023PN 4 41 5181094 A 1 44 502595LA 1 45 7051214 R 1 74 520341 1 75 5321153 A 1 DJ Urban 110 TA Oi...
Page 3: ...0 533297 DUST SEAL DIA 32 2 21 523261 STOP RING 2 22 528230 A OIL SEAL DIA 32 2 23 522403 A WASHER 2 24 538115 UPPER BUSHING DIA 32 2 25 538114 LOWER BUSHING DIA 32 2 26 5321261RS R A ECO BLACK TA MONOLITE UNIT 1 26 5321261RR R A FLAT BLACK TA MONOLITE UNIT 1 26 5321261ST R A MAGNUM GREY FL TA MONOL UNIT 1 26 5321261TI R A PURE WHITE MONOLITE UNIT 1 26 5321261SR R A SILVER DUST TA MONOLITE UNIT 1 ...
Page 4: ...75 5321153 A CABLE GUIDE 1 Marzocchi Suspension 2006 DJ Urban ...
Page 5: ...less Crown aluminium alloy forged and CNC machined Stanchions anodised aluminium One piece assembly made of magnesium alloy cast and CNC machined for lighter weight and more stiffness Sliding bushings made of friction free and wear free material Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents foam and keeps the viscosity unc...
Page 6: ... rings O rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Do not carry out any maintenance and or adjustment operations that are not explained in this manual Only use original Marzocchi spare parts Before servicing the fork we recommend washing the fork thoroughly Work in a clean organized and well lit place If possible avoid servicing you...
Page 7: ...ommended tightening torque 15 Nm 1 Check for the proper fork wheel alignment To do this begin by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Then lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake The wheel should not wobble from side to side or up and down Check...
Page 8: ...w lock cap 2 with a 21mm socket spanner Remove lock cap 2 Dismantling Draining the oil Remove the preload tube 1 and spring 2 from the right leg 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 M...
Page 9: ...the special 12mm spanner A loosen the right bottom nut 7 Pull out the bottom nut 7 complete with O ring 8 Take great care not to damage the O ring on the pumping element rod Using the special 12mm spanner A loosen the left bottom nut 1 Pull out the left bottom nut 1 complete with O ring 2 Pull the crown stanchion unit 3 off the arch slider assembly 4 Dismantling Removing the right pumping element ...
Page 10: ...r Dismantling Removing the left pumping element Remove the bottom pad 1 Pull out the pumping element 3 the rebound spring 7 and the preload tube 9 only on models with 130mm travel 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 Marzocchi Suspension 2006 DJ Urban ...
Page 11: ...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 Use the special extractor to remove the guide bushes Do not use other tools Fit the aluminium bush A to the extractor keeping the side with larger diameter towards the edge opposite to striker D Fit the extraction washer B ...
Page 12: ...ill let the washer pass underneath the bush to be extracted Pull the extractor rod so that the upper face of the washer stops against the lower face of the guide bush Insert the aluminium bush A in the seat of the sealing ring While holding the main rod in position the aluminium bush will drive the guide bushes during extraction Using striker D knock out and extract the guide bush 1 Remove the gui...
Page 13: ...her tools Fit first the bottom bushes then the top bushes Using the long introducer A fit the bottom bush 1 Using a hammer knock the introducer A into the arch slider assembly Using the short introducer B fit the top bush 2 Using a hammer knock the introducer B into the arch slider assembly Assembling Assembling the seals Insert the spring cup 4 in its seat Marzocchi Suspension 2006 DJ Urban ...
Page 14: ... obey the instructions below Do not at any times reverse the position of the pumping elements in the fork legs if you are unsure about anything please refer to the relevant exploded view The pumping element operating the hydraulic rebound braking that can be recognised by the segment must be installed in the right leg Assembling Assembling the right pumping element Replace the piston segment 8 if ...
Page 15: ... piston rod 3 Insert the pumping element into the stanchion and check it fits perfectly into its seat Fit the bottom pad 1 to the pumping element rod Assembling Reassembling the steering crown unit arch slider assembly A special spanner shall be used to assemble the bottom nuts Do not at any times use other tools Fit both dust seals 11 to the stanchions Marzocchi Suspension 2006 DJ Urban ...
Page 16: ...Fit the rebound adjusting knob 6 to the right leg Take great care not to damage the O ring fitted to the end of the pumping element rod Tighten the fixing screw 5 of the adjusting knob to the recommended tightening torque 2 Nm 0 5 Using the special 12mm spanner tighten the left bottom screw 1 complete with O ring 2 to the recommended tightening torque 10 Nm 1 Marzocchi Suspension 2006 DJ Urban ...
Page 17: ...nt prepare the quantity of oil to pour into the fork leg 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 Marzocc...
Page 18: ...the vice in vertical position fixing it by the dropouts Check that O ring is not damaged Using the 21mm socket spanner tighten cap 2 to the recommended tightening torque 10 Nm 1 Restore the correct air pressure see settings Fit the protection cap 1 Marzocchi Suspension 2006 DJ Urban ...
Page 19: ...lting in an accident personal injury or death Once the correct setting has been found we recommend noting the number of clicks or turns of the adjuster with respect to the fully closed position adjuster fully clockwise for a faster re setting of your fork in case of need Setting SAG SAG means the fork bottoming under the biker s weight How to measure the SAG Follow these simple steps to measure th...
Page 20: ...e and can be changed to meet the biker s riding style and the track condition Setting Rebound adjustment Right fork leg With the rebound adjuster you can control the return speed of the fork after compression The right rebound speed setting makes the bike stable letting it follow the variations in the terrain and any obstacles If the fork setting is too reactive this will make the rear suspension ...
Page 21: ...n screws 6 1 Wheel axle screws 15 1 User weight Air pressure kg lb bar psi 55 70 121 154 2 00 2 75 2 900 00 3 987 50 70 80 154 176 2 40 3 10 3 480 00 4 495 00 80 95 176 209 2 90 3 80 4 205 00 5 510 00 95 110 209 242 3 60 4 50 5 220 00 6 525 00 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 150 Left fork leg SAE 7 ...
Page 22: ... 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 soft Increase air pressure Fork stays down or packs up during multiple impacts Rebound damping is too high Decrease rebound damping with the relevant r...
