Marzocchi MXR Coil ext. Preload Instructions Manual Download Page 2

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MXR

Coil

ext.

Preload

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-rings at pumping element bottom and
adjusting rod damaged.

Replace the O-rings

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

Excessive play of stanchions in the sliders

Pilot bushings are worn

Replace pilot bushings

FAILURES

CAUSES

REMEDIES

Adjuster position does not affect fork
operation

1. Dirt inside legs
2. O-ring into pumping element damaged

1. Clean carefully and change oil
2. Replace O-ring

Summary of Contents for MXR Coil ext. Preload

Page 1: ...arts 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 simil...

Page 2: ...chion 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 oil seal Excessive play of stanchions in the sliders Pilot...

Page 3: ... 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 WARNING In cas...

Page 4: ...t ADJUSTMENT SPRING PRELOAD SpringpreloaddeterminesCOMPRESSION damping and is adjusted by turning the adjustment knob 3 on the top of the fork legs From the factory the fork is set at minimum preload i e the adjustment knob completely unscrewed counterclockwise However springs are slightly preloaded to counteract static loads By turning the ad justment knob clockwise the preload is increased up to...

Page 5: ... to determine which other parts you need to remove first DISASSEMBLY DIAGRAM FORK LEG OIL CHANGE SPRING FIG 2 STANCHION TUBE CAP FIG 1 SPRING CHANGE BOTTOM ADJUSTER FIG 3 CROWN AND STANCHIONS ASSEMBLY FIG 5 DUST SEAL FIG 6 STOP RING 7 PILOT BUSHING AND SEAL ASSEMBLY CHANGE FOOT NUT FIG 4 OIL SEAL FIG 8 UPPER WASHER FIG 9 PILOT BUSHING FIG 10 CHANGING PUMPING ELEMENT SEALS FOOT BUFFER FIG 11 PUMPIN...

Page 6: ...pring 30 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 28 to Fig 30 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 Remove adjuster assem bly 2...

Page 7: ...FIG 4 Remove foot nuts 26 and 29 with a socket wrench FIG 5 Withdraw the crown and stanchions as sembly 1 from the sliders FIG 6 Remove the dust seal 19 from the top of the sliders using a small screwdriver 26 29 Sx Dx 1 19 ...

Page 8: ... 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 20 21 A 22 ...

Page 9: ...emove the foot buffer 18 and 44 complete with ring 25 from the pumping rod ends 14 and 12 23 18 25 14 44 25 12 Dx Sx FIG 12 Withdraw the pumping elements 14 and 12 and the rebound springs 15 from the stanchion tube top CAUTION model with a travel of 80 fit two rebound springs 15 for every pump ing element Replace the seal ring 13 placed only on LH fork leg pumping element if damaged or worn out 14...

Page 10: ...aded end is disengaged from pumping element Remove inner rod and replace O ring 27 if damaged VALVE ASSEMBLY CHANGE only left leg FIG 14 To check that the valve assembly is operat ing correctly it is necessary to work on the inside of the left stanchion tube Slip off the stop ring 17 using pointed pliers Pull the valve assembly out of the stanchion with one finger in the following order covering 4...

Page 11: ...G 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 above s...

Page 12: ...eals 19 and fit them into the stanchions from the spring end PUMPING ROD ASSEMBLY FIG 20 only left leg Lubricate the O ring 27 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 33 marked during disassembly Fit stop ring 33 into inner rod seat and ring A into pumping element seat 19 33 14 A 27...

Page 13: ...tted to forks with a travel of 100 only fit one rebound spring 15 or two rebound springs 15 for a travel of 80 Insert the complete pumping element in the valve assembly 15 14 13 80 100 15 14 13 42 41 31 16 FIG 22 Lubricate the O rings 24 and 25 and reassemble the foot buffer 18 onto pump ing element end 14 and foot buffer 44 on pumping element top 12 FIG 23 only left leg Insert the LH pumping elem...

Page 14: ...down and check that threaded 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 ensu...

Page 15: ... 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 is H mm from the top of the stanchion tube in both legs H Travel mm H mm 80 45 100 40 SPRING AND CAP FIG 29 Fit the springs 30 into each stanchion tube 30 ...

Page 16: ...the cap 4 Turn the preload adjuster 9 see exploded view counterclockwise until it is at its minimum setting and install the lower wash er 11 Start the caps with the O ring 5 in place into the stanchion tube threads by hand Tighten caps 4 to 20 Nm 4 5 Nm 20 ...

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Marzocchi MXR Coil ext. Preload, Instructions Manual

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