Marzocchi Marathon SL User manual

Marathon SL
1/48
Features
TECHNICAL CHARACTERISTICS
Fork with Ø30 mm legs with "Double Air"
damping system.
Adjustment of the air preload (positive air)
on both legs.
Adjustment of the rebound damping
(negative air) on the left leg.
The ECC5 cartridge in the right leg lets you
adjust the rebound damping in five
positions "on the fly".
The stanchion tubes are pressed into the
crown with a cryogenic process.
New sliding system to improve the stiffness
and operation.
Magnesium alloy cast one-piece assembly,
CNC machined for lighter weight and more
stiffness.
Components subjected to friction are
lubricated and cooled by means of a
special oil
Steer tube :aluminium, 1-1/8", threadless.
Crown: BAM® aluminium alloy forged and
CNC machined.
Stanchions: anodised aluminium.
Sliding bushes: made of friction free and
wear free material.
Seals: computer designed oil seals that
guarantee the maximum seal in any
condition.
Oil: special formulated oil that prevents
foam and keeps the viscosity unchanged
while offering high performance; free from
static friction.
Dropout type: Standard.
Disk brake mount: XC International
Standard for 6" disk.
V-Brake fit.
BAM®: Bomber Aerospace Material:
special alloy coming from the aerospace
industry.

Marathon SL
2/48
Features

Marathon SL
3/48
Warning
INSTRUCTIONS FOR USE
GENERAL REGULATIONS
FITTING THE FORK ONTO THE FRAME
INSTALLING THE DISK BRAKE SYSTEM
INSTALLING THE V-BRAKE SYSTEM
ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS

Marathon SL
4/48
Warning
INSTRUCTIONS FOR USE
MARZOCCHI forks are based on an
advanced technology coming from the
company’s years long experience in the
professional mountain bike industry.
For the best results, it is advisable to
inspect and clean the area below the dust
seal and the stanchion tube after every use
and to lubricate the parts with some
silicone oil.
MARZOCCHI forks usually offer the best
performances since the very first rides.
Notwithstanding this, a short running-in
period may be necessary (5-10 hours) to
adjust the internal couplings. This
precaution will lengthen your fork’s life and
guarantee its best performances.
Changing the oil every 100 hours is
recommended.
The forks with a polished finish must be
treated periodically with polishing paste to
keep the exterior shining like new.

Marathon SL
5/48
Warning
GENERAL REGULATIONS
· After a complete breakdown, always use
new MARZOCCHI seals when
reassembling.
· Before reassembly, wash all new and old
components and dry them with some
compressed air, making sure there are
neither breaks nor burrs.
· Never use flammable or corrosive
solvents to clean the parts as this could
damage the seals. If necessary use specific
detergents that are not corrosive, not
flammable or have a high flash point
compatible with the materials of the seals
and preferably biodegradable.
· Before reassembling, always lubricate the
parts of the fork in contact with some oil for
forks.
· Never pour lubricants, solvents or
detergents which are not completely
biodegradable in the environment; these
must be collected and kept in the relevant
special containers, then disposed of in
accordance with the regulations in force.
· Always grease the seal lips before
reassembling.
· Use only metric spanners and not
imperial. Imperial spanners may have
similar sizes to metric ones but they can
damage the bolts and screws making it
impossible to unscrew them.
· Use the right size and sort of screwdriver
to unscrew slotted or crosshead screws.
· When using a screwdriver to assemble or
dismantle metal stop rings, O-ring seals,
guide bushes or seal segments, avoid
scratching or cutting the components with
the tip of the screwdriver.
· Use only original spare parts.
· Before servicing the fork, we recommend
washing the fork thoroughly.
· Work in a clean, ordered and well-lit place.
· Carefully check there are no metal
shavings in the work area.

Marathon SL
6/48
Warning
FITTING THE FORK ONTO THE FRAME
The fork is supplied with “A-Head Set” steer
tube to be cut according to frame size it will
be used on.
Fitting the fork onto the bike frame is a very
delicate operation that must be carried out
at one of our service centres only.
The assembling on the frame and the
adjustment of the steer tube must be
carried out following the instructions of the
steering set manufacturer.
A wrong installation can be dangerous
for the rider.
Marzocchi does not guarantee the
assembly and accepts no liability for
damage and/or accidents arising from a
wrong installation.
The steer tube must be pressed into the
crown; its replacement must be carried
out by one of our service centres using
the adequate tools.
A wrong installation of the steer tube
into the crown may cause the rider to
lose the control of the bike and lead to
serious personal injury.

Marathon SL
7/48
Warning
INSTALLING THE DISK BRAKE SYSTEM
Installing the brake system is a very
delicate operation that must be carried out
at our specialised service centres only.
Marzocchi does not guarantee the
installation and accepts no liability for
damage and/or accidents arising from a
wrong installation
Improper installation of the disk brake
system can overstress the caliper
mountings, which may break. The
installation of the brake system must be
carried out following the instructions of
the brake system manufacturer.
Improper installation can be dangerous
for the rider.
Use only brake systems in accordance with
the fork’s specifications.
If the fork comes standard with V-brake
mounts, remove such mounts and
install the cable guide (A) on the left
side and cap (B) on the right side.
After installation always check that the
brake tube is correctly fixed to the
special mount (A).

Marathon SL
8/48
Warning
INSTALLING THE V-BRAKE SYSTEM
Installing the brake system is a very
delicate operation that must be carried out
at our specialised service centres only.
Marzocchi does not guarantee the
installation and accepts no liability for
damage and/or accidents arising from a
wrong installation.
The installation of the brake system
must be carried out following the
instructions of the brake system
manufacturer. Improper installation can
be dangerous for the rider.
Use only brake systems in accordance with
the fork’s specifications.
If the fork does not come standard with
V-brake mounts, after removing the
cable guide (A) and the disk brake
mount cap (B), install the adapter (A)
and the bolt (D) on both legs, check that
the adapter is correctly oriented as
shown and tighten the bolt to the
recommended tightening torque (11±1
Nm).
On the thread of bolts (D) a special
anti-unscrewing treatment has been
applied; as a result, the removed bolts
cannot be re-used as they lose such
treatment.

Marathon SL
9/48
Warning
ASSEMBLING THE WHEEL ON FORKS
WITH STANDARD DROPOUTS
Install the wheel following the
instructions of the bike’s manufacturer.
A good and reliable operation of the fork
and all of the parts linked to it mainly
depend on the correct fixing of the front
wheel.
For a correct operation of the fork, install
the wheel as explained below:
Check the correct fork-wheel alignment by
fully compressing the fork a few times.
Lift the front wheel above the ground; turn
the wheel a few times to verify the correct
alignment with the disk brake.

Marathon SL
10/48
Diagnostic

Marathon SL
11/48
Disassembling
REMOVING THE TOP CAP – RIGHT LEG
REMOVING THE TOP CAP – LEFT LEG
DRAINING THE OIL
BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY
REMOVING THE HYDRAULIC CARTRIDGE - RIGHT LEG
REMOVING THE CARTRIDGE – LEFT LEG
REMOVING THE SEALS
REMOVING THE GUIDE BUSHES

Marathon SL
12/48
Disassembling
REMOVING THE TOP CAP – RIGHT LEG
· Put the fork in the vice in a vertical
position, fixing it by the dropouts.
· With a 2mm Allen wrench, loosen the
screw (2) of the ECC5 control knob.
· Remove the ECC5 control knob (3).
· Remove pin (4) and spring (5).

Marathon SL
13/48
Disassembling
· Using a small pin screwdriver, blow the air
off the fork leg, pushing on the air valve.
· Fully unscrew the lock cap (1) with a
21mm socket spanner.

Marathon SL
14/48
Disassembling
REMOVING THE TOP CAP – LEFT LEG
· Put the fork in the vice in a vertical
position, fixing it by the dropouts.
· Loosen and remove the protection cap (6).
· Using a small pin screwdriver, blow the air
off the fork leg, pushing on the air valve.
· Fully unscrew the lock cap (1) with a
21mm socket spanner.
Now you can remove the caps from the
cartridge rods. It is however recommended
to do this operation after having removed
the cartridge from the arch-slider assembly.

Marathon SL
15/48
Disassembling
DRAINING THE OIL
· Remove the leg caps (1) from the crown
unit.
· Free the fork from the vice and tip it into a
container of a suitable size to drain the oil;
compress the fork a few times to help the
oil flow out.
Do not pour used oils on the ground.

Marathon SL
16/48
Disassembling
BREAKING DOWN THE
CROWN-STANCHION UNIT /
ARCH-SLIDER ASSEMBLY
Use the special spanner to remove the
bottom nuts. Do not use other tools.
Using the special 12mm spanner (A),
loosen the two bottom nuts (1).
· Remove the bottom nuts (1) and the
O-rings (2).
· Pull the complete cartridges (10) off both
fork legs.

Marathon SL
17/48
Disassembling
· Pull the crown-stanchion unit (3) off the
arch-slider assembly (4).

Marathon SL
18/48
Disassembling
REMOVING THE CARTRIDGE – RIGHT
LEG
· Remove the stop ring (8).
· Remove the lock cap (1).
The ECC5 cartridge (7) is sealed through
machining and cannot be overhauled. In
the case of faults or a malfunctioning, it
must be replaced.

Marathon SL
19/48
Disassembling
REMOVING THE CARTRIDGE – LEFT
LEG
· Hold the cartridge rod in the vice using the
special jaws (A).
· With a 21mm socket spanner, fully
unscrew lock cap (2).
· Remove lock cap (2).
· Hold liner (3) firmly and, with a 19mm
hexagonal wrench, remove the cartridge
cap (4).
On the thread of cap (4) a special
anti-unscrewing treatment has been
applied. Do not re-use removed caps as
they loose such treatment.

Marathon SL
20/48
Disassembling
· Pull out the cartridge rod (5) complete with
cap (4) and rebound spring (6).
· Remove cap (4) complete with rebound
spring (6) from the cartridge.