Travel change for the 350 NCR (CR) series.

Travel change for the 350 NCR (CR) series.

We categorize procedure as advanced, only undertake this if you are a competent mechanic with access to the correct tools and working environment. If you are in any doubt please ask a professional to perform this process for you.

1/ Remove air-valve dust cap and let the air out of the fork.
2/ Using a 27mm socket, un-screw the air plug and then completely remove the plug and air tube from the station.
3/ Using a 1.5mm hex key, remove the rebound adjuster
4/ Using a 5mm hex key, remove the RH foot nut
5/ Using a 12mm socket, remove the LH foot nut
6/ Separate the upper assembly from the lowers
7/ Remove the dust seal external springs and remove the dust seals. NOTE: Removing the dust seals makes refitting the upper assembly easier.
8/ Once the dust seals have been remove re-fit the external springs (removing the springs prevents damage to the seal).
9/ Using cir-clip pliers remove the cir-clip from the base of the air leg and remove rod assembly.
10/ Remove the disc from the base of the leg, this is a tight fit and may require tapping off with a small hammer.
11/ Remove negative spring.
12/ Install travel spacer and push until you hear an audible click.
13/ Re-install the negative spring and push until you hear an audible click.
14/ Re-install the disc to the bottom of the rod, again this may need tapping down with a small hammer.
15/ Re-install the rod in to the base of the stanchion and re-install the cir-clip. NOTE: Check the cir-clip seating and make sure it’s fully in its groove.
16/ Install the dust seals on to the stanchion and re-fit the upper assembly. BE CAREFUL! Make sure the stanchions do not tear the oil seals as the stanchions pass through them.
17/ Re-fit both foot nuts and torque to 10NM + or – 1NM.
18/ Re-fit the rebound adjuster and secure using the 1.5mm hex key.
19/ Press the dust seals back in to the lower legs.
20/ Invert the air tube and place 25ml of 7.5w oil inside.
21/ Invert the fork and re-install the air tube. NOTE: You will need to tap the air tube in with your hand to get it past the piston head on the rod assembly, as the tube goes in the pressure inside it will increase so make sure you expel the air to make installing easier.
22/ Using the 27mm socket re-fit the air plug and torque to 20NM + or – 1NM
23/ Re-inflate to your desired pressure
24/ Check travel.

Part numbers for travel change spacers:

536181 = 20mm spacer
536216 = 10mm spacer

CR model: the procedure is pretty much the same except that the air tube in the CR is not removable.

350R internal for reference only

2005 66 travel change

Tools
15mm socket
10 & 26mm spanner
Torque wrench

1/ First off all make sure the adjusters are in the middle setting
2/ Unscrew the top cap using a 26mm spanner
3/ Compress the stanchion to expose the top cap assembly
4/ Holding the locknut (51) with a 10mm spanner, undo the top plug & remove
5/ Remove part 52 and remove the spring
6/ Using a 15mm socket, undo both foot nuts
7/ Remove both damper units & drain oil
8a/ if extending to 170mm; remove spacer 61 from damper shaft
8b/ turn part 52 upside down (o-ring on top) and place 61 over the o- ring seat
8c/ if reducing to 150mm; remove part 61 from part 52
8d/ turn part 52 upside down (o-ring underneath)
9/ place the part 61 over the damper shaft
10/ Re-fit damper units
11/ TORQUE foot nuts to 12Nmm
12/ Re-fill using SAE 7.5w oil with 210cc per leg
13/ Re-fit springs
14/ re-fit part 52 and lock nut 51
15/ Tighten lock nut and then top plug on to the damper shaft
16/ Tighten top plug in to the stanchion

Travel Adjust - Marzocchi forks 2010 +

In 2010 Marzocchi completely dropped the ATA travel adjust and reverted to a travel limiting spacer.

Models covered are 44 Micro Ti, 44 TST2, 44RLO, 44LR, Corsa LR, Marathon LR, Marathon R, 55CR, 55R.

The travel spacer is available as a spare part, Y536181, ssp £6.95 each

For new 2012/13 LR, CR and R models and additional bleed of the Dynamic bleed cartridge may be necessary, for this you need to watch this video:

 

Travel reduction: Z4/ MXC series

Another guide for UK mag MBR, this time we looked at the travel reduction of a simple damping rod model the MXC Air. This time we used an inverted technique where we could retain the volume of oil inside the stanchion.