Service guide: Marzocchi DH3 + XCR

 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)

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