Marzocchi MXC Air Instructions Manual Download Page 5

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MXR

Air

▲

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

CROWN AND STANCHIONS

ASSEMBLY CHANGE

FOOT BUFFER FIG. 11

PUMPING ROD FIG. 12

STOP RING. 7

FORK OIL CHANGE

PUMPING ELEMENT INNER O-RING

FIG. 13

STOP RING FIG. 14

VALVE ASSEMBLY FIG. 14

DUST SEAL FIG. 6

STANCHION TUBE CAP FIG. 1

REBOUND SPRING FIG. 12

BOTTOM ADJUSTER FIG. 3

VALVE ASSEMBLY CHANGE

FOOT NUT FIG. 4

CROWN AND STANCHIONS

ASSEMBLY FIG. 5

PUMPING ROD CHANGE

OIL SEAL FIG. 8

UPPER WASHER FIG. 9

PILOT BUSHING FIG. 10

Summary of Contents for MXC Air

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: ...mbly 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 Pressure drop Cap valve damaged Replace cap and or valve The fork reaches its end of stroke easily Valve at the bottom of the stanchion damaged Cha...

Page 3: ...hat should be carried 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 WARN...

Page 4: ...he connection and refit the cap 2 This adjustment is essential in order to have the right fork response for the rider s weight and riding style The fork is pre loaded at the factory to a standard value of 3 bar REBOUND ADJUSTMENT Each fork leg is equipped with an adjuster screw D for REBOUND damping at slider bottom To adjust always start from the minimum damping setting i e with the screw fully t...

Page 5: ...then look at the arrows to determine which other parts you need to remove first DISASSEMBLY DIAGRAM CROWN AND STANCHIONS ASSEMBLY CHANGE FOOT BUFFER FIG 11 PUMPING ROD FIG 12 STOP RING 7 FORK OIL CHANGE PUMPING ELEMENT INNER O RING FIG 13 STOP RING FIG 14 VALVE ASSEMBLY FIG 14 DUST SEAL FIG 6 STANCHION TUBE CAP FIG 1 REBOUND SPRING FIG 12 BOTTOM ADJUSTER FIG 3 VALVE ASSEMBLY CHANGE FOOT NUT FIG 4 ...

Page 6: ... oil drain out from the fork legs Pump the stanchions several times to help oil drain off WARNING Remember to always recycle any used oil To change the fork leg oil follow the proce dureasdescribedinsection REASSEMBLY from Fig 27 to Fig 29 PILOT BUSHING AND SEAL ASSEMBLY CHANGE FIG 3 only left leg Turn fork legs upside down and press adjuster retainer 28 with a small screw driver to release it Rem...

Page 7: ...19 FIG 4 Remove foot nuts 26 and 7 by the use of a 15 mm socket wrench FIG 5 Withdraw the crown and stanchions as sembly 1 from the sliders 11 FIG 6 Remove the dust seal 19 from the top of the sliders using a small screwdriver ...

Page 8: ...TANT when removing the stop ring make sure not to damage its seat 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 FIG 9 Remove the upper washer 22 from the slider ...

Page 9: ...the slider and make all necessary changes REPLACING PUMPING ELEMENT SEALS FIG 11 Remove the foot buffers 18 and 32 complete with ring 25 from the pumping rod ends 14 and 12 13 15 12 14 FIG 12 Withdraw the pumping elements 14 and 12 and the rebound spring 15 from the stanchion tube top Replace the seal ring 13 if damaged or worn out fitted to LH pumping rod only ...

Page 10: ...y out of the tube with one finger in the same sequence as in the figure covering 33 valve 34 rebound spring 30 and washer 16 FIG 13 only left leg Remove the stop ring 4 from pumping element bottom 14 with a small flat screw driver 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 is disengaged from pu...

Page 11: ...MBLY FIG 15 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 FIG 16 Fit the upper washer 22 into the slider so that it touches the pilot bushing FIG 17 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 ...

Page 12: ...e dust seals 19 and fit them into the stanchions from the spring end PUMPING ROD ASSEMBLY FIG 20 only left leg Lubricate the O ring 3 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 4 marked during disassembly Fit stop ring 4 into inner rod seat and ring A into pumping element seat ...

Page 13: ...semble valve components in correct sequence washer 16 rebound spring 30 valve 34 and covering 33 Then fit pumping rod 14 with seal ring 13 and rebound spring 15 into the valve assembly FIG 22 Lubricate the O rings 24 and 25 and reassemble the foot buffers 18 and 32 onto pumping element ends 14 and 12 FIG 23 only left leg Fit this LH assembly into the stanchion tube and properly seat the valve asse...

Page 14: ... ends of pumping elements 14 and 12 are com ing out through the bottom of the sliders Check to see 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...

Page 15: ...ter unit 28 HOW TO FILL WITH OIL FIG 28 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 FIG 29 Lubricate the O ring 6 on the cap 5 Lift the crown 1 and fit start caps 5 onto stanchion threads by hand ...

Page 16: ...MXR Air Nm 20 5 FIG 30 Tighten the caps 5 to 20 Nm Pressurize as shown in section ADJUST ING ...

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