Marzocchi Dirt Jam Comp 2005 Technical Instructions Download | Manualshive

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2005 - Dirt Jam Comp

Technical instructions

© Marzocchi Suspension

2005

-

Dirt Jam Comp

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Summary of Contents for Dirt Jam Comp 2005

Page 1: ...2005 Dirt Jam Comp Technical instructions Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 2: ... 538115 2 16 538114 2 19 5321202RS R A 1 19 5321202RR R A 1 20 DJ COMP DEC05 1 24 EXR FSB069 2 25 EXR FSW028 2 26 EXR FAA147 2 35 EXR FKE039 23 2 36 522403 A 2 37 EXR FEE095 2 39 EXR FEP052 2 40 EXR FKE038 2 41 EXR FEE247 2 Dirt Jam Comp 100 Oil levels Position Oil type Quantity cc Right fork leg EXR 9170 001 7 5 Left fork leg EXR 9170 001 7 5 Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 3: ...TOP RING 2 14 528230 A OIL SEAL DIA 32 2 15 538115 UPPER BUSHING DIA 32 2 16 538114 LOWER BUSHING DIA 32 2 19 5321202RS R A ECO BLACK MONOLITE UNIT 1 19 5321202RR R A FLAT BLACK MONOLITE UNIT 1 20 DJ COMP DEC05 LH RH LABELS DIRT JAM COMP 05 1 24 EXR FSB069 SCREW 2 25 EXR FSW028 BUFFER 2 26 EXR FAA147 O RING 2 35 EXR FKE039 23 ROD 2 36 522403 A WASHER 2 37 EXR FEE095 CAP 2 39 EXR FEP052 RING 2 40 E...

Page 4: ...0 A 2 15 538115 2 16 538114 2 19 5321202RS R A 1 19 5321202RR R A 1 20 DJ COMP DEC05 1 24 EXR FSB069 2 25 EXR FSW028 2 26 EXR FAA147 2 35 EXR FKE039 23 2 36 522403 A 2 37 EXR FEE095 2 39 EXR FEP052 2 40 EXR FKE038 2 Dirt Jam Comp 120 Oil levels Position Oil type Quantity cc Right fork leg EXR 9170 001 7 5 Left fork leg EXR 9170 001 7 5 Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 5: ... 2 13 523261 STOP RING 2 14 528230 A OIL SEAL DIA 32 2 15 538115 UPPER BUSHING DIA 32 2 16 538114 LOWER BUSHING DIA 32 2 19 5321202RS R A ECO BLACK MONOLITE UNIT 1 19 5321202RR R A FLAT BLACK MONOLITE UNIT 1 20 DJ COMP DEC05 LH RH LABELS DIRT JAM COMP 05 1 24 EXR FSB069 SCREW 2 25 EXR FSW028 BUFFER 2 26 EXR FAA147 O RING 2 35 EXR FKE039 23 ROD 2 36 522403 A WASHER 2 37 EXR FEE095 CAP 2 39 EXR FEP0...

Page 6: ...minium alloy forged and CNC machined Stanchions HI TEN steel One piece assembly made of magnesium alloy cast and CNC machined for lighter weight and more stiffness Sliding bushings made of friction free and wear free material Springs constant pitch Seals computer designed oil seals that guarantee maximum seal in any condition Dropout type standard or optional with QR20 With Bolt or with ø 20mm thr...

Page 7: ...lts making them impossible to loosen or tighten When using a screwdriver to assemble or disassemble metal stop rings O rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Do not carry out any maintenance and or adjustment operations that are not explained in this manual Only use original Marzocchi spare parts Before servicing the fork we reco...

Page 8: ... 1 Check for the proper fork wheel alignment To do this begin by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Then lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake The wheel should not wobble from side to side or up and down Check the owner s manual of the brake...

Page 9: ...g 3 and the bottom spring cup 4 from both legs Dismantling Breaking down the steering crown unit arch slider assembly Use the special spanner to remove the bottom nuts Do not use other tools Turn the arch slider assembly upside down With the 5mm Allen wrench loosen the bottom screw 5 of both legs Drive out the bottom screw 5 and washer 6 complete with O ring 7 Pull the crown stanchion unit 3 off t...

Page 10: ...e top of the fork Dismantling Removing the seals Prize the dust seal 1 off its seat with a small flat tip screwdriver Take great care not to damage the internal surfaces of the one piece assembly while removing the dust seal With the same screwdriver prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the one piece assembly while removing the stop ring Marzocchi ...

Page 11: ... extractor keeping the side with larger diameter towards the edge opposite to striker D Fit the extraction washer B with a black finish to 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 t...

Page 12: ...h A in the seat of the sealing ring While holding the main rod in position the aluminium bush will drive the guide bushes during extraction Using 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 Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 13: ...om 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 Using the short introducer B fit the top bush 2 Using a hammer knock the introducer B into the arch slider assembly Smear the guide bushes with the recommended grease Assembling Assembling the seals Insert the spring cup 4 in its seat Marzocchi Suspens...

Page 14: ...ce assembly when fitting the stop ring The dust seals shall be refitted when reassembling the crown stanchion unit arch slider assembly Assembling During the assembly of the pumping unit strictly obey the instructions below Do not at any times reverse the position of the pumping elements in the fork legs if you are unsure about anything please refer to the relevant exploded view Assembling Assembl...

Page 15: ...ts Do not at any times use other tools Fit both dust seals 11 to the stanchions Insert the crown stanchion unit 3 in the arch slider assembly 4 Fit washer 6 and O ring 7 on the bottom screw 5 of both legs then tighten to the recommended tightening torque 10 Nm 1 with the 5mm Allen wrench Using introducer A insert the dust seals 11 in their seats Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 16: ... assembly Insert the bottom spring cup 4 spring 3 elastomer 2 and the top spring cup 1 in both legs Assembling Mounting the top caps Put the fork in the vice in vertical position fixing it by the dropouts Using the special spanner tighten the lock cap 2 to the recommended tightening torque 10 Nm 1 Restore the correct preload value if necessary see settings Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 17: ...p can compromise the inflating operation and cause malfunction or damage to the fork resulting in an accident personal injury or death Once the correct setting has been found we recommend noting the number of clicks or turns of the adjuster with respect to the fully closed position adjuster fully clockwise for a faster re setting of your fork in case of need Setting SAG SAG means the fork bottomin...

Page 18: ...Do not force the adjuster beyond its limit of travel Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 19: ...ps 10 1 Pumping element locking bottom nuts 10 1 Wheel axle Allen screws 6 1 Wheel axle screws 15 1 Position Oil type Quantity cc Right fork leg EXR 9170 001 7 5 Left fork leg EXR 9170 001 7 5 Position Oil type Quantity cc Right fork leg EXR 9170 001 7 5 Left fork leg EXR 9170 001 7 5 Marzocchi Suspension 2005 Dirt Jam Comp ...

Page 20: ...oft needs more than the maximum preload Oil is too fluid Check oil levels Fork is too soft needs more than the maximum preload Spring rate too soft Change to stiffer spring rate Fork is too soft needs more than the maximum preload Spring rate too soft Increase air pressure Fork stays down or packs up during multiple impacts Rebound damping is too high Decrease rebound damping with the relevant reg...

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