Marzocchi X-Fly Instructions Manual Download Page 7

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X-Fly

11-12

STANCHION PLUG
FIG. 1 (only left leg)

Loosen screw

(3)

and remove rebound

limiting knob

(4)

FIG. 2

Depressurize each fork leg (see section
ADJUSTMENT).
Unscrew the caps

(7)

with a 21 mm socket

wrench.

FIG. 3

Lock the check nut

(26)

and remove the cap

(7)

from hydraulic cartridges ends

(12)

and

(11)

Summary of Contents for X-Fly

Page 1: ...th 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 t...

Page 2: ...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 Pressure drop Cap valve damaged Replace cap and or valve Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings F...

Page 3: ...unting 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 case of improper installation of the steer tube into the crown the rider might lose control of his herbicycle thusjeopardizinghis hersafety DIS...

Page 4: ...special MARZOCCHI pump with 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 only right leg The right fork leg is equipped with an adjuster screw A for REBOUND damp ing Turning this adjuster clockwise into the cartridge rod...

Page 5: ...bound limit in this posi tion this also allows to decrease fork leg height for optimal attitude uphill thus sup porting suspension compression operation Reposition the knob to its original position so that the fork will rebound and restart to work as before WARNING do not position to LOCK when riding downhill as available travel might not be enough thus jeopardizing rider s safety ...

Page 6: ...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 AIR VALVE CHANGE FIG 13 FOOT NUTS FIG 5 PILOT BUSHING AND SEAL ASSEMBLY CHANGE CARWON AND STANCHIONS ASSEMBLY FIG 7 DUST SEAL FIG 8 STOP RING FIG 9 OIL SEAL FIG 10 UPPER WASHER FIG 11 PILOT BUSHING FIG 12 HYDRAULIC C...

Page 7: ...left leg Loosen screw 3 and remove rebound limiting knob 4 FIG 2 Depressurize each fork leg see section ADJUSTMENT Unscrew the caps 7 with a 21 mm socket wrench FIG 3 Lock the check nut 26 and remove the cap 7 from hydraulic cartridges ends 12 and 11 ...

Page 8: ...e of a 15 mm socket wrench complete with O Rings 19 FIG 6 Pull the hydraulic cartridge 12 and 11 complete with rebound spring IMPORTANT cartridges fitted to forks with a travel of 100 feature a rebound spring 9 that is the same fitted in both fork legs Rebound springs in forks with a travel of 80 are different rebound spring 9 is in the LH fork leg while rebound spring 6 is in the RH fork leg Remo...

Page 9: ...bly 1 from the sliders 18 FIG 8 Remove the dust seal 13 from the top of the sliders using a small screwdriver FIG 9 Remove the stop ring 14 from the sliders 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 its seat ...

Page 10: ...RTANT when removing the oil seal make sure not to damage its seat Once removed the oil seals should not be used again FIG 11 Remove the upper washer 16 from the slider FIG 12 Fit the bit of a small screwdriver into upper edge slot of the pilot bushing 17 and lift gently Pull the bushing out of the slider and make all necessary changes ...

Page 11: ...th the fork removed keep the fork vertical so as to avoid any oil leakage Remove the air valve 29 and its O ring 30 from cap using a standard valve wrench Check O Ring and blow compressed air onto valve to eliminate possible clogging Immediately replace damaged valve When reassembling slightly lubricate the O ring 30 and screw the air valve 29 until it stops without forcing Then refit the cap 2 ...

Page 12: ... the oil seal until it touches the lower washer by using the above seal press REASSEMBLY CAUTION before reassembling all metal components should be washed carefully with inflammable preferably biodegrad able solvent and dried with compressed air PILOT BUSHING AND SEAL ASSEMBLY FIG 14 Check that no dirt or debris is between slider and bushing Insert the pilot bushing 17 into place so that it adhere...

Page 13: ... and squared into 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 the dust seals 13 on top of the sliders FIG 17 Insert t...

Page 14: ... 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 HYDRAULIC CARTRIDGE RE ASSEMBLY FIG 20 Push the stanchions up to slider bottom If removed insert the bottom washers 23 see exploded view in the stanchion Slide in the cartridges fitted to forks with travel of 100 the rebound spring 9 Slide in the LH cartridge fitted to...

Page 15: ... hand Tighten both caps to 20 Nm Pressurize as shown in section ADJUSTING FIG 23 Screw the caps 7 on hydraulic cartridges end 12 and 11 and bring them fully home on cartridge rods Lock check nuts on caps to the torque of 6 Nm FIG 25 left leg only Set rebound limiting knob 4 on LH leg adjuster and tighten screw 3 to the torque of 1 5 Nm ...

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