Marzocchi X-Fly User manual

X-Fly
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.

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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.
FAILURES CAUSES REMEDIES
Oil leaking through the bottom of slider O-ring on the pumping rod or on cartridge
securing nut bottom damaged
Replace the O-ring
Oil leaking through the top of the slider 1. Oil seal is worn out
2. Stanchion tube is scored
3. Excessive dirt on slider 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
Pressure drop Cap valve damaged Replace cap and/or valve
Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings
Fork rebounds too fast in any adjuster
position
Dirt inside fork legs Clean carefully and change oil
Adjuster position does not affect fork opera-
tion
1. Dirt inside legs
2. RH fork cartridge faulty
1. Clean carefully and change oil
2. Replace hydraulic cartridge
Fork does not react to rebound lock LH fork cartridge faulty Replace hydraulic cartridge

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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 and check pressure at
least every 10 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 absolutely forbidden
to loosen and remove original brake sup-
ports fixing pins. In fact, apart from retain-
ing Cantilever or V-brake levers, they also
play an important role in securing slider
bottom to slider-arch monolith. If needed,
replace these pins with screws (part no.
532979QF) available as spare parts.
Tighten the above screws to 10 Nm.
IMPORTANT: screw and pin threading is
treated to ensure hydraulic seal. Never
reuse screws and pins which have been
removed.
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.

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D
D
D1
2
CC
A
ADJUSTMENTS
FORK LEG PRESSURIZATION
Blow pressurized air through the valves to set
COMPRESSION damping. To change the
pressure inside the fork legs, remove the
protection cap (2) and depressurize each
leg by pushing lightly on valve pin with a bit.
Fully tighten adapter fitting (D), supplied
with the fork, on M ARZOCCHI pump (C).
Screw fitting end –with O-ring (D1) on
valve, and pressurize until the required value
is reached. Unscrew the fitting/pump as-
sembly and refit the cap (2).
IMPORTANT: inflate using special
M ARZOCCHI pump with pressure gauge.
Use of improper tools or other procedures
than specified ones might lead to improper
inflating.
NOTE: in case of air leakages when adapter
fitting (D) is fitted, ensure that the O-ring
(D1) is not damaged.
REBOUND ADJUSTMENT
(only right leg)
The right fork leg is equipped with an
adjuster screw (A) for REBOUND damp-
ing. Turning this adjuster clockwise into the
cartridge rod, changes the hydraulic set-
ting of the inner valves. In short, the amount
of adjustment applied on the piston in the
fluid determines the rate of 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.

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LOCK
4
REBOUND LIMITER
(only left leg)
In case of hard uphill path, fork leg rebound
can be locked for improved behavior.
Position the knob (4) on l.h. fork leg top to
“LOCK” to lock rebound limit in this posi-
tion; this also allows to decrease fork leg
height for optimal attitude uphill, thus sup-
porting suspension compression operation.
Reposition the knob to its original position
so that the fork will rebound and restart to
work as before.
WARNING: do not position to
“LOCK” when riding downhill as
available travel might not be enough, thus
jeopardizing rider’s safety

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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 OIL CHANGE
STANCHION TUBE CAP FIG. 1/2/3
AIR VALVE CHANGE
FIG. 13
FOOT NUTS FIG. 5
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
HYDRAULIC CARTRIDGES,
REBOUND SPRING AND WASHER FIG. 6
HYDRAULIC CARTRIDGES CHANGE

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4
3
7
26
11-12
7
STANCHION PLUG
FIG. 1 (only left leg)
Loosen screw (3) and remove rebound
limiting knob (4).
FIG. 2
Depressurize each fork leg (see section
ADJUSTMENT).
Unscrew the caps (7) with a 21 mm socket
wrench.
FIG. 3
Lock the check nut (26) and remove the cap
(7) from hydraulic cartridges ends (12)
and (11).

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118
20
19
12 11
9
6-9
Sx.Dx.
FIG. 4
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 proce-
dure as described in section “REASSEMBLY”
from Fig. 22 to Fig. 24.
HYDRAULIC CARTRIDGE CHANGE
FIG. 5
Turn the fork leg upside-down and unscrew
the foot nuts (20) by the use of a 15 mm
socket wrench complete with O-Rings (19).
FIG. 6
Pull the hydraulic cartridge (12) and (11)
complete with rebound spring.
IMPORTANT: cartridges fitted to forks
with a travel of 100 feature a rebound
spring (9) that is the same fitted in both fork
legs.
Rebound springs in forks with a travel of
80 are different: rebound spring (9) is in
the LH fork leg, while rebound spring (6) is
in the RH fork leg.
Remove the bottom washers (23, see ex-
ploded view) from inside the stanchions.
NOTE: the hydraulic cartridge is supplied
with gaskets and lock nut (26).
These parts can be also ordered separately
(see exploded view).
Replace the whole hydraulic cartridges.

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1
18
13
14
REPLACING SEALING UNIT AND
GUIDE BUSHES
FIG. 7
Withdraw the crown and stanchions as-
sembly (1) from the sliders (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.

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15
A
16
17
FIG. 10
Fit the slider protector (A) onto the slider
and remove the oil seal (15) 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. 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.