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X-FLY

(80)

TRA

VEL 80

100

130

175

L.MAX=461

L.L.=451 L.MIN=371

396

Ø30

9.2

248.5

-0.1

+0.1

Ø30

+0.05

G E N E RA L

• Special air/oil damped cross-country fork: each leg uses pressu-

rized air blown through a special valve on stanchion caps as
damping medium.

• The right leg rebound is damped by a hydraulic cartridge.
• Rebound damping adjustment controlled via external top right leg

adjuster.

• Stanchions fitted into lower Crown by cryofit technique. Full length

bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weight and

improved rigidity.

• Parts subjected to friction are cooled and lubricated by a specially

formulated oil.

Steer tube:

EASTON aluminum steer tube available for 1 1/8”

diameter, threadless.

Crown:

Forged and CNC-machined BAM

❊

aluminum alloy.

Arch:

Cast magnesium alloy.

Stanchions:

anodized aluminum with variable section.

Sliders:

Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

Slider bushing:

Full length guide bushings composed of a copper

base and impregnated with an anti-friction coating.

Seals:

Computer designed oil seals guarantee the highest quality

seals available.

Oil:

Specially formulated oil which eliminates foaming and viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil:

type EBH 16 - SAE 7.5.

– right leg 110 cc,
– left leg 85 cc.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

Содержание X-Fly 100

Страница 1: ...e cooled and lubricated by a specially formulated oil Steer tube EASTON aluminum steer tube available for 1 1 8 diameter threadless Crown Forged and CNC machined BAM aluminum alloy Arch Cast magnesium alloy Stanchions anodized aluminum with variable section Sliders Forged and CNC machined BAM aluminum alloy Left slider comes with supports for disc brake caliper Slider bushing Full length guide bus...

Страница 2: ...re cooled and lubricated by a specially formulated oil Steer tube EASTON aluminum steer tube available for 1 1 8 diameter threadless Crown Forged and CNC machined BAM aluminum alloy Arch Cast magnesium alloy Stanchions anodized aluminum with variable section Sliders Forged and CNC machined BAM aluminum alloy Left slider comes with supports for disc brake caliper Slider bushing Full length guide bu...

Страница 3: ...with a special preferablybiodegradablesolvent such as trichloroethane or trichloroethylene 4 Before reassembling lubricate all parts in contact with each other using sili cone 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 dam age the fastening devices even when theirsizeissimilartothat...

Страница 4: ...Excessive dirt on slider oil seal 1 Replace oil seal 2 Replace crown stanchions assembly oil seals and dust seals 3 Cleantheoilsealseatandreplaceoilseal 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...

Страница 5: ...et mounting and adjustment must be carried out in compliance with the head set manufacturer s instructions Improper installation 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 her bicycle thus jeopardizing his her s...

Страница 6: ...e using special MARZOCCHI pump with pressure gauge Use of improper tools or other procedures than specified ones might lead to im proper inflating NOTE in case of air leakages when adapter fitting D is fitted ensure that the O ring D1 is not damaged REBOUND ADJUSTMENT The right fork leg is equipped with an adjuster screw A for REBOUND damp ing Turning this adjuster clockwise into the cartridge rod...

Страница 7: ...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 AIR VALVE CHANGE FIG 13 FOOT NUT FIG 4 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 PUMPING ROD REBOUND SPRING AND WASHER FIG 6 HYDRAULIC...

Страница 8: ...FIG 2 only right leg Lock the check nut 26 and remove the cap 7 from hydraulic cartridge end 12 FIG 3 Push the stanchions 1 into the sliders 18 and let all the 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 procedure as described in section REASSEMBLY from Fig 22 to Fig 2...

Страница 9: ... right leg Pull the hydraulic cartridge 12 complete with rebound spring 9 and foot washer 23 see exploded view out of the R H stanchion tube Replace the whole hydraulic cartridge FIG 6 only left leg A pumping rod 8 complete with re bound spring 9 and foot washer 23 see exploded view is fitted into the L H leg inside the stanchion Withdraw the above parts from the tube top by pushing them from slid...

Страница 10: ...rs 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 ...

Страница 11: ...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 ...

Страница 12: ...bled with the fork removed keep the fork vertical so as to avoid any oil leakage Remove the air valve 27 and its O ring 28 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 28 and screw the air valve 27 until it stops without forcing Then refit the c...

Страница 13: ...s the oil seal until it touches the lower washer by using the above seal press REASSEMBLY CAUTION beforereassembling allmetal 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 adheres...

Страница 14: ... and squared into the sliders Check to see that the stanchions slide unrestricted 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 th...

Страница 15: ... 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 HYDRAULIC CARTRIDGE right leg AND PUMPING ROD left leg RE ASSEMBLY FIG 20 Push the stanchions up to slider bottom Fit the hydraulic cartridge 12 complete with the rebound spring 9 and foot washer 23 see exploded view into the R H stanchion...

Страница 16: ...e stanchions start the cap 7 onto the threads by hand Screw cap 6 onto LH stanchion tube and tighten both caps to 12 Nm Pressurize as shown in section ADJUST ING FIG 23 only right leg Screw the cap 7 on hydraulic cartridge end 12 and tighten to proper torque Lock check nut on cap ...

Страница 17: ...MARZOCCHI TOOLS Ref I t e m Description and use A R 5089 AB Slider protector to remove the oil seal from the slider B R 5090 Oil seal press to press oil seal into the slider C R 4008 C Inflating pump D 5321038 Adapter fitting ...

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