Marzocchi Monster T User manual

Monster
T
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing M ARZOCCHI special tools only.
2. On reassembling the suspension system,
always use new seals.
3. If two screws are close one to the other,
always tighten using a 1-2-1 sequence.
In short, screw the first screw just up to the
point it is well tightened, then tighten the
second screw and then go back to the
first one and screw it tighter.
4. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
5. Before reassembling, lubricate all parts
in contact with each other using silicone
fat spray or a specific oil for oil seals.
6. Always grease the conic seal rings be-
fore reassembling.
7. 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.
INSTRUCTIONS

Monster
T
FAILURES, CAUSES AND REMEDIES
This paragraph reports some troubles 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 seal on the cartridge nut is damaged Replace the O-ring seal
Fork has not been used for some time and
is locked out
Oil seals and dust seals tend to stick to
stanchion tube
Raise dust seal and lubricate stanchion
tube, oil seal and dust seal
Fork rebounds too fast even though the
adjuster is set to hardest damping position
Cartridge is faulty Replace hydraulic cartridge
Excessive play of stanchions into the sliders Main slider bushings are worn Replace main slider bushings
1. Oil seal is worn out
2. Stanchion tube is scored
3. Excessive dirt on slider oil seal
1. Replace oil seal
2. Replace stanchion tube, oil seal and dust
seal
3. Clean the oil seal seat and replace oil
seal
Excessive oil build up on stanchions
FAILURES CAUSES REMEDIES
Adjuster position does not affect fork opera-
tion
Dirt inside legs Clean carefully and change oil

Monster
T
28
29
31
29
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.
INSTALLATION
Installing the fork on a bicycle is a very
delicate operation that should be carried
out with extreme care.
A threadless steer tube is pre-installed on
the fork from the factory. It will need to be
cut to the required length for a proper fit.
Always have the installation checked at one
of our Technical Service Centers.
WARNING: “A-Head Set” head-
set/steer tube mounting and adjust-
ment must be carried out in compliance
with the headset manufacturer’s instruc-
tions. Improper installation may jeopardize
the safety of the rider.
After any installation always check for the
following:
– proper torque of bolts fastening stan-
chion tube onto lower crown and upper
crown;
– proper torque of bolts fastening brake
arch onto slider
– proper torque of bolts fastening shaft to
drop out
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.
MOUNTING THE FORK
ON THE FRAME
FIG. A
Remove the upper crown (28) from steer
tube and fork legs by loosening the fasten-
ing screws (29) and (31).

Monster
T
28
28
13
C
31
29
Nm11
FIG. B
Assemble the fork to the frame complete
with headset. Fit the upper crown (28) into
the upper stanchions and the steer tube.
FIG. C
The stanchions edge (13) must be aligned
with or slightly lower than the upper crown
(28). If fork legs overprotrude, fit some
spacers (C) to the plate close to the steer
tube.
In case of frame with higher steer tube, use
the optional plate supplied on request.
FIG. D
Fit the handlebar support and the “A-Head
Set” cap over the upper crown (28) and
then adjust the steering.
Now finally tighten the screws (29) and
(31) on the upper crown to 11 Nm.
WARNING: Loosen the screws (29)
and (31) on the upper crown before
adjusting the steering. Tighten the above
bolts to the required torque when finished.

Monster
T
26
H
26
H
FIG. E
If the crown (26) position with respect to
the stanchions (13) has been changed for
any reason, adjust the original distance.
– Distance “H” between crown and tyre
edge (when inflated) should not be lower
than total travel (175 mm) + 3 mm.
WARNING: If lower Crown is im-
properly matched with stanchions, it
may touch the tyre and cause severe inju-
ries to the rider.
FIG. F
Tighten the 4 stanchions fastening screws
(27) onto the crown to 11 Nm.
WARNING: do not overtighten the
screws holding the stanchions to the
crown as this may distort the stanchions and
weaken the whole structure.

Monster
T
Nm20
23
29
Nm6
29
23
FIG. H
Tighten the wheel shaft (23) counter clock-
wise from the opposite end with a 8-mm
Allen wrench. Tighten to 20 Nm.
FIG. I
Compress the fork several times so the
sliders will become properly seated onto
the wheel shaft. Lock the pinch bolt (29) on
the r.h. lug to 6 Nm.
DISASSEMBLY
To remove the wheel proceed as follows:
– loosen the bolt (29) on the r.h. drop-out;
– screw the wheel shaft (23) clockwise
onto the l.h. drop-out (see FIG. H);
– remove the shaft (23) from the opposite
side (see FIG. G).
FRONT WHEEL FIXING
IMPORTANT: for a safe and proper per-
formance of this fork and all related de-
vices, the front wheel should be absolutely
secured as specified in the instructions given
below.
FIG. G
Insert the complete wheel assembly be-
tween the sliders and fit the wheel shaft
(23) into the slider that accommodates the
wheel shaft pinch bolt (29) from the right
hand side.
Rotate wheel shaft clockwise to start it into
the LH slider.

Monster
T
25 38
21
36
37
11
FORK CONFIGURATION FOR 3"
WHEEL INSTALLATION
(Fig. L)
Before you can install a 3" wheel, you will
need to:
– replace standard arch with oversized
arch (38). Reuse the fastening bolts
(25).
– Fit the spacers (36) to hydraulic car-
tridges ends (11).
– Replace the standard foot nuts with the
special nuts (37).
WARNING: Unless fork is properly
configured as detailed above, tyre
will touch the arch when a 3" wheel is
installed.
DISC BRAKE SYSTEM ASSEMBLY
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 sup-
ports, which might break.
This system should be assembled by spe-
cialized technicians in a position to fully
understand and properly follow the instruc-
tions given by the manufacturer.

Monster
T
E
2
REBOUND DAMPING ADJUSTMENT
Fork legs feature an adjuster (E) for RE-
BOUND DAMPING adjustment. Turning
this adjuster clockwise into the cartridge
rod, changes the hydraulic setting of the
inner valves. In short, the amount of adjust-
ment applied on the piston in the fluid
determines the rate of compressionrebound
damping.
To adjust, always start from the minimum
damping setting, i.e. unscrew completely
counterclockwise. About 8 turns - abt. 4 mm
of the adjustment - are possible.
ADJUSTMENTS
SPRING PRELOAD
The spring preload for COMPRESSION
damping can be adjusted by turning the
knob (2) on top of fork legs. From the
factory the fork is set at minimum preload,
i.e. the adjustment knob completely un-
screwed counterclockwise. However,
springs are slightly preloaded to help coun-
teract static loads during COMPRESSION.
By turning the adjustment knob clockwise,
the preload is increased up to the maximum
value equal to 15 mm of spring preload.
This adjustment is essential in order to have
the right fork response for the rider’s weight
and riding style.

Monster
T
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
DISASSEMBLY
GENERAL
– The reference numbers given in this section relate to the components shown in the forks exploded view.
– These operations refer to the fork legs having already been removed from the crown and disassembled from the brake arch.
– Before starting any operation, please read the diagram below. It shows the quickest procedure and the exact sequence in which it should
be disassembled. Start from the part first to be disassembled and then follow the arrows to remove the remaining parts.
DISASSEMBLY DIAGRAM
GUIDE BUSHINGS AND
SEAL ASSEMBLY
CHANGE
DUST SEAL FIG. 8
SLEEVE FIG. 10
STOP RING FIG. 11
OIL SEAL FIG. 12
LOWER WASHER FIG. 13
SLIDER BUSHING FIG. 14
CIRCLIP FIG. 10
STANCHION TUBE FIG. 9
HYDRAULIC
CARTRIDGE CHANGE
FOOT NUT FIG. 6
REBOUND SPRING FIG. 7
STANCHION BUSHING
FIG. 10
HYDRAULIC CARTRIDGE
FIG. 7
SPRING CHANGE
PRELOAD KNOB FIG. 1
STANCHION TUBE CAP
FIG. 3/4
UPPER WASHER - PRELOAD
SLEEVE - SPRING - LOWER
WASHER FIG. 5
FORK OIL CHANGE
STOP RING FIG. 2

Monster
T
2
3
4
56
SPRING CHANGE
FIG. 1
Set knob (2) to minimum preload value.
Loosen the grub screw (3) fastening the
preload knob (2) by means of a 1.5 mm
Allen wrench. Remove grub screw from cap
assembly.
FIG. 2
Remove the stop ring (4) from the top of the
preload knob support with a small screw-
driver.
FIG. 3
Place the stanchion tube in a vice. Be sure
not to damage or dent it in the process.
Unscrew the cap (5) complete with O-ring
(6) with a 26 mm end wrench.

Monster
T
5
6
43
9
1
8
22
21
FIG. 4
Position the plunger (7, see exploded view),
into the cap, to the minimum preload value.
Push down the stanchion tube.
Lock the check nut (43) and remove the cap
(5) from hydraulic cartridge top.
FIG. 5
Remove the upper washer (8), the preload
sleeve (1) and the spring (9).
Let all the oil drain into the fork leg. By
following this procedure, there is no need to
check the oil level. Make all necessary
changes.
HYDRAULIC CARTRIDGE CHANGE
FIG. 6
Let all the oil drain out.
WARNING: Remember to always
recycle any used oil.
To change the fork leg oil follow the proce-
dure as described in REASSEMBLY from
FIG. 24 to FIG. 29.
Turn the fork leg upside-down and unscrew
the foot nut (22) complete with O-ring (21)
by the use of a 15 mm socket wrench.

Monster
T
11
12
46
14
13
FIG. 7
Pull the hydraulic cartridge (11) complete
with lower washer (46) and rebound spring
(12) out of the stanchion tube.
Replace the whole hydraulic cartridge.
GUIDE BUSHINGS AND SEAL
ASSEMBLY CHANGE
FIG. 8
Use a small screwdriver and remove the
dust seal (14) from the top of the slider.
Pull the dust seal out of the stanchion tube.
FIG. 9
Pull the stanchion tube (13) completely out
of the slider.
Pull strongly to overcome the resistance of
the guide bushing of the stanchion tube to
slide through the slider bushing.
IMPORTANT: the seal unit will be perma-
nently damaged by the guide bushing.
Always change the oil seals after the above
procedure.

Monster
T
13 32
13 34
15
16
A
FIG. 10
A sleeve (33) is located inside the stan-
chion tube. Remove the outer snap ring
(32) to remove the sleeve (33). Should the
guide bushing (34) be damaged, remove
it from the stanchion (13) inserting a small
screwdriver into the bushing slot.
FIG. 11
Remove the stop ring (15) from the slider
by placing the screwdriver bit in one of the
three openings on the stop ring and care-
fully lifting the ring out of place.
IMPORTANT: when removing the stop
ring, make sure not to damage its seat.
FIG. 12
Fit the slider protector (A) onto the slider
and remove the oil seal (16) with the help
of a large slot screwdriver.
IMPORTANT: when removing the oil seal,
make sure not to damage its seat. Once
removed, the oil seals should not be used
again.

Monster
T
17
18
FIG. 13
Remove the upper washer (17) from the
slider.
FIG. 14
To remove the guide bushing (18), beat
powerfully the slider edge on a wooden
surface. Perform this operation with ex-
treme care and try to keep the slider perpen-
dicular to the wooden surface.

Monster
T
32
33
13
16
17 18
34
REASSEMBLY
CAUTION: before reassembling, all metal
components should be washed carefully
with inflammable and biodegradable sol-
vent and dried with compressed air.
FIG. 15
Fit the sleeve (33), with its completely open
side facing outwards, on the stanchion
edge (13). Fit the outer snap ring (32).
Make sure it is fully seated in the tube.
FIG. 16
Stick some adhesive tape onto the stan-
chion bottom (13) to protect it. Insert the oil
seal (16), duly lubricated, the bushing
washer (17) and the slider guide bushing
(18) into the stanchion. Remove the adhe-
sive tape and clean the stanchion.
FIG. 17
Insert the bit of the flat screwdriver into the
guide bushing slot (34) to fit it on the
stanchion tube. Ease it into the tube seat by
hand.

Monster
T
18
16
13
17
16
B
15
FIG. 18
Gently insert the stanchion tube (13) into
the slider from the bushing side.
Fit the guide bushing (18) and the bushing
washer (17) into the slider seat by hand.
FIG. 19
Press the oil seal (16) into place until it
touches the lower washer (17) by using the
seal press (B).
FIG. 20
Insert the stop ring (15) making sure it is
properly seated into place.
Use buffer (B) to properly seat the ring into
the slider.

Monster
T
14
11
12
46
Nm11
22
21
FIG. 21
Lubricate the dust seal (14) and insert it into
the top of the slider.
Fit it into the slider seat.
HYDRAULIC CARTRIDGE
FIG. 22
Fit the rebound spring (12) and the lower
washer (46) into the hydraulic cartridge.
Insert the complete hydraulic cartridge (11)
with the stanchion tube pressed fully down.
FIG. 23
Grease the O-ring (21) on the foot nut (22)
and screw the nut onto the hydraulic car-
tridge thread.
Tighten to 11 Nm.
Pump stanchion up and down several times
to make sure it slides properly through the
stroke.

Monster
T
100
9
1
8
10
5
611
HOW TO FILL WITH OIL
FIG. 24
Pour the oil little by little when the stanchion
tube is fully down and then pump the
cartridge rod (11) up and down so as to
have a better filling. Cartridge is full when
no air is detected when pumping, in the fully
compressed position. Check that oil level is
100 mm from the top of the stanchion tube
in each leg.
SPRING AND CAP
FIG. 25
Fit the spring (9), the preload sleeve (1)
and the upper washer (8) into the stanchion
tube.
Lubricate the O-ring (10) on the top of the
preload knob support and the O-ring (6) on
the cap (5).
FIG. 26
Position the plunger (7, see exploded view),
into the cap, to the minimum preload value.
Screw the complete plug (5) fully onto the
cartridge rod (11).

Monster
T
5
Nm20
4
Nm1,5
23
FIG. 27
Lift the stanchion tube and fit the plug (5) by
hand. Place the stanchion tube in vice.
Make sure not to damage or squeeze it.
Tighten to 20 Nm.
FIG. 28
Fit the stop ring (4) of the preload knob
support and make sure it is fitted properly
into its seat.
FIG. 29
Fit the preload knob (2), secure it on the
support and tighten the Allen bolt (3) to 1.5
Nm.
Fit the brake arch to the fork leg, and then
install fork legs into crown and upper crown
as specified in section “INSTALLATION”.