Wednesday, 23 July 2014

SERVICE: Marzocchi XC500, XC600 & XC700

This service procedure will cover the XC500 (24mm stanchions), XC600 (26mm stanchions) and XC700 (26mm stanchions)  models with the in-line damping adjuster.
XC 700
Tools Required: R5008BZ air cap puller

General Tools: Cir-clip pliers, flat bladed screwdriver

Service Instructions
1/ Let all the air out of the fork
2/ Place air cap extractor tool on shreader valve
3/ Tap tool (thus tapping plug) 10mm into the stanchion
4/ Remove cir-clip from inside the stanchion
5/ Pull upper plug unit out of the stanchion
6/ Empty fork of oil
7/ Remove dust seal
8/ Remove Oil seal retaining cir-clip
9/ Replace upper plug
10/ Carefully place the stanchion in a vice (the plug will stop you crushing the stanchion)
11/ Pull lower leg away from the stanchion & the two parts will separate,
12/ The oil seal will come out with the stanchion
13/ Remove upper plug
14/ Clean fork components and check for wear & tear
15/ Place the new oil seal on the stanchion and replace stanchion
16/ Replace cir-clip
17/ Replace dust seal
18/ Re-fill with 20w oil (XC50/51 = 7.5w) 35mm from the top of the stanchion with the
stanchion fully compressed
19/ Replace upper plug & cir-clip
20/ Inflate to 30-45 psi

Conic seal ring replacement on the damper. The damper is retained by a grub screw located under the main XC700 decal on the front of the fork. Once the screw is removed you can push the adjuster up in to the leg and the damper will come out.

first image step 8 - second image step 11 - third image stanchion assembly 

Update: The genuine Marzocchi oil seal in no longer available and we are currently looking at aftermarket seals to match them up. The seal size is ID 26mm x OD 35mm x height 6mm. If anybody finds a seal of this size please let me know! 

Tuesday, 3 June 2014

Making adjustments: Internally adjustable SSV damping

Internally adjustable damping was common throughout the Marzocchi range from 2002-2007 and featured in many models including the Z4, MXC, Z1 Wedge, Z1 Drop Off, Drop Off Triple, EXR and many more.

The adjusting tool can either be a brass 3mm hex key, a white plasitc M8 hex key or the multi-size Marzocchi tool YR5162,

top, 3mm, middle 8mm, bottom Marzoochi tool
The adjustable damper can be located inside one or both legs and by adjusting the rebound phase you can alter (hydraulically) the speed the fork will extend.

To adjust the internal rebound damping you will firstly need to expel the air from both legs and remove both top caps using a 21mm socket.

Using the adjustable tool, place tool into the centre of the stanchion and locate in the adjuster valve at the bottom (this is quite tricky, once located you will be able to push the tool right in to the fork).

To increase the damping (slower) rotate tool anti-clockwise, to decrease damping (faster) rotate tool clockwise.
this is a rod removed from the fork so you can better see the valve