Tuesday, 18 June 2013

Service: Marzocchi 888RC3 2008-2013

The 2008-2013 888RC3 is a simple fork to service as it follows the same procedure as all open bath Marzocchi's, however it just has more parts!

Parts needed 
Y8501451, 38mm seal kit
Y5249, SAE 7.5w oil

Tools Required 
YR5214/C, 38mm seal press

General Tools 
1.5, 2mm allen wrench
17, 24mm socket
Torque wrench

Service Instructions

1/ Remove all adjuster knobs, be careful when removing the pre-load knob not to loose spring (95) and ball bearing (96) that index’s the adjuster.
2/ Undo both top plugs using a 24mm socket.
3/ Remove spring guide (53) and main spring (51).
4/ Pour oil out of the top of the fork. Make sure you use a suitable container and recycle responsibly.
5/ Undo both foot nuts, RH (37) using a 5mm hex key, LH (88) using a 17mm socket.
6/ Remove RC3 cartridge unit (80).
7/ Separate the stanchions (21) from the lower legs (3) by simply pulling them apart.
8/ Prise the dust seal up (12) using a flat bladed screw driver.
9 /Remove foam ring (19).
10/ Remove oil seal retaining clip (13).
11/ Remove oil seal (14) using tool Y536064GG/C and a flat bladed screw driver.
12/ Inspect and clean all parts.

13/ Install new oil seal (14) using press tool YR5214/C
14/ Install oil seal retaining clip (13).
15/ Install dust seal (12) on to the stanchion (21).
16/ Install foam ring (19) on to stanchion (21). For best performance pre-soak rings in SAE 7.5w fork oil.
17/ Insert stanchions (21) in to the lower legs (3), making sure you do not snag the oil seal.
18/ Using your thumbs seat the dust seals in to the lower leg.
19/ Re-fit RC3 cartridge unit (80).
20/ Re-fit both foot nuts and torque to 10NM.
21/ Re-fill with SAE 7.5w synthetic motorcycle fork oil. For oil volumes please refer to the oil volume table is these differ on model years/ Damper design.
22/ Cycle RC3 damper (80) several times to ensure the cartridge fills completely.
23/ Re-fit the main spring (51) and spring guide (53).
24/ Re-fit both top plugs and torque to 10NM.
25/ Re fit adjusters.

Service: Shiver SC 2002-2005

The Shiver SC service is fairly straight forward , however there are some major relating to the bushing over a standard service, we have detailed the procedure here.

Parts needed
Y850690, 30mm seal kit
Y5249, SAE 7.5w oil

Tools Required
R5089AB, seal removal tool
R5107AC, seal insert tool

General Tools
1.5, 2mm allen wrench
15, 21mm socket
8, 10mm spanner
Flat bladed screwdriver
Electrical tape
Torque wrench

Service Instructions

1/ Remove ETA lever & Pre-load adjusters
2/ Remove cir-clip
3/ Using a 21mm socket remove both top plugs
4/ Remove internal pre-load adjusters, washers & springs
5/ Drain the fork of oil.
6/ Using a 15mm socket remove both foot nuts
7/ Remove damper assembles
8/ Carefully prise both dust seals up and slide along the stanchions
9/ Remove oil seal retaining cir-clip
10/ Place the steerer tube in a vice and sharply pull each stanchion away from the
upper assembly
11/ Remove stanchion bush and slide off seals, washers & the static bush
step 9                                                         step 10                                                    step 11
12/ Place electrical tape over the bush seat and apply oil to the tape
13/ Slide dust seal on, oil seal, washer & static bush
14/ Remove tape and refit stanchion bush

step 12                                                      step 13                                                     step 14

15/ Slide stanchion back in to upper assembly
16/ Using Shiver SC seal tool seat oil seal and refit cir-clip
17/ Re-fit dust seal
18/ Refit damper cartridges and torque foot nuts to 11 Nmm
19/ Re-fill with SAE 7.5w oil, 35mm from the top of the slider when fully compressed
20/ Re-fit springs, internal pre-load assembly
21/ Re-fir top plugs, cir-clips, pre-load adjusters and ETA lever

Pre-load Stock spring HARD, options; soft 5141162, medium 5141163, x-hard 5141191
for x-hard use SAE 10w
Rebound 1-3 turns out from fully in, depending on pre-load