this service procedure is for the classic Marzocchi DH3, the routine can also be applied to the XCR (Nitro) and also the XC50/51 models (24mm stanchions)
Seal kit:
Y8501558/C
Tools
YR4208/C – low pressure shock pump
YR5008BZ - Air cap puller
seal press no longer available
General Tools
6mm allen wrench (extra long)
Cir-clip pliers
Flat bladed screwdriver
Service Instructions:
Let all the air out of the fork
Place air cap extractor tool on shreader valve (17)
Tap tool (thus tapping plug) 10mm into the stanchion (19)
Remove cir-clip from inside the stanchion (38H)
Pull upper plug unit out of the stanchion (17)
Y8501558/C
Tools
YR4208/C – low pressure shock pump
YR5008BZ - Air cap puller
seal press no longer available
General Tools
6mm allen wrench (extra long)
Cir-clip pliers
Flat bladed screwdriver
Service Instructions:
Let all the air out of the fork
Place air cap extractor tool on shreader valve (17)
Tap tool (thus tapping plug) 10mm into the stanchion (19)
Remove cir-clip from inside the stanchion (38H)
Pull upper plug unit out of the stanchion (17)
Empty fork of oil into a suitable container
Use an extra long 6mm allen key down the centre of the stanchion and undo (53)
Remove stanchion (19)
Remove Dust seal(20), cir-clip (38) & oil seal (22)
Clean fork components and check for wear & tear.
Replace oil seal, cir-clip & dust seals.
Replace stanchion & tighten foot screw
Re-fill with 20w oil (XC50/51 = 7.5w) 35mm from the top of the stanchion with the stanchion fully compressed.
Replace upper plug (17) & cir-clip (38H)
Pull plug (17) up hard against the cir clip (38H) using air plug tool to check that the cir clips is correctly seated.
Inflate to 30-45 psi
Remove stanchion (19)
Remove Dust seal(20), cir-clip (38) & oil seal (22)
Clean fork components and check for wear & tear.
Replace oil seal, cir-clip & dust seals.
Replace stanchion & tighten foot screw
Re-fill with 20w oil (XC50/51 = 7.5w) 35mm from the top of the stanchion with the stanchion fully compressed.
Replace upper plug (17) & cir-clip (38H)
Pull plug (17) up hard against the cir clip (38H) using air plug tool to check that the cir clips is correctly seated.
Inflate to 30-45 psi
Where can I found Seal replacement kit for Marzocchi DH3?
ReplyDeleteAre these still available anywhere?
the seal kit has now been discontinued from Marzocchi, so your only option is to find some 'new old stock' or pattern parts?
ReplyDeleteI managed to buy off a bike shops older Marzocchi stuff, especily 26mm oil seals, but have also other parts.
ReplyDelete--> you can contact me via http://dr-marzocchi.projectweb.de/me/contact/
All seals, tools and spares are available, please visit my website at https://dr-marzocchi.projectweb.de/
ReplyDeleteThese are basic service instructions but what about servicing the on the fly damping adjusters on the front of the XCR'S? I was gifted a set and have it completely torn down. My only real issue is the knobs for the rebound dampers(rebound right definitely not a compression damper?) Were missing. Do you have any tips for a work around other than a flat head screwdriver?
ReplyDeleteWhat about simply new dials?🖐✨🥇🤣🎈 --> Search Dr-Zocchi in the net.
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