Marzocchi MAX COMP + ETA - 105 Manual Download | Manualshive

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MX Comp + ETA

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Disassembling

REMOVING THE TOP CAP – RIGHT LEG

REMOVING THE TOP CAP – LEFT LEG

DRAINING THE OIL

BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY

BREAKING DOWN PUMPING ELEMENT AND VALVE – RIGHT LEG

REMOVING THE ETA CARTRIDGE - LEFT LEG

REMOVING THE SEALS

REMOVING THE GUIDE BUSHES

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Summary of Contents for MAX COMP + ETA - 105

Page 1: ...jected to friction are lubricated and cooled by means of a special oil Steer tube steel or optional aluminium 1 1 8 threadless Crown BAM aluminium alloy forged and CNC machined Stanchions anodised aluminium Springs constant pitch Sliding bushes made of friction free and wear free material Seals computer designed oil seals that guarantee the maximum seal in any condition Oil special formulated oil ...

Page 2: ...MX Comp ETA 2 45 Features ...

Page 3: ...p ETA 3 45 Warning INSTRUCTIONS FOR USE GENERAL REGULATIONS FITTING THE FORK ONTO THE FRAME INSTALLING THE DISK BRAKE SYSTEM INSTALLING THE V BRAKE SYSTEM ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS ...

Page 4: ...ter every use and to lubricate the parts with some silicone oil MARZOCCHI forks usually offer the best performances since the very first rides Notwithstanding this a short running in period may be necessary 5 10 hours to adjust the internal couplings This precaution will lengthen your fork s life and guarantee its best performances Changing the oil every 100 hours is recommended The forks with a p...

Page 5: ...e not completely biodegradable in the environment these must be collected and kept in the relevant special containers then disposed of in accordance with the regulations in force Always grease the seal lips before reassembling Use only metric spanners and not imperial Imperial spanners may have similar sizes to metric ones but they can damage the bolts and screws making it impossible to unscrew th...

Page 6: ... tube must be carried out following the instructions of the steering set manufacturer A wrong installation can be dangerous for the rider Marzocchi does not guarantee the assembly and accepts no liability for damage and or accidents arising from a wrong installation The steer tube must be pressed into the crown its replacement must be carried out by one of our service centres using the adequate to...

Page 7: ...disk brake system can overstress the caliper mountings which may break The installation of the brake system must be carried out following the instructions of the brake system manufacturer Improper installation can be dangerous for the rider Use only brake systems in accordance with the fork s specifications If the fork comes standard with V brake mounts remove such mounts and install the cable gui...

Page 8: ...of the brake system manufacturer Improper installation can be dangerous for the rider Use only brake systems in accordance with the fork s specifications If the fork does not come standard with V brake mounts after removing the cable guide A and the disk brake mount cap B install the adapter A and the bolt D on both legs check that the adapter is correctly oriented as shown and tighten the bolt to...

Page 9: ...tion of the fork and all of the parts linked to it mainly depend on the correct fixing of the front wheel For a correct operation of the fork install the wheel as explained below Check the correct fork wheel alignment by fully compressing the fork a few times Lift the front wheel above the ground turn the wheel a few times to verify the correct alignment with the disk brake ...

Page 10: ...MX Comp ETA 10 45 Diagnostic ...

Page 11: ...CAP RIGHT LEG REMOVING THE TOP CAP LEFT LEG DRAINING THE OIL BREAKING DOWN THE CROWN STANCHION UNIT ARCH SLIDER ASSEMBLY BREAKING DOWN PUMPING ELEMENT AND VALVE RIGHT LEG REMOVING THE ETA CARTRIDGE LEFT LEG REMOVING THE SEALS REMOVING THE GUIDE BUSHES ...

Page 12: ...t the fork in the vice in a vertical position fixing it by the dropouts Remove the protection cap 1 Using a small pin screwdriver blow the air off the fork leg pushing on the preload valve Fully unscrew the lock cap 2 using a 21mm socket spanner Remove the lock cap 2 ...

Page 13: ...5 Disassembling REMOVING THE TOP CAP LEFT LEG With a 2mm Allen wrench loosen screw 1 Remove first the screw 1 then the ETA control knob 3 Fully unscrew the lock cap 4 using a 21mm socket spanner Lift out the lock cap 4 ...

Page 14: ...MX Comp ETA 14 45 Disassembling Holding locknut 5 with the 10mm spanner use the 21mm spanner to unscrew the lock cap 4 completely Remove the lock cap 4 ...

Page 15: ...45 Disassembling DRAINING THE OIL 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 ...

Page 16: ...NCHION UNIT ARCH SLIDER ASSEMBLY Use the special spanner to remove the bottom nuts Do not use other tools Using the special 12mm spanner A loosen the two bottom nuts 1 Remove the bottom nuts 1 and the O rings 2 Pull the complete ETA cartridge 9 off the left leg ...

Page 17: ...MX Comp ETA 17 45 Disassembling Pull the crown stanchion unit 3 off the arch slider assembly 4 ...

Page 18: ...MX Comp ETA 18 45 Disassembling BREAKING DOWN PUMPING ELEMENT AND VALVE RIGHT LEG Remove the bottom pad 1 Using the round nose pliers remove the stop ring 2 ...

Page 19: ...lete with rebound spring and valve Remove bushing 4 valve 5 three point ring 6 and rebound spring 7 from the pumping element Pull out the preload tube 9 only for models with 105mm travel If the piston segment 8 is damaged prize it off with a small flat tip screwdriver ...

Page 20: ...areful during this operation as the preloaded spring 2 could eject with violence the parts located on the top nut 1 washer 3 and preload tube 7 To avoid dangerous situations slightly preload the spring pressing down washer 3 so that it can counteract the action of the spring Do not direct the fork assembly side towards people or animals ...

Page 21: ...45 Disassembling Remove washer 3 the preload tube 7 and spring 2 The ETA cartridge 5 has been sealed through machining and cannot be overhauled In the case of faults or a malfunctioning this cartridge must be replaced ...

Page 22: ...emove the dust seal 1 from its seat using a small flat tip screwdriver With the same screwdriver prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the arch slider assembly when removing the dust seal and the stop ring ...

Page 23: ... with the special tool A With a screwdriver prize the sealing ring 3 off Remove the sealing ring 3 Take great care not to damage the internal surfaces of the arch slider assembly when removing the sealing ring The old sealing rings and dust seals must not be used again ...

Page 24: ...o the extractor During use remove the non used washer from the extractor Remove first the top bushes then the bottom bushes Fit the extraction washer keeping the blunt side towards the threaded grubscrew C fixed crosswise on to the main rod as shown The slot in the rod lets the extraction washer swing inside the rod itself Insert the extractor in the arch slider assembly from the side of washer B ...

Page 25: ...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 drives the guide bushes during extraction With striker D knock out and extract the guide bush 1 Remove the guide bush 1 from the extractor Repeat the steps above to remove the bottom guide bush ...

Page 26: ...MX Comp ETA 26 45 Assembling ASSEMBLING THE GUIDE BUSHES ...

Page 27: ...pecial introducers short type for the top bush and long type for the bottom bush both with a black finish Do not use other 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 ...

Page 28: ...MX Comp ETA 28 45 Assembling Using the short introducer B fit the bottom bush 2 Using a hammer knock the introducer B into the arch slider assembly ...

Page 29: ...ck in the introducer A and drive the sealing ring home into the arch slider assembly With a small tip screwdriver mount the stop ring 2 and check it fits perfectly into its groove Take great care not to damage the internal surfaces of the arch slider assembly when fitting the stop ring The dust seals shall be refitted when reassembling the crown stanchion unit arch slider assembly ...

Page 30: ...T LEG Replace the piston segment 8 if necessary Insert the preload tube 9 only for models with 105mm travel and the rebound spring 7 in the piston rod Assemble the valve unit in this order bushing 4 valve 5 three point ring 6 and check that the parts are oriented as shown ...

Page 31: ...n Insert the valve and the pumping element 3 into the stanchion Take great care not to damage the segment and if necessary use a small flat tip screwdriver to help the piston of the pumping element into the stanchion Using the special round nose pliers mount the stop ring 2 and check it fits perfectly into its groove ...

Page 32: ...MX Comp ETA 32 45 Assembling Fit the bottom pad 1 to the pumping element rod ...

Page 33: ...e 7 and washer 3 in the ETA cartridge rod Screw down nut 1 without tightening During this operation it might be necessary to slightly preload the spring pressing down washer 3 so that it can counteract the action of the spring Never direct the assembling side of the fork towards people or animals ...

Page 34: ...LING THE CROWN STANCHION UNIT ARCH SLIDER ASSEMBLY A special spanner shall be used to assemble the bottom nut Do not use other tools Fit the dust seals 11 to the stanchions Insert the crown stanchion unit 3 in the arch slider assembly 4 ...

Page 35: ... Comp ETA 35 45 Assembling Fit the complete ETA cartridge 9 in the left leg With the special 12mm spanner A tighten the bottom nut 1 with O ring 2 of both legs to the recommended tightening torque 11 Nm 1 ...

Page 36: ...MX Comp ETA 36 45 Assembling Re assemble the dust seals 11 in their seats using the special introducer A ...

Page 37: ...ly 1 3 of the oil required into each stanchion then pump the fork a few times to remove any traces of air Pour the rest of the oil in Lower again the crown stanchion unit on the arch slider assembly Wait for a few minutes and check the volume of the air h if necessary refill to the right level A lower or higher volume of air or a type of oil other than the recommended type can change the behaviour...

Page 38: ...MX Comp ETA 38 45 Assembling Lift the crown stanchion unit on the arch slider assembly ...

Page 39: ...AP RIGHT LEGT Put the fork in the vice in vertical position fixing it by the dropouts With the 21mm socket spanner tighten the lock cap 2 to the recommended tightening torque 20 Nm 1 Restore the preload pressure see settings Fit the protection cap 1 ...

Page 40: ... THE TOP CAP LEFT LEG Screw the lock cap 4 down on the ETA cartridge rod without tightening being very careful not to damage the O ring Using the 10mm and 21mm spanners tighten locknut 5 on cap 4 to the recommended tightening torque 6 Nm 1 ...

Page 41: ... 21mm socket spanner tighten the lock cap 4 on the steering crown to the recommended tightening torque 20 Nm 1 Fit the ETA control lever 3 and screw 1 Using the 2mm Allen wrench tighten screw 1 to the recommended tightening torque 2 Nm 0 5 ...

Page 42: ...MX Comp ETA 42 45 Settings AIR PRELOAD REBOUND ADJUSTMENT ETA TRAVEL LIMITING DEVICE ...

Page 43: ... extractor Drawing in compressed air through valve A changes the damping of the forces resulting from the COMPRESSION of the fork legs Adjusting the leg s pressure increases the preload To increase the pressure in the fork leg Remove the protection cap B Tighten the threaded adapter on the pump Inflate till reaching the pressure you wish see table Refit the protection cap B The pressure values in ...

Page 44: ... being careful to center the notch of the adjusting screw C Turning the adjusting screw counter clockwise increases the hydraulic damping making the fork slower during the rebound phase Turning the adjusting screw clockwise decreases the hydraulic damping making the fork more responsive during the rebound phase Do not force the adjusting screw C beyond its limit stops ...

Page 45: ...ing the fork travel to 30 mm Turning the control A clockwise activates the ETA cartridge function Turning the control A counter clockwise brings the fork back to normal function and deactivates the limiting device Do not use the ETA devices when riding on steep downhills The fork would not react safely enough when hitting an obstacle ...

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