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Diagnostics

  

 

Finding the problem

Finding the possible cause

Possible solutions proposed 

Fork doesn't get full travel

Oil level too high

Check oil levels

Fork doesn't get full travel

Spring rate too stiff

Change to softer spring rate

Fork doesn't get full travel

Spring rate too stiff

Decrease air pressure

Fork extends too quickly; harsh top-out after 
impacts

Rebound damping is not enough

Increase rebound damping

Fork extends too quickly; harsh top-out after 
impacts

Rebound damping is not enough

Replace the oil (SAE 7.5) with one of higher 
viscosity index

Fork has too much sag

Oil is too fluid

Check oil levels

Fork has too much sag

Spring rate too soft

Change to stiffer spring rate

Fork has too much sag

Spring rate too soft

Increase air pressure

Fork has too much sag

Spring rate too soft

Increase spring preload by replacing the preload 
tube

Fork is “sticky”; fork does not perform as new

Dirty sealing rings; fork needs to be 
serviced

Renew all seals

Fork is too soft, but the sag is the one 
recommended

Compression damping is not enough

Increase compression damping by changing oil 
volumes

Fork is too soft, 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 
register

Front wheel tends to tuck under while turning left 
or right

Rebound damping is too high

Decrease rebound damping with the relevant 
register

Front wheel tends to tuck under while turning left 
or right

Spring rate too soft

Change to stiffer spring rate

Heavy amount of oil on stanchions; oil dripping 
down legs

Sealing rings damaged

Renew all seals

Heavy amount of oil on stanchions; oil dripping 
down legs

The stanchion tubes could be damaged

Have the stanchions be checked

Knocking sound during rebound, but no harsh top-
out

Rebound damping is too high

Decrease rebound damping with the relevant 
register

Loss of sensitivity

Old oil

Change the oil

Loss of sensitivity

Sliding bushes worn

Renew the sliding bushes

Oil leaking from the bottom of the fork leg

Bottom nut/screw loose

Tighten the nut or screw

Oil ring on stanchions

Sealing rings dirty

Renew all seals

© Marzocchi Suspension

2005

 - 

Dirt Jam Comp

Содержание Dirt Jam Comp 2005

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

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

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

Страница 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 ...

Страница 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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