GENERAL

• Special air/oil damped XC and Marathon fork: each leg uses

18
pressurized air blown through a special valve on stanchion caps
177
as damping medium.
• RH fork leg is fitted with a hydraulic cartridge and a knob
+0.05 controlling:
Ø 30 0
- extension or return damping adjustment;
M - fork legs extension limit (ECC).
• LH fork leg is fitted with an air-operated cartridge controlling fork

60,5
A leg extension according to air pressure input.
• Stanchions fitted into lower Crown by cryofit technique. Full
R length bushings guarantee superior rigidity.

80
TRAVEL 80
• Sliders and arch are an integral assembly offering evident
A

CORSA
L.MIN=358
Ø 30 advantages in terms of reduced weight and improved rigidity.

T • Parts subjected to friction are cooled and lubricated by a

specially formulated oil.
H L.L.=458 ±2 Steer tube: aluminum steer tube available for 1 1/8” diameter,
O threadless.
Crown: Forged and CNC-machined BAM❊ aluminum alloy.
N 80
15 -0.1
0

+1
Sliders + Arch: full cast magnesium alloy.
Left slider comes with supports for disc brake caliper.
21,4 0
L.MAX=468

Stanchions: anodized aluminum with variable section.

397,5 ±2

S Slider bushing: Full length guide bushings composed of a

copper base and impregnated with an anti-friction coating.

248.5
Seals: Computer designed oil seals guarantee the highest quality
seals available.
(80) Oil: Specially formulated oil which eliminates foaming and viscos-
ity breakdown while providing complete stiction-free performance.
Fork leg oil: type EBH 16 - SAE 7.5.
– right leg 115 cc,
– left leg 30 cc.

100
+0.5
0
9.2 +0.1
0

130 25

❊
BAM: Bomber Aerospace Material.
Special alloy developed from aerospace material.
 GENERAL
• Special air/oil damped XC and Marathon fork: each leg uses
18
pressurized air blown through a special valve on stanchion caps
177
as damping medium.
• RH fork leg is fitted with a hydraulic cartridge and a knob
+0.05 controlling:
Ø 30 0
- extension or return damping adjustment;
M - fork legs extension limit (ECC).

60,5
• LH fork leg is fitted with an air-operated cartridge controlling fork
A leg extension according to air pressure input.
• Stanchions fitted into lower Crown by cryofit technique. Full
R

100
TRAVEL100
length bushings guarantee superior rigidity.
• Sliders and arch are an integral assembly offering evident
A

CORSA
L.MIN=378
Ø 30 advantages in terms of reduced weight and improved rigidity.

T • Parts subjected to friction are cooled and lubricated by a

specially formulated oil.
H L.L.=478 ±2 Steer tube: aluminum steer tube available for 1 1/8” diameter,
O threadless.
Crown: Forged and CNC-machined BAM❊ aluminum alloy.
N 80
15 -0.1
0

+1
Sliders + Arch: full cast magnesium alloy.
Left slider comes with supports for disc brake caliper.
21,4 0
L.MAX=488

Stanchions: anodized aluminum with variable section.

397,5 ±2

S Slider bushing: Full length guide bushings composed of a

copper base and impregnated with an anti-friction coating.

248.5
Seals: Computer designed oil seals guarantee the highest quality
seals available.
(100) Oil: Specially formulated oil which eliminates foaming and viscos-
ity breakdown while providing complete stiction-free performance.
Fork leg oil: type EBH 16 - SAE 7.5.
– right leg 115 cc,
– left leg 30 cc.

100
+0.5
0
9.2 +0.1
0

130 25

❊
BAM: Bomber Aerospace Material.
Special alloy developed from aerospace material.
 GENERAL
• Special air/oil damped XC and Marathon fork: each leg uses
18
pressurized air blown through a special valve on stanchion caps
175
as damping medium.
• RH fork leg is fitted with a hydraulic cartridge and a knob
+0.05 controlling:
Ø 30 0
- extension or return damping adjustment;
M - fork legs extension limit (ECC).
• LH fork leg is fitted with an air-operated cartridge controlling fork

60,5
A leg extension according to air pressure input.
• Stanchions fitted into lower Crown by cryofit technique. Full
R length bushings guarantee superior rigidity.

75
TRAVEL 75
• Sliders and arch are an integral assembly offering evident
A

CORSA
L.MIN=405
Ø 30 advantages in terms of reduced weight and improved rigidity.

T • Parts subjected to friction are cooled and lubricated by a

specially formulated oil.
H L.L.=485 ±2 Steer tube: aluminum steer tube available for 1 1/8” diameter,
O threadless.
Crown: Forged and CNC-machined BAM❊ aluminum alloy.
N 0
15 -0.1
Arch: Cast magnesium alloy.
Stanchions: anodized aluminum with variable section.
80
L.MAX=495

+1
20 0
Sliders: Forged and CNC-machined BAM❊ aluminum alloy. Left
29"
427,5 ±2

slider comes with supports for disc brake caliper.

Slider bushing: Full length guide bushings composed of a

287.4
copper base and impregnated with an anti-friction coating.
Seals: Computer designed oil seals guarantee the highest quality
seals available.
Oil: Specially formulated oil which eliminates foaming and viscos-
ity breakdown while providing complete stiction-free performance.
Fork leg oil: type EBH 16 - SAE 7.5.
– right leg 115 cc,
– left leg 30 cc.

100
+2 9.2 +0.1
0

130 25

❊
BAM: Bomber Aerospace Material.
Special alloy developed from aerospace material.
 INSTRUCTIONS

GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the MARZOCCHI special tools only.
M 2. On reassembling the suspension system,
always use new seals.
A 3. Clean all metal parts with a special,
preferably biodegradable solvent, such
R as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
A in contact with each other using silicone
fat spray or a specific oil for seals.
T 5. Always grease the lip seal rings before
reassembling.
H 6. Use wrenches with metric size only.
O Wrenches with inch size might damage
the fastening devices even when their
N size is similar to that of the wrenches in
metric size.
 FAILURES, CAUSES AND REMEDIES
This paragraph reports some failures that may occur when using the fork. It also indicates possible causes and suggests a remedy. Always
refer to this table before doing any repair work.

FAILURES CAUSES REMEDIES

M
A Oil leaking through the top of the slider 1. Oil seal is worn out
2. Stanchion tube is scored
1. Replace oil seal
2. Replace crown/stanchions assembly, oil
R 3. Excessive dirt on slider oil seal seals and dust seals
3. Clean the oil seal seat and replace oil
A seal and dust seal

T Oil leaking through the bottom of slider O-ring seal on the cartridge nut is damaged Replace the O-ring
H
O Fork has not been used for some time
and is locked out
Oil seals and dust seals tend to stick to
stanchions
Raise dust seal and lubricate stanchion
tube, dust seal and oil seal
N
Pressure drop Cap valve damaged Replace cap and/or valve

Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings

Fork rebounds too fast in any adjuster 1.Dirt inside fork legs 1.Clean carefully and change oil
position 2. RH stanchion cartridge is damaged 2. Replace RH stanchion cartridge
3. LH stanchion cartridge is faulty 3. Check LH stanchion cartridge

Adjuster position does not affect fork 1.Dirt inside legs 1.Clean carefully and change oil
operation 2. Check cartridges operation 2. Replace and/or overhaul cartridges
 RECOMMENDATIONS FOR INSTALLATION
MAINTENANCE Installing the fork on a bicycle is a very DISC BRAKE SYSTEM ASSEMBLY
MARZOCCHI forks are based on advanced delicate operation that should be carried WARNING: if a disc brake system
technology, supported by year-long experi- out with extreme care. The installation should is installed on Marathon 29" forks
ence in the field of professional mountain always be checked by one of our Technical featuring sliders glued to the arch, it is
biking. In order to achieve best results, we Service Centers. absolutely forbidden to remove the original
recommend to check and clean the area bolts (ref. B). In case of a Marathon S fork
M below the dust seal and the stanchion tube
after each use and lubricate with silicone
WARNING: steer tube/headset
mounting and adjustment must be
it is allowed since arch-slider monolith is
molded.
A oil. carried out in compliance with the headset
manufacturer’s instructions. Improper in-
In general, MARZOCCHI forks can offer top For Marathon 29”, apart from retaining
R performance from the start. However, in stallation may jeopardize the safety of the cantilever or linear pull brakes, they also
rider.
A some cases a short running-in period is
required (5-10 hours) for inner adjustments. To replace it, contact one of our Technical
secure the sliders legs to the slider monolith.
If needed, the brake boss bolts can be
T This running-in period will make fork life
longer and ensure fork top performance
Service Centers with the required tools. replaced with buttonhead bolts (ref. A,
part #532979QF).
H over time. WARNING: in case of improper
installation of the steer tube into the
Tighten the above-mentioned bolts to 10
Nm.
O IMPORTANT: change oil at least every
100 working hours and check pressure at
crown, the rider might lose control of his/
her bicycle, thus jeopardizing his/her safety. IMPORTANT: the bolt threads (ref. A)
N least every 10 working hours. are treated to ensure a hydraulic seal.
Never reuse the bolts once they have been
Polished forks should be cleaned with removed.
bodywork polish at regular intervals in
order to preserve their original finish. Assembling the brake caliper onto the slider
is a very delicate operation that should be
carried out with extreme care.
Improper assembly might overstress the
caliper supports which might break.
When installing the disc brake system, be
sure to properly follow the instructions given
by the manufacturer.
 ADJUSTMENTS
FORK LEG PRESSURIZATION IMPORTANT: inflate using the special REBOUND ADJUSTMENT
Pump air through the valves to set COM- MARZOCCHI pump with the proper pressure (r.h. fork leg)
PRESSION damping, as indicated in the gauge. Use of improper tools or other The right fork leg is equipped with an
figure. To change the pressure inside the procedures than specified ones might lead Extension Control Cartridge adjuster knob
fork legs, remove the protection cap (32) to improper inflating. (28) for REBOUND damping up to max.
(LH fork leg), remove plug (21), turn knob rebound damping - “Lock Out”. Turning this
M (28) until you can see the valve under it (RH
fork leg). Depressurize each leg by pushing
NOTE: in case of air leakages when adapter
fitting (D) is fitted, ensure that the O-ring
adjuster into the cartridge rod, changes the
hydraulic setting of the inner valves.
A lightly on valve pin. Fully tighten adapter
fitting (D) supplied with the fork, on a
(D1) is not damaged.
You can have three adjustments:
R MARZOCCHI pump (C). Screw fitting end – Pos. 1: “Lock Out”
with O-ring (D1) on valve, and pressurize Turn the knob completely counter-clockwise
A until the required value is reached. Un- to obtain full ECC lockdown (maximum

T screw the fitting/pump assembly and refit

the cap (32).
rebound damping) for steep climbs and
road riding.
H Pos. 2: “Intermediate rebound
damping”
O Turn the knob clockwise until hearing the
first click. This mediuam position offers slow
N rebound damping for fast starts and rough
climbs.

C C
C C 21 28
D 32 D
D1
D1

D 2
D

28
1 3
 Pos. 3: “Minimum rebound REBOUND ADJUSTMENT
damping” (l.h. fork leg) IMPORTANT: inflate using the special
Turn the knob completely clockwise until Pump air into the valve, as indicated, to set MARZOCCHI pump with the proper
hearing the last click. In this position the fork REBOUND damping. To change the pres- pressure gauge. Use of improper tools or
will have fast rebound damping for sure inside the fork legs, remove the protec- other procedures than specified ones
downhilling. tion cap (32) (LH fork leg) and depressur- might lead to improper inflating.
ize the leg by pushing lightly on valve pin.
Fully tighten adapter fitting (D), supplied NOTE: in case of air leakage when adapter
M IMPORTANT: do not force the adjuster
knob (28) past its limit.
with the fork, on MARZOCCHI pump (C). fitting (D) is installed, be sure that the O-
A Screw fitting end –with O-ring (D1) on
valve, and pressurize until the required
ring (D1) is not damaged.

R value is reached. The higher the pressure in

the LH cartridge, the more sensitive the fork
A will be and vice versa.
Unscrew the fitting/pump assembly and
T refit the cap (32).

H
O
N

28 C C
32 D
D1

2 D

1 3
 DISASSEMBLY
GENERAL
– The reference numbers given in this section relate to the components shown in the fork exploded view.
– Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence.
Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to remove first.

M DISASSEMBLY DIAGRAM

A STANCHION TUBE CAP FIG. 1/2/3/4 ▲ ▲

R HYDRAULIC CARTRIDGE CHANGE AIR-OPERATED CARTRIDGE
A
▲ CHANGE (left leg)
(right leg)
FORK OIL CHANGE ▲
T
▲
FOOT NUT FIG. 6
H ▲ ▲

O HYDRAULIC CARTRIDGE FIG. 7 AIR-OPERATED CARTRIDGE FIG. 8

N
▲ ▲
PILOT BUSHING AND SEAL ASSEMBLY CHANGE
▲

▲ CARWON AND STANCHIONS ASSEMBLY FIG. 9 ▲

▲
AIR VALVE CHANGE AIR-OPERATED CARTRIDGE
DUST SEAL FIG. 10 OVERHAUL FIG 16/17/18
FIG. 15 ▲
STOP RING FIG. 11
▲
OIL SEAL FIG. 12
▲
UPPER WASHER FIG. 13
▲
PILOT BUSHING FIG. 14
 REMOVING UPPER CAP FIG. 2 (only right leg) FIG. 3
FIG. 1 Remove the RH cartridge circlip (27) with Unscrew the caps (30) and (33) complete
(r.h. fork leg) a small screwdriver. with O-ring (24) with a 21-mm socket
Undo screw (29) with an Allen wrench and Remove and keep the pin (26) and counter wrench.
remove knob (28). spring (25). Remove the cap (30) from the right stan-
(l.h. fork leg) chion and from the hydraulic cartridge rod
Completely undo knob (32). WARNING: never use the fork with- (5).
Depressurize each fork leg (see section out this component otherwise the
M ADJUSTMENT). hydraulic cartridge fitted to the slider bot-
A tom might slide out from the top cap and
release the arch-slider monolith.
R
A
T
H
O
N

26
29 28 32 25 30
27 24 33
24
 FIG. 4 (only left leg) FIG. 5 REMOVING CARTRIDGES
Lock the rod (16) and remove the cap (33) Push the stanchions (23) into the sliders (3) FIG. 6
from hydraulic cartridge end (22). and let all the oil drain out from the fork legs. Turn the fork leg upside-down and unscrew
If this operation proves difficult, vice the rod Pump the stanchions several times to help the foot nuts (2) by the use of a 15 mm
with jaws (E) (see Fig. 28). oil drain off. socket wrench complete with O-Rings (1).

WARNING: dispose of exhausted

oil in compliance with current laws.
M
A To change the fork leg oil follow the proce-
dure as described in section “REASSEMBLY”
R from Fig. 29 to Fig. 33.

A
T
H
O
N

2
33
23 3
16 1
 FIG. 7 (only right leg) FIG. 8 (only left leg) FIG. 9
Pull the hydraulic cartridge (5) out of the Pull the air-operated cartridge (22) out of Withdraw the crown and stanchions as-
R.H. stanchion tube. the L.H. stanchion tube. sembly (23) from the sliders (3).
Replace the whole hydraulic cartridge. Replace the whole cartridge or overhaul as
described in next paragraph.

M
A
R
A
T
H
O
N

23

22
3
 REMOVING GUIDE BUSHING FIG. 11 FIG. 12
AND SEAL ASSEMBLY Remove the stop ring (9) from the sliders by Fit the slider protector (A) onto the slider
FIG. 10 placing the screwdriver bit in one of the and remove the oil seal (8) with the help of
Remove the dust seal (10) from the top of three openings on the stop ring. a large screwdriver.
the sliders using a small screwdriver.
IMPORTANT: when removing the stop
ring, make sure not to damage slider inner IMPORTANT: when removing the oil seal,
seat. make sure not to damage slider inner seat.
M Once removed the oil seals should not be
used again.
A
R
A
T
H
O
N

10
9
8

A
 FIG. 13 FIG. 14 REPLACING AIR VALVE
Remove the upper washer (7) from the Fit the bit of a small screwdriver into upper FIG. 15
slider. edge slot of the pilot bushing (6) and lift This operation can be performed when fork
gently. Pull the bushing out of the slider and is fully assembled and fitted on bike, but
make all necessary changes. only after draining inner pressure.
If the air valve is disassembled with the fork
removed, keep the fork vertical so as to
M avoid any oil leakage.
Remove protection cap (21) (only RH fork
A leg) and remove air valve (39) and O-ring
(40) from the cap, with a standard valve
R wrench.
Check O-Ring and blow compressed air
A onto valve to eliminate possible clogging.

T Immediately replace the valve if it is dam-

aged.
H When reassembling, slightly lubricate the
O-ring (40) and screw the air valve (39)
O until it stops without forcing. Then, refit the
cap (21).
N

Sx. Dx.
39
40
39

40 21
6

7
 AIR-OPERATED CARTRIDGE FIG. 17
OVERHAUL With a small screwdriver, remove the seal
FIG. 16 (19) and the O-rings (18) from the rod
Hold cartridge (22) and undo the ring nut body (16). Lubricate the O-rings before
(14) and the O-ring (15) with a hex. reassembly.
wrench. Remove ring nut assembly (14)
and rod (16), then remove rod (16) from
ring nut (14).
M
A
R
A
T
H
O
N

16
14
16

15
18
22 19
 REASSEMBLY
CAUTION: before reassembling, all metal PILOT BUSHING AND SEAL FIG. 20
components should be washed carefully ASSEMBLY Fit the upper washer (7) into the slider so
with inflammable, preferably biodegrad- FIG. 19 that it touches the pilot bushing.
able, solvent and dried with compressed Check that no dirt or debris is between
air. slider and bushing. Insert the pilot bushing
(6) into place so that it adheres to the slider.
M RE-ASSEMBLING AIR-OPERATED
CARTRIDGE
A FIG. 18
Insert the rod (16) and ring nut assembly
R (14) in the cartridge body (22) and tighten
A the ring nut to the specified torque. During
this operation, be careful not to damage the
T O-rings (15) and (18).

H
O
N

7
16 10 Nm
14 6

22
 FIG. 21 FIG. 22 FIG. 23
Lubricate the oil seal (8) and place it onto Insert the stop ring (9) into the slider making Lubricate the dust seals (10) and fit them
the seal press (B) with the hollow side sure it is properly seated into place. into the stanchions from the spring end.
toward the slider. Use buffer (B) to properly seat the ring into
Press the oil seal until it touches the lower the slider.
washer by using the above seal press.

M
A
R
A
T
H
O
N

9 10

B
8
 CROWN AND STANCHIONS REASSEMBLING CARTRIDGES FIG. 26
ASSEMBLY FIG. 25 Lubricate O-Rings (1) on the foot nuts (2)
FIG. 24 Push the stanchions up to slider bottom and and screw them onto the cartridge (5) and
Fit the crown and stanchions assembly (23) slightly grease O-ring (4), then fit it on (22) threaded ends.
- with the dust seals in place - gently into the cartridge rod (5). Tighten to the specified torque.
sliders seals. Fit the hydraulic cartridge (5) into the R.H. Pump the stanchions up and down several
stanchion and push until it reaches the times to check proper assembly.
WARNING: to avoid any damages bottom.
M to sealing surfaces, keep the stan- Fit the air-operated cartridge (22) into the
A chions duly lubricated and squared into the
sliders.
L.H. stanchion and push to the bottom.

R Check to see that the stanchions slide unre-

A stricted by cycling the fork up and down
several times.
T The tube should slide freely inside the seal
assembly without any side play. In the event
H it is too hard or too soft, repeat the previous
steps described above and check compo-
O nents to ensure they are not damaged.
N Seat the dust seals (10) on top of the
sliders.

Dx. Sx.
4 11 Nm

23

5
22
2
10 10

1
 HOW TO FILL WITH OIL REASSEMBLING UPPER CAP FIG. 29
FIG. 27 FIG. 28 (l.h. cartridge only) Lubricate the O-rings (24) on the caps and
Pour in the oil little by little when the Using pliers, (F) clamp the air-operated lift the stanchions caps (30) and (33) by
stanchions are fully down and then stroke cartridge rod (16). Grease O-ring (31) hand.
the crown up and down to cycle the oil and and fully tighten the cap (33) on the rod Tighten both caps to the recommended
to remove any trapped air. end. torque.
Check that the oil quantity (Q) inside the Inflate as described in ADJUSTMENT sec-
fork legs corresponds to the value indicated tion.
M in the table.
A
R
A
T
H
O
N

20 Nm

Q(cc) 16
30
24 33
Fork Travel Leg Q
model (mm) (cc)
33 24
Sx. 30
Marathon 80 Dx. 115 31
S
100
Sx. 30 E
Dx. 115
Marathon Sx. 30
29" 80 Dx. 115
 FIG. 30 FIG. 31
Fit circlip (27) of the adjustment knob (r.h. fork leg)
support and check for the proper position in Fit knob (28) and fully tighten the bolt (29)
the seat. Fit also spring (25) and pin (26). to the recommended torque.
(l.h. fork leg)
WARNING: never use the fork with- Screw knob (32) fully home.
out this component otherwise the
hydraulic cartridge fitted to the slider bot-
M tom might slide out from the top cap and
A release the arch-slider monolith.

R
A
T
H
O
N

3 Nm

26
25 29 28 32
27
 SPECIFIC MARZOCCHI TOOLS
Ref. Item. Description and use
A R 5099 AC Slider protector: to remove the oil seal from the slider
B R 5098 AC Oil seal press: to press oil seal into the slider
C R 4008/C Inflating pump
D 5321038 Adapter fitting
M E R 5106 Tool for tightening cap on air-operated cartridge rod
A
R
A
T A
H
O B
E
N D
C