Marzocchi MARATHON Instructions Manual Download Page 6

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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 OIL CHANGE

STANCHION TUBE CAP FIG. 1/2/3/4

AIR VALVE CHANGE

FIG. 15

FOOT NUT FIG. 6

PILOT BUSHING AND SEAL ASSEMBLY CHANGE

CARWON AND STANCHIONS ASSEMBLY FIG. 9

DUST SEAL FIG. 10

STOP RING FIG. 11

OIL SEAL FIG. 12

UPPER WASHER FIG. 13

PILOT BUSHING FIG. 14

AIR-OPERATED CARTRIDGE FIG. 8

HYDRAULIC CARTRIDGE FIG. 7

AIR-OPERATED CARTRIDGE

CHANGE (left leg)

HYDRAULIC CARTRIDGE CHANGE

(right leg)

AIR-OPERATED CARTRIDGE
OVERHAUL FIG 16/17/18

Summary of Contents for MARATHON

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: ...on the cartridge nut is damaged Replace the O ring 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 Pressure drop Cap valve damaged Replace cap and or valve Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings Fork rebounds too fast in any a...

Page 3: ...nce 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 thusjeopardizinghis hersafety DISC BRAKE SYSTEM ASSEMBLY WARNING if a disc brake syst...

Page 4: ...al MARZOCCHI pump with the proper pressure gauge Use of improper tools or other procedures than specified ones might lead to improper inflating NOTE incaseofairleakageswhenadapter fitting D is fitted ensure that the O ring D1 is not damaged REBOUND ADJUSTMENT r h fork leg The right fork leg is equipped with an Extension Control Cartridge adjuster knob 28 for REBOUND damping up to max rebound dampi...

Page 5: ...ap 32 LH fork leg and depressurize the leg by pushing lightly on valve pin Fully tighten adapter fitting D supplied with the fork on MARZOCCHI pump C Screw fitting end with O ring D1 on valve and pressurize until the required value is reached The higher the pressure in the LH cartridge the more sensitive the fork will be and vice versa Unscrew the fitting pump assembly and refit the cap 32 IMPORTA...

Page 6: ...look at the arrows to determine which other parts you need to remove first DISASSEMBLY DIAGRAM FORK OIL CHANGE STANCHION TUBE CAP FIG 1 2 3 4 AIR VALVE CHANGE FIG 15 FOOT NUT FIG 6 PILOT BUSHING AND SEAL ASSEMBLY CHANGE CARWON AND STANCHIONS ASSEMBLY FIG 9 DUST SEAL FIG 10 STOP RING FIG 11 OIL SEAL FIG 12 UPPER WASHER FIG 13 PILOT BUSHING FIG 14 AIR OPERATED CARTRIDGE FIG 8 HYDRAULIC CARTRIDGE FIG...

Page 7: ...ve the RH cartridge circlip 27 with a small screwdriver Remove and keep the pin 26 and counter spring 25 WARNING neverusetheforkwith out this component otherwise the hydraulic cartridge fitted to the slider bot tom might slide out from the top cap and release the arch slider monolith FIG 3 Unscrew the caps 30 and 33 complete with O ring 24 with a 21 mm socket wrench Remove the cap 30 from the righ...

Page 8: ...he sliders 3 and let all the oil drain out from the fork legs Pump the stanchions several times to help oil drain off WARNING dispose of exhausted oil in compliance with current laws To change the fork leg oil follow the proce dureasdescribedinsection REASSEMBLY from Fig 29 to Fig 33 REMOVING CARTRIDGES FIG 6 Turn the fork leg upside down and unscrew the foot nuts 2 by the use of a 15 mm socket wr...

Page 9: ...he R H stanchion tube Replace the whole hydraulic cartridge FIG 8 only left leg Pull the air operated cartridge 22 out of the L H stanchion tube Replace the whole cartridge or overhaul as described in next paragraph FIG 9 Withdraw the crown and stanchions as sembly 23 from the sliders 3 ...

Page 10: ...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 slider inner seat FIG 12 Fit the slider protector A onto the slider and remove the oil seal 8 with the help of a large screwdriver IMPORTANT when removing the oil seal make sure not to damage slider inner seat Once removed the oil seals should not be used again...

Page 11: ... and fitted on bike but only after draining inner pressure If the air valve is disassembled with the fork removed keep the fork vertical so as to avoid any oil leakage Remove protection cap 21 only RH fork leg and remove air valve 39 and O ring 40 from the cap with a standard valve wrench Check O Ring and blow compressed air onto valve to eliminate possible clogging Immediately replace the valve i...

Page 12: ...d cartridge 22 and undo the ring nut 14 and the O ring 15 with a hex wrench Remove ring nut assembly 14 and rod 16 then remove rod 16 from ring nut 14 FIG 17 With a small screwdriver remove the seal 19 and the O rings 18 from the rod body 16 Lubricate the O rings before reassembly ...

Page 13: ...t it touches the pilot bushing 14 16 22 Nm 10 REASSEMBLY CAUTION before reassembling all metal components should be washed carefully with inflammable preferably biodegrad able solvent and dried with compressed air RE ASSEMBLING AIR OPERATED CARTRIDGE FIG 18 Insert the rod 16 and ring nut assembly 14 in the cartridge body 22 and tighten the ring nut to the specified torque During this operation be ...

Page 14: ...the stop ring 9 into the slider making sure it is properly seated into place Use buffer B to properly seat the ring into the slider 8 B FIG 21 Lubricate the oil seal 8 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 ...

Page 15: ...erated cartridge 22 into the L H stanchion and push to the bottom 23 10 10 CROWN AND STANCHIONS ASSEMBLY FIG 24 Fit the crown and stanchions assembly 23 with the dust seals in place gently into the sliders seals WARNING to avoid any damages to sealing surfaces keep the stan chions duly lubricated and squared into the sliders Check to see that the stanchions slide unre stricted by cycling the fork ...

Page 16: ... clamp the air operated cartridge rod 16 Grease O ring 31 and fully tighten the cap 33 on the rod end Q cc Travel mm Q cc Leg Fork model Marathon S Marathon 29 Sx 80 100 80 Dx Sx Dx Sx Dx 30 30 30 115 115 115 HOW TO FILL WITH OIL FIG 27 Pour in the oil little by little when the stanchions are fully down and then stroke the crown up and down to cycle the oil and to remove any trapped air Check that...

Page 17: ...nob 32 fully home 26 27 25 FIG 30 Fit circlip 27 of the adjustment knob support and check for the proper position in the seat Fit also spring 25 and pin 26 WARNING never use the fork with out this component otherwise the hydraulic cartridge fitted to the slider bot tom might slide out from the top cap and release the arch slider monolith ...

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