Marzocchi EXR Coil User manual

EXR
Coil
INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M ARZOCCHI special tools only.
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts 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 similar to that of the wrenches in
metric size.

EXR
Coil
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-ring on pumping rod nut damaged Replace the O-ring
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
FAILURES CAUSES REMEDIES
Excessive play of stanchions in the sliders Pilot bushings are worn Replace pilot bushings

EXR
Coil
RECOMMENDATIONS FOR
MAINTENANCE
M ARZOCCHI forks are based on advanced
technology, supported by year-long experi-
ence in the field of professional mountain
biking. In order to achieve best results, we
recommend to check and clean the area
below the dust seal and the stanchion tube
after each use and lubricate with silicone
oil.
In general, M ARZOCCHI forks can offer top
performance from the start. However, in
some cases a short running-in period is
required (5-10 hours) for inner adjustments.
This running-in period will make fork life
longer and ensure fork top performance
over time.
IMPORTANT: change oil at least every
100 working hours.
Polished forks should be cleaned with
bodywork polish at regular intervals in
order to preserve their original finish.
INSTALLATION
Installing the fork on a bicycle is a very
delicate operation that should be carried
out with extreme care. The installation should
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 case of improper
installation of the steer tube into the
crown, the rider might lose control of his/
her bicycle, thus jeopardizing his/her safety.
DISC BRAKE SYSTEM ASSEMBLY
WARNING: If a disc brake system
is installed, it is possible to replace
original brake supports fixing pins with
screws (part no. 532979QF) available as
spare parts.
Tighten the above screws to 10 Nm.
Assembling the brake caliper onto the slider
is a very delicate operation that should be
carried out with extreme care.
Improper assembly might overstress the
caliper supports which might break.
When installing the disc brake system, be
sure to properly follow the instructions given
by the manufacturer.

EXR
Coil
ADJUSTMENT
SPRING PRELOAD
Take off the rubber protection (2).
To change preload, turn the screw (4)
inside cap (5) using a 4 mm Allen wrench.
Turn out the screw (4) completely, then
tighten it until it touches the upper washer
(7). From this starting position, which cor-
responds to “0” preload, turn in as many
turns as the preload you want. Each turn
corresponds to 1.25 mm.
When supplied, the fork is set to the mini-
mum preload. However, spring is slightly
preloaded to counteract static loads. By
turning the adjustment screw clockwise, the
preload is increased up to the maximum
value equal to 15 mm’s of spring preload.
This adjustment is essential in order to have
the right fork response for the rider’s weight
and riding style.
2
5
4
7

EXR
Coil
DISASSEMBLY
GENERAL
– The reference numbers given in this section relate to the components shown in the fork exploded view.
– Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence.
Locate the 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 LEG OIL CHANGE
PUMPING ROD CHANGE
FOOT NUT FIG. 3
SPRING FIG. 2
DUST SEAL FIG. 5
STOP RING. 6
OIL SEAL FIG. 7
PUMPING ROD FIG. 8
REBOUND SPRING FIG. 8
VALVE ASSEMBLY CHANGE
SEAL ASSEMBLY CHANGE
STANCHION TUBE CAP FIG. 1
CROWN AND STANCHIONS ASSEM-
BLY FIG. 4
SPRING CHANGE
STOP RING FIG. 9
VALVE ASSEMBLY FIG. 9

EXR
Coil
SPRING CHANGE
FIG. 1
Unscrew the caps (5) with a 21 mm socket
wrench.
Remove the caps complete with O-ring (6)
from the stanchions.
FIG. 2
Push the stanchions into the sliders and
remove the lower washer (7) and the
spring (8) 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. 17 to Fig. 19.
SEAL ASSEMBLY CHANGE
FIG. 3
Turn the fork leg upside-down and unscrew
the foot nuts (20) complete with O-ring
(19) by the use of a 15 mm socket wrench.
5
6
8
7
20
19

EXR
Coil
FIG. 4
Withdraw the crown and stanchions as-
sembly (1) from the sliders (18).
FIG. 5
Remove the dust seal (15) from the top of
the sliders using a small screwdriver.
FIG. 6
Remove the stop ring (16) 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.
1
18
15
16

EXR
Coil
FIG. 7
Fit the slider protector (A) onto the slider
and remove the oil seal (17) 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. 8
Withdraw the pumping elements (10) and
the rebound spring (11) from the stanchion
tube top. Replace the seal ring (9) if dam-
aged or worn out.
VALVE ASSEMBLY CHANGE
FIG. 9
To check that the valve assembly is operat-
ing correctly, it is necessary to work on the
inside of the stanchion tube.
Slip off the stop ring (22) using pointed
pliers.
Pull the valve assembly out of the tube with
one finger in the same sequence as in the
figure: covering (14), valve (13) and
washer (12).
17
A
9
11
10
22
14 13 12

EXR
Coil
REASSEMBLY
CAUTION: before reassembling, all metal
components should be washed carefully
with inflammable, preferably biodegrad-
able, solvent and dried with compressed
air.
SEAL REASSEMBLY
FIG. 10
Lubricate the oil seal (17) 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 seal press.
FIG. 11
Insert the stop ring (16) into the slider
making sure it is properly seated into place.
Use buffer (B) to properly seat the ring into
the slider.
17
B
16
FIG. 12
Lubricate the dust seals (15) and fit them
into the stanchions from the spring end.
15

EXR
Coil
VALVE AND PUMPING ROD
ASSEMBLY
FIG. 13
After having overhauled or replaced the
valve unit and after having cleaned the
inside of the tube, reassemble. Assemble
valve components, in correct sequence:
washer (12), valve (13) and covering
(14).
Then fit pumping rod (10) with seal ring (9)
and rebound spring (11) into the valve
assembly.
FIG. 14
Fit this assembly into the stanchion tube and
properly seat the valve assembly (C).
Insert the stop ring (22).
CROWN AND STANCHIONS
ASSEMBLY
FIG. 15
Fit the crown and stanchions assembly (1)
- with the dust seals in place - gently into the
sliders seals.
WARNING: to avoid any dam-
ages to sealing surfaces, keep the
stanchions duly lubricated and squared
into the sliders.
Press the crown and stanchions assembly
fully down and check that threaded ends of
pumping elements (10) are coming 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 ensure they are not damaged.
Seat the dust seals (15) on top of the
sliders.
10
12
13
14
11
9
22
C
1
15 15

EXR
Coil
FIG. 16
Grease the O-ring (19) on the foot nut (20)
and screw the nut on the pumping rod
thread (10).
Tighten to 11 Nm.
Check to verify that the stanchions slide
properly through the stroke by pumping
them up and down several times.
HOW TO FILL WITH OIL
FIG. 17
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 (H) is as required in
both legs.
SPRING AND CAP
FIG. 18
Fit the spring (8) and washer (7) into each
stanchion tube.
20
19
Nm11
H
Travel (mm) H (mm)
80 47
100 47
8
7

EXR
Coil
FIG. 19
Lubricate the O-ring (6) on the cap (5).
Turn the preload adjuster (4) inside the cap
until setting minimum preload (see section
ADJUSTMENT).
Start the complete cap assembly into the
stanchion tube thread by hand. Tighten the
cap (5) to 20 Nm.
Set spring preload as specified in section
ADJUSTMENT.
Nm20
5
6