Always wear a properly fitted and fastened bicycle helmet, that has been approved by ANSI , SNELL or CE, and any other safety equipment necessary for your riding style. When riding in wet conditions, remember that the stopping power of your brakes is greatly reduced and that the adherence of the tires on the ground is considerably reduced. This makes it harder to control and stop your bicycle. Extra care is required when riding your bicycle in wet conditions to avoid an accident. Avoid biking at night because it is more difficult for you to be seen by traffic, and it is more difficult for you to see obstructions on the ground. If you do ride at night, you should equip your bicycle with and use a headlight and a taillight. Wear clothes that are snug-fitting and that make you visible to traffic, such as neon, fluorescent, or other bright colors. B. BEFORE EVERY RIDE DO NOT RIDE YOUR BICYCLE IF IT DOES NOT PASS THIS PRE-RIDE TEST. CORRECT ANY CONDITION BEFORE YOU RIDE. Check your forks for any leaks or other evidence of oil, which is indicative of a problem with your forks. Be sure to turn your bicycle upside down to check areas such as the underside of the crown for evidence of an oil leak. Be sure that all components of you forks, and the remainder of your bicycle, including, but not limited to, your brakes, pedals, handgrips, handlebars, frame, and seating system, are in optimum condition and suitable for use. Be sure that none of the components of your suspension system, or the remainder of your bicycle, are bent, deformed, cracked, chipped, out of aliment, or otherwise damaged. Check to be sure that all quick release fasteners, nuts and bolts are properly adjusted. Bounce the bicycle on the ground while listening and looking for anything that may be lose.
Be sure that your wheels are perfectly centered. Spin the wheels to be sure that they do not wobble up and down or from side to side, and that they do not make contact with the fork legs or brake pads while rotating. Be sure that all cables and other components of your braking system are in their proper position, properly adjusted and that your braking system is functioning properly. Be sure that your tires are inflated to the correct pressure and that there is no damage whatsoever in the tread or sidewall of the tire. Check all reflectors to make sure that they are clean, straight, and securely mounted. Be sure to read and follow all the instructions and warnings that originally accompanied your bicycle. Learn and follow the local bicycle laws and regulations, and obey all traffic signals, signs and laws while you ride.
II. INTENDED USE INSTRUCTIONS
A. SELECT THE CORRECT FORK FOR YOUR RIDING STYLE Marzocchi suspension forks are among the most durable and technologically advanced forks on the market today. However, no fork can withstand misuse, abuse or improper use that, over a short period of time, can cause your forks to fail when you least expect it. It is critical that you select and use the fork that is appropriate for your riding style, and that you use the fork properly. WARNING! Failure to properly match the forks to your frame could cause the forks to fail, resulting in a loss of control of the bicycle, and possible serious injury or death to the rider. In addition, improperly matching your forks to your frame will void the forks warranty.

1. Identify Your Riding Style: Cross Country (XC)/Marathon: Riding along hilly trails where some bumps and smaller obstacles, such as rocks, roots, or depressions, may be encountered. XC riding does not include jumps or drops (riding off rocks, fallen trees or ledges) from any height. XC forks must be used with tires specifically designed for cross country riding, and disk, rim or linear pull brakes. All Mountain (AM): Riding with more emphasis on aggressive XC riding over and around larger obstacles. This riding style does not include jumps. These forks should only be used with disk brakes, and those frames, wheels and other components specifically designed for this riding style. The disk brakes must be attached to the designated mounting points provided on the fork. Never make any modification to your fork when attaching any equipment. Trekking: Trekking is similar to XC riding, but less aggressive. It involves riding at a slower pace and not riding over obstacles such as rocks, roots, and depressions. You should only attach generators and racks to the designated mounting points provided on the forks. Never make any modification to your fork when attaching any equipment. FreeRide (FR): This riding style is for skilled riders, and involves steep, aggressive slopes, large obstacles, and moderate jumps. Freeride forks should be used only with disk brakes, and those frames, wheels and other components specifically designed for this riding style. The disk brakes must be attached to the designated mounting points provided on the fork. Never make any modification to your fork when attaching any equipment.
Dirt Jumper (DJ) / Urban Riding: This BMX or motocross style of riding is only for the most skilled riders, and involves jumping from one mound of dirt to another. It also includes riding over and around urban obstacles such as man-made, or other concrete, structures. These forks should only be used with disk brakes, and those frames, wheels and other components specifically designed for this riding style. The disk brakes must be attached to the designated mounting points provided on the fork. Never make any modification to your fork when attaching any equipment. Downhill (DH) / Extreme Freeride: This discipline is only for professional or highly skilled riders. It includes relatively high jumps or drops and negotiating larger obstacles such as boulders, fallen trees, or holes. These forks should be used only with disk brakes, and those frames, wheels and other components specifically designed for this riding style. The disk brakes must be attached to the designated mounting points provided on the fork. Never make any modification to your fork when attaching other equipment.

WARNING! Ride ONLY in areas specifically designated for your riding style. 2. Select the Correct Fork for Your Riding
Style from the Table below.
Using the table below, select the fork that matches your riding style. Please see your Marzocchi retailer, or contact Marzocchi directly, if you require assistance in selecting the correct fork.

Tab 1: 14

2006 Fork Riding Categories and Intended USE All Mountain All Mountain SL All Mountain 1 All Mountain 2 All Mountain 3 AM 1 / TW AM 2 / TW AM 3 / TW AM 4 / TW Urban Riding Dirt Jumping Dirt Jumper 1 Dirt Jumper 2 Dirt Jumper 3 Dirt Jam Pro Dirt Jam Comp Extreme Freeriding Freeriding Downhill Z1 SL Doppio Air Z.1 Light Z.1 Sport Drop-Off I Drop-Off II Drop-Off IV 66 SL 66 RC2X 66 Light 66 VF 66 VF2 Downhill Junior T 888 RC2X 888 RCVFVF Monster Drop-Off Triple Super T
Trekking XC / Marathon TXC TXC ECC Marathon RACE Marathon SL Doppio Air Marathon XC MX 85 MX Pro SL MX Pro MX Comp MZ I MZ II MZ III Gran Fondo RC Gran Fondo 1 Gran Fondo 2 Gran Fondo 3
Drop-Off III 888 RC2X 888 RCVFVF

WARNING

USE ONLY FOR:
CROSS COUNTRY ALL MOUNTAIN DO NOT USE FOR:
FREERIDE DIRT JUMPER FREERIDE EXTREME DOWNHILL
Improper use of this fork can result in fork failure and personal injury FOR MORE DETAILS SEE OWNERS MANUAL OR WWW.MARZOCCHI.COM
CROSS COUNTRY ALL MOUNTAIN FREERIDE DIRT JUMPER DO NOT USE FOR:
FREERIDE EXTREME DOWNHILL
3. Ride Properly Do Not Misuse or Abuse of Your Forks Never abuse or misuse your forks. Learn how to ride, and always ride within your abilities. An out-of-control ride puts the equivalent of years of hard use on your forks after only a few rides. Learn how to properly flow around obstacles on the trail. Hitting obstacles such as rocks, trees or holes straight-on puts forces on your fork it was not designed to absorb. Landing improperly after a jump or drop also puts forces on your fork it was not designed to absorb. You should only perform jumps or drops when a transition, or down ramp, is available to help your bicycle absorb the impact forces generated during the landing by having both wheels smoothly make contact with the transition, or down ramp, at the same time. Any other type of landing is dangerous, as it could result in a component part failure and an accident. The steepness and length of the transition, or down ramp depends on the height from which you jump or drop. Every situation is different for every rider, so consult with an experienced rider before attempting any jump or drop.

WARNING! Failure to properly flow around obstacles on the trail, or failure to properly land after a jump or drop, could cause your forks to fail, resulting in a loss of bicycle control, serious injury, or death to the rider. WARNING! Your forks require regular maintenance and repair. The harder you ride, the more often you must inspect and perform maintenance on your forks. If your forks are leaking, bent, deformed, cracked, or chipped, no matter how slight, immediately have a Certified Marzocchi Repair Center inspect the forks before you ride again. REMEMBER Even forks made out of solid metal will fail if they are misused, abused, or improperly used! Extreme use can eventually wear out and break even the strongest components.
Ride fast, yet ride Smart
Use and maintenance instruction manual

English

Introduction. 114 Conventions.. 114 Orientation of the fork.. 114

7.1 7.2

Summarizing tables.131 Warranty..151 Warranty for eu countries..151 Warranty rest of the world Usa included.152
1.1.2.1 2.2 2.3 2.3.1 3.2 3.3 3.4
Technical information.. 115 Spring System. 115 Damping system.. 116 Lubrication and Cooling.. 117 Sliding Bushing and Oil Seals. 117 Installation.. 118 Installing on the frame. 118 Installing the brake system. 119 Wheel Installation. 120 Wheel axle securing system.. 120 Wheel installation on A standard fork.. 120 Wheel installation on 32 mm forks with a 20 mm Trough-Hole Axle. 121

3.4.1 3.4.2

3.5 3.6
Fender Installation.. 122 Handlebar Clamp Installation. 122 Handlebar Clamp Installing On All Dual Crown Models (Super T Drop Off Triple). 122
4 4.1 4.2 4.3 4.5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8
Maintenance.. 123 Problems - Diagnosis - Solutions. 123 Periodic Maintenance.. 124 General Maintenance Recommendations. 125 Cleaning The Fork Legs. 125 Adjustments.. 126 Adjustment kit and springs. 126 Spring preload. 126 Positive Air. 126 SAG.. 127 Rebound Adjustment. 128 Compression Adjustment. 128 ECC (Extension Control Cartridge) 128 LOCK-UP.. 129 ETA (Extension Travel Adjustment) 129

Introduction 1

INTRODUCTION
1.1 Conventions 1.1.1 Orientation of the fork

M TO OT B

Picture 1 - Conventional orientation of the fork

B A C K LE FT

Technical information 2

TECHNICAL INFORMATION

2.1 Spring System
Inside MARZOCCHI forks you will find coil springs, or air, used as suspension mechanism.

Table 1 - Spring systems

Fork TXC 1 TXC 1 (+ Coil) TXC 2 TXC 2 (+ Coil) TXC ECC TXC ECC (+ Coil) MZ I MZ II MZ III Gran Fondo RC Gran Fondo 1 Gran Fondo 2 Gran Fondo 3 Gran Fondo 3 (+ Coil) AM 1 / TW AM 2 / TW AM 2 / TW (+ LOCKUP) AM 3 / TW AM 4 / TW Drop-Off I Drop-Off II Drop-Off III Drop-Off IV Super T Drop-Off Triple Dirt Jam Pro Dirt Jam Comp
Spring systems Right fork leg Air Spiral spring Air Spiral spring Air Spiral spring Spiral spring + MCU elastomer Spiral spring + MCU elastomer Spiral spring + MCU elastomer Spiral spring Spiral spring Spiral spring Air Spiral spring Air Air Air Air Air Spiral Spring Spiral Spring Spiral Spring Spiral Spring Spiral Spring Spiral Spring Air Spiral Spring + MCU elastomer Left fork leg Air Spiral spring + MCU elastomer Spiral spring + MCU elastomer Air Air / Spiral spring + MCU elastomer Spiral spring + MCU elastomer / / Air Air Air Spiral spring Air / Air Air Spiral Spring Spiral Spring Air Air Spiral Spring Air Spiral Spring Spiral Spring + MCU elastomer English Spiral spring

Technical information

2.2 Damping system
The damping load that is generated during compression and rebound of the fork legs can be adjusted by hydraulic valve pumping rods, or by special cartridges.

Table 2 - Damping System

Fork TXC 1 TXC 2 TXC ECC MZ I MZ II MZ III Gran Fondo RC Gran Fondo 1 Gran Fondo 2 Gran Fondo 3 AM 1 / TW AM 2 / TW AM 2 / TW (+ LOCK-UP) AM 3 / TW AM 4 / TW Drop-Off I Drop-Off II Drop-Off III Drop-Off IV Super T Drop-Off Triple Dirt Jam Pro Dirt Jam Comp
Damping systems Right fork leg SSV pumping rod with rebound setting by internal adjuster SSV pumping rod with rebound setting by internal adjuster SSV pumping rod with rebound setting by internal adjuster MCU elastomer MCU elastomer MCU elastomer VF2 pumping rod with rebound setting by external adjuster VF2 pumping rod with rebound setting by external adjuster SSVF pumping rod with rebound setting by external adjuster SSV pumping rod with rebound setting by internal adjuster VF2 pumping rod with rebound setting by external adjuster
Left fork leg / MCU elastomer ECC cartridge LOCK-UP cartridge MCU elastomer MCU elastomer LOCK-UP cartridge with remote control LOCK-UP cartridge / / ETA cartridge Pumping rod with compression setting by external adjuster LOCK-UP cartridge with remote control / / ETA cartridge Pumping rod with compression setting by external adjuster / / Pumping rod with compression setting by external adjuster /

VF2 pumping rod with rebound setting by external

adjuster

adjuster VF2 pumping rod with rebound setting by internal adjuster VF2 pumping rod with rebound setting by external adjuster
VF2 pumping rod with rebound setting by internal
adjuster VF2 pumping rod with rebound setting by internal adjuster MCU elastomer

/ MCU elastomer

SSV: The SSV system, thanks to the speed sensitive valve, allows for control of the damping system based on the forks compression and rebound speed, as well as the forks position in the travel. SSV pumping rods can have a fixed or adjustable rebound setting by internal or exsternal adjusters. SSVF: The SSVF system is the evolution of the SSV system to further improve the forks sensitivity, thanks to the spring-preloaded valve. SSVF pumping rods can have a fixed or adjustable rebound setting by internal or exsternal adjusters. VF2: The new VF2 system is the evolution of the SSV system to further improve the control of the damping system based on the forks rebound speed, as well as the forks position in the travel. VF2 pumping rods have an adjustable rebound setting by internal or external adjusters. ETA: The ETA system allows for adjustments to be made to the extension travel and forks locking, while still offering 25-30mm of travel. ECC: The ECC cartridge (Extension Control Cartridge) allows for on-the-fly adjustment of the extension damping. The LOCK position blocks the forks legs making it easier to face hard, steep climbs. LOCK-UP: The LOCK-UP cartridge allows for on-the-fly adjustment of the compression damping. The LOCK position holds the forks legs compressed (while still offering 20 mm of travel) making it easier to face hard, steep climbs. On some models, the LOCK-UP system can be activated by a remote control on the handlebar.
2.3 Lubrication and Cooling
Pumping rods are immersed in oil (Open Bath System). This system provides proper lubrication and cooling of the inner sliding parts. Furthermore, the oil volume works as a damping and setting element. The Open Bath system reduces the maintenance frequency compared to a sealed cartridge system. On models of the fork that use elastomers, the proper internal lubricant is 117 grease. English
2.4 Sliding Bushing and Oil Seals
Stanchion tubes are guided in the sliders by two Teflon-coated bushings, free from static friction. The seal system minimizes oil leaks, and contamination from particles entering the fork, by means of a special, dual-lip oil seal and a dust seal at the top of each slider.

Installation 3

INSTALLATION
3.1 Installing on the frame
The fork is supplied with an A-Head Set steer tube to be cut according to the frame size the fork is being installed on. Installing the fork on the bicycle frame is a delicate and critical operation, and should only be performed by skilled, trained personnel. WARNING! Suspension system installation requires specialized knowledge, tools and experience. General mechanical aptitude may not be sufficient to properly install your suspension system. Please have your suspension system installed only by an authorized Marzocchi Suspension Center. Improper installation can result in failure of your Marzocchi Suspension System, an accident, personal injury, or death. The steer tube must be press fit into the crown. Replacement of the steer tube requires the use of specialized tools, so it should only be performed at one of our authorized service centers.

Polished surfaces need to be periodically 125 treated with a polishing compound to be kept as bright as new. Carefully check to see that your work area is free of dust and metal shavings from any component of the forks. Never modify your fork in any way.
4.4 Cleaning The Fork Legs
Marzocchi lubricates the dust seals of its forks with grease to help the stanchion tubes slide easier, particularly when the forks have not been used for a long period of time. Use of the forks can melt the grease, causing it to stick to the stanchions, and give the appearance of an oil leak. Inspect the forks to ensure that this is not the result of an oil leak. After every use, carefully clean the forks outside surfaces, with special attention to stanchion tubes and dust seals. WARNING! If your forks develop an oil leak, do not ride your bike. Correct the leak before you ride again. WARNING! Mud and dust may cause serious damage to the suspension system if not immediately removed.

Adjustments 5

ADJUSTMENTS
NOTE Once you have found the best setting, we suggest taking notes of the adjuster clicks or the number of turns, in respect to the all-closed position (adjuster completely turned clockwise), so that it will be easier to re-establish the original setting after possible changes.
Obtaining the maximum performance from your suspension system depends on using the correct settings and making the proper adjustments. This section describes how to properly set and make adjustments to your Marzocchi forks. In order to find the best settings for you, you will need to try several times to understand where and how to make adjustments. When doing so, please ride in an open area, free from traffic, obstacles and other hazards. The best settings not only depend on the mountain bike frame geometry, the riders weight and the types of trail or obstacles, but also on many other personal factors connected with your riding style. Therefore, it is not possible to provide you with objective information concerning your desired settings. However, if you carefully follow the instruction given below, you may find the best settings for you in a short time. Changing the settings on your forks must be done by acting on only one adjuster at a time, taking note of the modifications you carry out and the improvements you obtain. WARNING! During the setting operations, never force the adjusters past their limits and do not exceed the recommended maximum air pressure. WARNING! To keep the pressure inside the forks legs, only use the special MARZOCCHI pump with pressure gauge, which can be purchased at any authorized Marzocchi center. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.

Rebound adjustment by internal adjuster - Right leg Using a small pin extractor eliminate any pressure from the right leg. Unscrew and remove the protection cap with a 21mm cap key. Insert a 12mm tee-key into the stanchion being very careful to center the notch of the adjuster. By turning the adjuster counter-clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. After adjustment, refit and tighten the protection cap to the recommended tightening torque. Re-inflate to the recommended air pressure value.

2.40 3.1.15

2.90 3.52

Table 20 - AM 1 / TW

AM 1 / TW
32 mm 110 mm - 130 mm - 150 mm Standard
XC INTL STD 6 (The installation of 8" disk is only possible when the specific adapter is supplied by the brake system manufacturer)
No 2.8 x 26 Positive air - Right leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap.
ETA - Left leg By turning the knob clockwise, you activate the ETA cartridge function. By turning the knob counter-clockwise, you reset the suspensions normal function.

2.40 3.45

Table 21 - AM 2 / TW

AM 2 / TW

No 2.8 x 26 Positive air - Both legs (For version with LOCK-UP system only right leg) Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Rebound adjustment by external adjuster- Right leg By turning the adjuster clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. Compression adjustment by external adjuster - Left leg (Not present in the version with LOCK-UP system) By turning the adjuster clockwise, you increase the hydraulic damping during the compression phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping during the compression phase. LOCK-UP with remote control (Remote control located under the handlebar on the right; only for version with LOCK-UP system with remote control; it replaces the positive air and the external compression adjuster on the left leg) By shifting the control lever forwards, you activate the LOCK-UP cartridge function blocking the suspension. By shifting the control lever backwards, you reset the suspensions normal function.

Table 22 - AM 3 / TW

AM 3 / TW
32 mm 110 mm - 130 mm - 150 mm Standard XC INTL STD 6 (The installation of 8" disk is only
possible when the specific adapter is supplied by the brake system manufacturer)
No 2.8 x 26 Positive air - Both legs English Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Rebound adjustment by external adjuster - Right leg By turning the adjuster clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase.

Table 23 - AM 4 / TW

AM 4 / TW
Legs diameter Available travels Wheel dropout type Max disk dimension V-brake fit Max wheel dimensions 32 mm 110 mm - 130 mm - 150 mm Standard XC INTL STD 6 (The installation of 8" disk is only
No 2.8 x 26 Positive air - Both legs
142 Rebound adjustment by internal adjuster - Right leg Using a small pin extractor eliminate any pressure from the right leg. Unscrew and remove the protection cap with a 21mm cap key. Insert a 12mm tee-key into the stanchion being very careful to center the notch of the adjuster. By turning the adjuster counter-clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. After adjustment, refit and tighten the protection cap to the recommended tightening torque. Re-inflate to the recommended air pressure value. 2.40 3.210 2.90 3.52

Table 24 - Drop-Off I

Drop-Off I
Legs diameter Available travels Wheel dropout type 32 mm 130 mm - 150 mm Standard ( 20mm through-hole axle as an optional) XC INTL STD 6 (The installation of 8" disk is only Max disk dimension V-brake fit Max wheel dimensions
No 2.8 x 26 Spring preload with air - Right leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Rebound adjustment by external adjuster - Right leg By turning the adjuster clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. English

180 210

Table 25 - Drop-Off II

Drop-Off II

No 2.8 x 26 Spring preload with air - Both legs
Compression adjustment by external adjuster - Left leg By turning the adjuster clockwise, you increase the hydraulic damping during the compression phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping during the compression phase. kg lbs bar psi 0 1.110+ 210 220+

Table 26 - Drop-Off III

Drop-Off III
Legs diameter Available travels Wheel dropout type 32 mm 130 mm - 150 mm Standard ( 20mm through-hole axle as an optional) XC INTL STD 6 (The installation of 8" disk is only Max disk dimension V-brake fit Max wheel dimensions Positive air - Left leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Spring preload with air - Right leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Rebound adjustment by external adjuster - Right leg By turning the adjuster clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. Riders weight Positive air pressure Preload air pressure kg lbs bar psi bar psi 2.00 2.180 2.40 3.1.210 2.90 3.110+ 210 220+ 3.60 4.65 English

No 2.8 x 26

Table 27 - Drop-Off IV

Drop-Off IV

Legs diameter Available travels Wheel dropout type 32 mm 130 mm - 150 mm Standard ( 20mm through-hole axle as an optional) XC INTL STD 6 (The installation of 8" disk is only possible when the specific adapter is supplied by the
brake system manufacturer)
Max disk dimension V-brake fit Max wheel dimensions Positive air - Left leg
146 Spring preload with air - Right leg
Rebound adjustment by internal adjuster - Right leg Using a small pin extractor eliminate any pressure from the right leg. Unscrew and remove the protection cap with a 21mm cap key. Insert a 12mm tee-key into the stanchion being very careful to center the notch of the adjuster. By turning the adjuster counter-clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. After adjustment, refit and tighten the protection cap to the recommended tightening torque. Re-inflate to the recommended air pressure value. kg lbs bar psi bar psi 2.00 2.180 2.40 3.1.210 2.90 3.110+ 210 220+ 3.60 4.65

Table 28 - Super T

Super T
32 mm 170 mm 20mm through-hole axle XC INTL STD 6 (The installation of 8" disk is only
No 2.8 x 26 Spring preload with air - Both legs Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Rebound adjustment by external adjuster - Right leg By turning the adjuster clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. English
Compression adjustment by external adjuster - Left leg By turning the adjuster clockwise, you increase the hydraulic damping during the compression phase. By turning the adjuster counter-clockwise, you reduce the hydraulic damping during the compression phase. Riders weight Preload air pressure kg lbs bar psi 0 1.110+ 210 220+
Table 29 - Drop-Off Triple

Drop-Off Triple

Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. Spring preload with air - Right leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap.
English Riders weight Positive air pressure Preload air pressure

Table 30 - Dirt Jam Pro

Dirt Jam Pro
Legs diameter Available travels Wheel dropout type 32 mm 100 mm - 120 mm Standard ( 20mm through-hole axle as an optional) XC INTL STD 6 (The installation of 8" disk is only Max disk dimension V-brake fit Max wheel dimensions Positive air - Right leg Remove the protection cap. Tighten the pump adapter on the valve and inflate till reaching the pressure you wish. Refit the protection cap. English
possible when the specific adapter is supplied by thebrake system manufacturer)
Spring preload by external adjuster - Left leg By turning the knob clockwise, you increase the preload value. By turning the knob counter-clockwise, you reduce the preload value.

Rebound adjustment by internal adjuster - Right leg Using a small pin extractor eliminate any pressure from the right leg. Unscrew and remove the protection cap with a 21mm cap key. Insert a 12mm tee-key into the stanchion being very careful to center the notch of the adjuster. By turning the adjuster counter-clockwise, you increase the hydraulic damping making the fork slower during the rebound phase. By turning the adjuster clockwise, you reduce the hydraulic damping making the fork more reactive during the rebound phase. After adjustment, refit and tighten the protection cap to the recommended tightening torque. Re-inflate to the recommended air pressure value. kg lbs bar psi 2.00 2.180 2.40 3.210 2.90 3.110+ 210 220+ 3.60 4.65

Table 31 - Dirt Jam Comp

Dirt Jam Comp
Legs diameter Available travels Wheel dropout type 32 mm 100 mm - 120 mm Standard ( 20mm through-hole axle as an optional) XC INTL STD 6 (The installation of 8" disk is only Max disk dimension V-brake fit Max wheel dimensions
Spring preload by external adjuster - Both legs By turning the knob clockwise, you increase the preload value. By turning the knob counter-clockwise, you reduce the preload value.
Table 32 - Tightening Torques
Part to be tightened V-brake locking pins Fork's top caps Adjuster locking screws Pumping rod / cartridge foot nuts Pumping rod foot screws Pumping rod locking (TXC series) Fender fixing screws Handlebar clamp fixing screws (Drop-Off Triple, Super T) Lower crown fixing screws (Drop-Off Triple, Super T) Upper crown fixing screws (Drop-Off Triple, Super T) Wheel axle screws Allen screws for wheel axles
Tightening torque (Nm) 0,1 61

Warranty 7 WARRANTY

7.1 WARRANTY FOR EU COUNTRIES
Marzocchi S.p.a. warrants that its new Suspension Systems are free from original conformity defects throughout a period of two (2) years from the date of the purchase, in accordance with Directive 99/ 44/EC. The retail invoice or, if any, the warranty certificate dated and stamped by Marzocchi retailer, enclosed with the product, prove the commencement date of the warranty. In the event of a conformity defect within the aforesaid term, the purchaser should return the product to the Marzocchi retailer where he/she bought it, illustrating the defect and the reasons of the warranty claim. The retailer will inform the purchaser when the product has been repaired or replaced. 1. NOT COVERED: This warranty does not cover non-conformity defects after the purchase, such as damage resulting from accidents, alteration, neglect, misuse, abuse, improper use, improper assembly, repairs improperly performed, replacement parts or accessories not conforming to Marzocchi S.p.A.s specifications, modifications not recommended or approved in writing by Marzocchi S.p.A., activities such as acrobatics, stunt jumping, ramp riding, racing, commercial use, competitive use, use in mountain biking or BMX parks, use on BMX trails, and/or normal wear or deterioration occasioned by the use of the suspension system. This warranty does not cover, as they are not original non-conformities, items subject to normal wear occasioned by use, 151 including, but not limited to, oil, dust seals, oil seals, and bushings. In addition, this warranty is void in the event that the forks are used with rental bicycles. This warranty will be automatically void if the serial number of the Marzocchi Suspension System is altered, erased, defaced or otherwise subject to any tampering. Finally, this warranty will not cover Marzocchi second-hand suspension systems and in this case the retailer will offer a warranty for the second-hand product, without liability of any kind, either direct or indirect, of Marzocchi. English

TAVARES & TIMMERMANS, Lda. Bike Center Condomnio Industrial de Alcolombal Estrada de Alcolombal, Armazm 1 2705-833 TERRUGEM-SINTRA Portugal PORTUGAL Contact: Hans Timmermans Tel. +351 (0)Fax +351 (0)bikecenter@mail.telepac.pt www.bikecenter-pt.com CULT d.o.o. Trzaska 77 SLOVENIA 1370 LOGATEC - Slovenia Tel: +30 Fax: +39 OFFICIAL DISTRIBUTOR ALSO FOR: CROATIA, SERBIA, MONTENEGRO, BOSNIA HERZEGOVINA, MACEDONIA TEAM BIKE S.L. Elche Parque Industrial c/ Juan de la Cierva, Torrellano-Elche Alicante Spain SPAIN Contact : Simon Tel.: +34 Fax: +10 Info@teambike.es TOKIND Nydamsvej 49 DK-8362 Hoerning - Denmark SWEDEN Contact: Claes Rehn Tel. : +7800 Fax: +7377 info@tokind.se www.tokind.se INTERCYCLE Prufundmatte 3 CH-6210 SURSEE Switzerland SWITZERLAND Tel.: +41 (0)Fax: +41 (0)LIECHTENSTEIN Info@intercycle.com ( www.intercycle.com SOLENT UK Ltd. t/a Windwave Unit D2- D3 Heritage Business Park Heritage Way - GOSPORT UNITED KINGDOM Hants PO12 4BG - UK IRELAND Tel. +44 (0)Fax +44 (0)Office@windwave.co.uk www.windwave.co.uk

OTHER COUNTRIES

COUNTRY

AUSTRALIA NEW ZEALAND

COMPANY
GROUPE SPORTIF PTY. LTD. 27 Ceylon Street, NUNAWADING 3131, Victoria Australia Tel.: +Fax: +help@groupesportif.com www.groupesportif.com PLINIO CURI IMP. EXP.LTDS Rwa Pamplona 8185 Andar - 01405-030 SAO PAOLO Brasil Tel.: +2510633 Fax: +2515069 pcuri@ibm.net NORCO PRODUCTS LTD. 1465 Kebet Way - PORT COQUITLAM, B.C. V3C 6L3 - Canada Tel.: +Fax: +Sales@norco.com www.norco.com CYCLE TRADING COMPANY LTD. Hapardes Rd. - RISHPON, Israel Tel.: +9513010 Fax: +9509783

BRAZIL

CANADA

ISRAEL

sales@ctc.co.il www.ctc.co.il FOURS 69-6 Jeongja-Dong Bundang-Gu KOREA Seongnam-Si, KYONGGI-DO, Korea Tel.: +82 (0)6520/21 Fax: +82 (0)6519 FAREN ENTERPRISES #59_E Bansalangin St., Project 7 - 1105 Quezon City PHILIPPINES Philippines Tel. +2541 Fax +2311 hansgee@mydestiny.net CAPPA TRADING PTE. LTD. 85 Kaki Bukit Avenue , Shun Li Industrial Park SINGAPORE SINGAPORE 417955 - Singapore Tel.: +Fax: +cappa@pacific.net.sg OFFICIAL DISTRIBUTOR ALSO FOR: MALAYSIA - INDONESIA - BRUNEI THAILAND

Cod. 9001154

Marzo - 2005 - Ed. 00

Marzocchi Suspension 2006 - 888 VF2

2006 - 888 VF2

Technical instructions
Exploded view - 888 VF2 - 170

Rif. Code

528260 810052AC/R 501536LA 528297 7051211/R 7051210/R 528034>B 538038>A 520341 5321153>A 850956/C 520349LA 5181254 5141398/C 509135 5321193SS/R>A 5321193RS/R>A 5321193RR/R>A 5321193TD/R>A 5321193TI/R>A 520344PN 507665/C 528051 520178PN 8031485/C 524180 850881/C 505083LA 526145>A 502587LA 508997/C 508998CD/C 8501031/C 526262RX 520396AR 505084LA 5321387 8031486/K/C 505108LA 505085LA 505107LA 526157KR 526158KR 8501030/C 5141294/C 522244AA 549089>A 547708

Quantity

888 VF2 - 170 - Oil levels
Position Oil type Quantity (cc) 220 220
Right fork leg SAE 7,5 - 550013 Left fork leg SAE 7,5 - 550013
Spare part list - 888 VF2 - 170
Rif. Code 528260 810052AC/R 501536LA 528297 7051211/R 7051210/R 528034>B 538038>A (replaces 547631) 520341 5321153>A 850956/C (replaces R5127LA) 520349LA 5181254 5141398/C 509135 5321193SS/R>A 5321193RS/R>A 5321193RR/R>A 5321193TD/R>A 5321193TI/R>A 520344PN 507665/C 528051 520178PN 8031485/C 524180 850881/C 505083LA 526145>A 502587LA Description O-RING PRELOAD SPRING PLUG-888 VF'06 UPPER CROWN-888 '06 O-RING CROWN+ALLOY STEM- 888 '06 LOWER CROWN+STEEL STEM-888 '06 DUST SEAL DIA.35 STOP RING OIL SEAL DIA.35 UPPER BUSHING DIA.35 SLEEVE LOWER BUSHING WASHER FATTY 2006 LABEL-CHROME FATTY LABEL 2006-BLACK RH+LH 888VF2'06 LABELS-BLK+RED SCREW CABLE GUIDE AXLE+SCREW KIT-66/888 AXLE SCREW -QR 20 PRELOAD SLEEVE 44MM SPRINGS KIT K=3,1 888'06 O-RING VALVE 20,3 DIA.35 FERRULE MAGNUM GREY MONOL.DIA.35 MONOLITE D.35- GLOSS ECO BLACK MONOLITE D.35-FLAT BLACK OLIMPIC PINK MONOL.DIA.35 PURE WHITE MONOL.DIA.35 SCREW 888 STANCHION O-RING SCREW COMP.PIST.ROD 888VF2'06 TR.170 PISTON RING DIA.35 HANDLEBAR CLAMP KIT - 888 '04 WASHER SPRING LOWER HANDLEBAR CLAMP- 888 COMPR.FERRULE-888/66 VF '06 STOP RING FOOT BUFFER RUBBER BUSHING LOWER CROWN 888 '06 Q.ty in the model 4 1
508997/C 508998CD/C 8501031/C 526262RX 520396AR 505084LA 5321387 8031486/K/C 505108LA 505085LA 505107LA 526157KR 526158KR 8501030/C 5141294/C 522244AA 520278 528030
ALLOY STEM STEEL STEM FENDER KIT- 888 '06 FENDER BUSHING- 888 '06 SCREW RH CLAMP -888 NUT UNIT- 66/888 FORK '06 REB.PIST.ROD 888VF2'06 TR.170 CLAMP 888'06 LH CLAMP -888 LOWER HANDLEBAR CLAMP 888 '06 BUSHING BUSHING HANDLEBAR CLAMP KIT - 888 '06 STOP RING O-RING REBOUND SPRINGS KIT K=2.5 NUT UNIT-66/888VF'06-REB.SIDE ADJUSTER WASHER SCREW O-RING
549089>A PLASTIC KNOB (replaces 549089KR) 547708 ALLOY STEM -LABELS EXT.REBOUND ADJ.MTB'06 LABEL EXTER.COMPRESS.ADJUST.-LABEL
Exploded view - 888 VF2 - 200
528260 810052AC/R 501536LA 528297 7051211/R 7051210/R 528034>B 538038>A 520341 5321153>A 850956/C 520349LA 5181254 5141398/C 509135 5321193SS/R>A 5321193RS/R>A 5321193RR/R>A 5321193TD/R>A 5321193TI/R>A 520344PN 507665/C 528051 520178PN 8031484/C 524180 850881/C 505083LA 526145>A 502587LA 508997/C 508998CD/C 8501031/C 526262RX 520396AR 505084LA 5321387 8031483/C 505108LA 505085LA 505107LA 526157KR 526158KR 8501030/C 5141294/C 522244AA 549089>A 547708
Spare part list - 888 VF2 - 200
Rif. Code 528260 810052AC/R 501536LA 528297 7051211/R 7051210/R 528034>B 538038>A (replaces 547631) 520341 5321153>A 850956/C (replaces R5127LA) 520349LA 5181254 5141398/C 509135 5321193SS/R>A 5321193RS/R>A 5321193RR/R>A 5321193TD/R>A 5321193TI/R>A 520344PN 507665/C 528051 520178PN 8031484/C 524180 850881/C 505083LA 526145>A 502587LA Description O-RING PRELOAD SPRING PLUG-888 VF'06 UPPER CROWN-888 '06 O-RING CROWN+ALLOY STEM- 888 '06 LOWER CROWN+STEEL STEM-888 '06 DUST SEAL DIA.35 STOP RING OIL SEAL DIA.35 UPPER BUSHING DIA.35 SLEEVE LOWER BUSHING WASHER FATTY 2006 LABEL-CHROME FATTY LABEL 2006-BLACK RH+LH 888VF2'06 LABELS-BLK+RED SCREW CABLE GUIDE AXLE+SCREW KIT-66/888 AXLE SCREW -QR 20 PRELOAD SLEEVE 44MM SPRINGS KIT K=3,1 888'06 O-RING VALVE 20,3 DIA.35 FERRULE MAGNUM GREY MONOL.DIA.35 MONOLITE D.35- GLOSS ECO BLACK MONOLITE D.35-FLAT BLACK OLIMPIC PINK MONOL.DIA.35 PURE WHITE MONOL.DIA.35 SCREW 888 STANCHION O-RING SCREW COMPR.ROD 888VF2 '06 TR.200 PISTON RING DIA.35 HANDLEBAR CLAMP KIT - 888 '04 WASHER SPRING LOWER HANDLEBAR CLAMP- 888 COMPR.FERRULE-888/66 VF '06 STOP RING FOOT BUFFER RUBBER BUSHING LOWER CROWN 888 '06 Q.ty in the model 4 1

508997/C 508998CD/C 8501031/C 526262RX 520396AR 505084LA 5321387 8031483/C 505108LA 505085LA 505107LA 526157KR 526158KR 8501030/C 5141294/C 522244AA 520278 528030
ALLOY STEM STEEL STEM FENDER KIT- 888 '06 FENDER BUSHING- 888 '06 SCREW RH CLAMP -888 NUT UNIT- 66/888 FORK '06 REBOUND ROD 888VF2 '06 TR.200 CLAMP 888'06 LH CLAMP -888 LOWER HANDLEBAR CLAMP 888 '06 BUSHING BUSHING HANDLEBAR CLAMP KIT - 888 '06 STOP RING O-RING REBOUND SPRINGS KIT K=2.5 NUT UNIT-66/888VF'06-REB.SIDE ADJUSTER WASHER SCREW O-RING
Technical characteristics: Technical characteristics
Dual-crown fork with 35mm legs. Available travels: 170 mm, 200 mm. Right fork leg damping element: spring. Left fork leg damping element: spring. Right fork leg damping system: SSVF pumping element with external rebound adjustment. Left fork leg damping system: SSVF Pumping rod with compression setting by external adjuster. The stanchion tubes are joined with screws to the steering crown. Lubrication and cooling of the parts subject to friction with a specially formulated oil. Steer tube: steel or (optional) reinforced aluminium, 1-1/8", threadless. Crown: aluminium alloy forged and CNC machined. Top crown: aluminium alloy forged and CNC machined. Stanchions: anodised aluminium. One-piece assembly: made of magnesium alloy cast and CNC machined for lighter weight and more stiffness. Sliding bushings: made of friction-free and wear-free material. Seals: computer designed oil seals that guarantee maximum seal in any condition. Oil: specially formulated oil that prevents foam and keeps the viscosity unchanged while offering high performance; free from static friction. Dropout type: motocross type wheel axle support, with advanced axle and double screw locking system on both dropouts (specific wheel axle, 20 mm, supplied). Disk brake mount: XC International Standard for 6" disk (fitting the special adapter supplied by the brake system manufacturer you can install the 8" disk). Max wheel size: 2.8" x 26". Integrated fender: available as optional. Handlebar with direct clamp on top crown: available as option.
Warnings: Instructions for use
MARZOCCHI forks are based on an advanced technology coming from the companys years long experience in the professional mountain bike industry. For the best results, we recommend inspecting and cleaning the area below the dust seal and the stanchion tube after every use and lubricating the parts with some silicone oil. MARZOCCHI forks usually offer the best performances since the very first rides. Notwithstanding this, a short running-in period may be necessary (5-10 hours) to adjust the internal couplings. This precaution will lengthen your forks life and guarantee its best performances. We recommend changing the oil at least every 100 hours. The forks with a polished finish must be treated periodically with polishing paste to keep the exterior shining like new.

Warnings: General safety rules
After disassembling the forks, always use new, original Marzocchi seals when reassembling. To tighten two bolts or nuts that are near each other, always follow the sequence 1-2-1, and tighten to the required tightening torque. Before reassembly, wash all new and old components and dry them with some compressed air, making sure there are neither breaks nor burrs. Never use flammable or corrosive solvents when cleaning the forks, as these could damage the forks seals. If you must use a solvent, use biodegradable detergents that are not corrosive, non-flammable, or have a high flash point. Before reassembling, always lubricate those components that are in contact with the forks oil. If you are planning not to use your forks for a long period of time, always lubricate those components that are in contact with the forks oil. Always collect and keep any lubricants, solvents, or detergents, which are not completely biodegradable in the environment. These materials should be kept in appropriate containers, and disposed of according to local laws. Always grease the seal lips before reassembling. All of the components of Marzocchi forks require the use of metric tools. Use only metric tools. Imperial (US) tools may have similar sizes, but can damage the bolts, making them impossible to loosen or tighten. When using a screwdriver to assemble or disassemble metal stop rings, O-rings, sliding bushings, or seal segments, avoid scratching or cutting the components with the screwdriver tip. Do not carry out any maintenance and / or adjustment operations that are not explained in this manual. Only use original Marzocchi spare parts. Before servicing the fork, we recommend washing the fork thoroughly. Work in a clean, organized, and well-lit place. If possible, avoid servicing your forks outdoors. Carefully check to see that your work area is free of dust and metal shavings from any component of the forks. Never modify your fork in any way. We recommend overhauling one fork leg at a time. We recommend overhauling one fork leg at a time.
Warnings: Fitting the fork onto the frame
In case of oversized diameter areas on the stanchions or sliders, the crowns clamping can only be done in the shaded area shown in Picture A.
For a correct installation of the fork onto the frame, check that distance H, corresponding to the length of the steer tube between the two crowns, is less than 158 mm.
A different position of the crowns can result in damage to the fork and in serious personal injury.
Warnings: Installing the disk brake
Installing the brake system is a delicate and critical operation that must be carried out by an authorized Marzocchi Service Center. Marzocchi is not responsible for the installation and accepts no liability for damage and/or accidents arising from this operation. Improper installation of a disk brake system can overstress the caliper mountings, which may cause the caliper mountings to break, resulting in loss of control of the bicycle, an accident, personal injury, or death. Be sure that the brake system installation is also performed in strict compliance with the instructions provided by the brake system manufacturer. Improper installation can result in an accident, personal injury, or death. Use only brake systems that comply with the forks specifications. Make sure, after installation, that the brake cable of the brake system is correctly connected to the proper mounting (A).

The brake cable must never touch the crown and stanchions.
Warnings: Assembling the fender
The fender can be supplied with the fork or purchased separately. Fender (1) must be assembled by placing the small support bush (2) between the screw and the fender as shown and by tightening screws (3) with an 8mm fixed spanner to the recommended tightening torque (6 Nm 1).
Warnings: Assembling the wheel
For a correct operation of the fork, install the wheel as explained below: Align the center of the wheel with each wheel axle clamp. Insert the wheel axle (1) through the right dropout, the wheel and the left dropout. With the 6mm Allen wrench act on cap (2) and tighten the wheel axle to the recommended tightening torque (15 Nm 1). Check for the proper fork-wheel alignment. To do this, begin by fully compressing the fork a few times. The wheel should not make contact with, or come close to any portion of the fork. Then lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake. The wheel should not wobble from side to side or up and down. Check the owners manual of the brake system for the proper specifications.
With a 4mm Allen wrench, tighten screws (3) on both dropouts to the recommended tightening torque (6 Nm 1) following the sequence 1-2-1.
Warnings: Installing the handlebar mount
For a correct installation of the handlebar mount, follow the instructions below: Install the bottom handlebar mount (1) onto the top crown so that the fixing holes match. With a 4mm Allen wrench, lock the handlebar mount tightening screws (2) to the recommended tightening torque (6 Nm 1).
Fit the handlebar right in the middle of the mount. Lock the handlebar in position with the special U-bolts (3). With a 4mm Allen wrench, tighten screws (4) to the recommended tightening torque (6 Nm 1). On request, special adapters (5) are available to install handlebars with a different diameter.
To install the handlebar clamp, please carefully follow the instructions below: Place the lower mounting segment (6) of the handlebar clamp on the upper crown (7) of the fork and align the corresponding holes from each of these components. Secure the lower mounting segment of the handlebar clamp by tightening the screws (2) to the required torque (6 Nm 1) using a 4mm Allen key.

Place the handlebar (11) into the lower mounting segment of the handlebar clamp, being sure that it is centered. Place the upper segment (10) of the handlebar clamp over the handlebar and align the holes of the upper segment with the corresponding holes of the lower mounting segment. Secure the handlebar in place by tightening each screw (9) to the required torque (6 Nm 1) using a 4mm Allen key. For installation of handlebars having different diameters, reduction sleeves (12) may be placed around the handlebar (between the handlebar and each segment of the handlebar clamp) to ensure the handlebar is held in place.
Dismantling: Removing the top caps
Put the fork in the vice in vertical position, fixing it by the dropouts. Fully unscrew lock cap (2), with a 26mm fixed spanner. Remove lock cap (2) being careful not to damage the O-ring (3).
Dismantling: Draining the oil
Block the fork in the vice, in perfectly vertical position.
Remove the preload tube (1) and spring (2) from both legs.
Free the fork from the vice and tip it into a container of a suitable size to drain the oil; compress the fork a few times to help the oil flow out. Do not pour used oils on the ground.
Dismantling: Breaking down the steering crown unit / arch-slider assembly
Use the special spanner to remove the bottom nuts. Do not use other tools. Turn the arch-slider assembly upside down. Loosen the screw (5) fixing the rebound adjustment knob (6) on the right leg using a 2mm Allen key. Remove screw (5), washer (11) and the adjustment knob (6).
Using the special 12mm spanner (A), loosen the right bottom nut (1). Pull out the right bottom nut (1) complete with O-ring (2).
With a small flat screwdriver, pull the compression adjustment knob (9) off the left leg. Be very careful not to damage the O-ring on the bottom nut.
Remove the compression adjustment knob (10) and the O-ring (12) from their seat on the bottom nut.
Using the special 12mm spanner (A), loosen the left bottom nut (1). Pull out the left bottom nut (1) complete with O-ring (2).
Pull the crown-stanchion unit (3) off the arch-slider assembly (4).
Dismantling: Dismantling the right pumping element and valve
Remove the bottom pad (1).
Using the special round-nose pliers, remove stop ring (2).
Pull out the pumping element (3) complete with rebound spring and valve.
Remove bushing (4), valve (5), the conical spring (11) and the three-point ring (6) from the pumping element. Remove the rebound spring (7).
If the piston segment (8) is damaged, you can prize it off with a small flat-tip screwdriver.

Dismantling: Removing the left pumping element
Pull out the pumping element (3) complete with rebound spring and bushing.
Remove bushing (4) and rebound spring (7) from the pumping element.
Dismantling: Removing the seals
Prize the dust seal (1) off its seat with a small flat-tip screwdriver. Take great care not to damage the internal surfaces of the one-piece assembly while removing the dust seal.
With the same screwdriver, prize off the metal stop ring (2). Take great care not to damage the internal surfaces of the one-piece assembly while removing the stop ring.
Protect the upper part of the slider with the special tool (A). With a screwdriver, prize off the sealing ring (3). Remove the sealing ring (3). Take great care not to damage the internal surfaces of the one-piece assembly while removing the sealing ring.
Remove the spring cup (4).
The old sealing rings and dust seals must not be used again.
Dismantling: Removing the guide bushes
Knock the top end of the one-piece assembly against a wooden surface and remove the top guide bush (1), spacer (2) and the bottom guide bush (3). Do this operation with extreme caution and hold the one-piece assembly perpendicular to the wooden surface.
Assembling: Assembling the guide bushes
Fit the bottom guide bush (3). With the help of spacer (2), press the bottom guide bush into the arch-slider assembly. Insert the top guide bush (1) in its seat. To help the bushes enter their seats you can use the special introducer.
Assembling: Assembling the seals
Insert the spring cup (4) in its seat.
Smear the dust seal and the sealing ring with some grease. Insert the sealing ring (3) in its seat with the special introducer (A). Using a hammer, knock in introducer (A) and drive the sealing ring home into the arch-slider assembly.
Using a small flat-tip screwdriver, fit the stop ring (2) and check that it fits perfectly into its groove. Take great care not to damage the internal surfaces of the one-piece assembly when fitting the stop ring. The dust seals shall be refitted when reassembling the crown-stanchion unit / arch-slider assembly.
Assembling: Assembling the right pumping element and valve
Replace the segment (8) of the pumping element, if necessary.
Insert the rebound spring (7) into the piston rod.
Assemble the valve unit in this order: bushing (4),valve (5), conical spring (11), three-point ring (6), and check that the parts are oriented as shown.
Insert the pre-assembled valve in the piston rod from the three-point ring side as shown. Insert the valve and the pumping element (3) into the stanchion.
Take great care not to damage the segment and if necessary use a small flat-tip screwdriver to help the piston of the pumping element into the stanchion. Using the special round-nose pliers, mount the stop ring (2) and check it fits perfectly into its groove.

Fit the bottom pad (1) to the pumping element rod.
Assembling: Assembling the left pumping element
Replace the segment (8) of the pumping element, if necessary. Insert the rebound spring (7) and bushing (4) into the stanchion.
Insert the pumping element (3) into the stanchion.
Assembling: Reassembling the steering crown unit / arch-slider assembly
A special spanner shall be used to assemble the bottom nuts. Do not, at any times, use other tools. Fit both dust seals (11) to the stanchions.
Insert the crown-stanchion unit (3) in the arch-slider assembly (4).
With the special 12mm spanner, tighten the right bottom nut (1) complete with O-ring (2) to the recommended tightening torque (10 Nm 1).
Fit the rebound adjusting knob (6) to the right leg. Take great care not to damage the O-ring fitted to the end of the pumping element rod. Tighten the fixing screw (5) of the adjusting knob to the recommended tightening torque (2 Nm 0.5).
Using the special 12mm spanner, tighten the left bottom screw (1) complete with O-ring (2) to the recommended tightening torque (10 Nm 1).
Insert the O-ring (12) in its seat on the bottom nut. Refit the compression adjustment knob (10) to the bottom nut locking the same on the O-ring.
Using introducer (A) insert the dust seals (11) in their seats.
Assembling: Filling with oil
Block the fork in the vice, in perfectly vertical position. Lower the crown-stanchion unit on the arch-slider assembly.
In a graduated recipient, prepare the quantity of oil to pour into the fork leg (see table). Pour roughly 1/3 of the oil required into each stanchion, then pump the fork a few times to eliminate any traces of air. Pour the rest of oil in.
A lower or higher volume or a type of oil other than the one recommended can change the behaviour of the fork in every phase. Lift the crown-stanchion unit on the arch-slider assembly.
Insert spring (2) and the preload tube (1) in the left leg.
Assembling: Mounting the top caps
Put the fork in the vice in vertical position, fixing it by the dropouts. Using the 26mm fixed spanner, tighten cap (1) to the recommended tightening torque (10 Nm 1).
Setting: General rules for calibration
By carefully calibrating the damping system you can get the maximum performance out of the same. This paragraph indicates the sequence of operations to perform to set up the Marzocchi forks correctly. In order to find the best settings for you, you will need to try several times to understand where and how to make adjustments. When doing so, please ride in an open area, free from traffic, obstacles and other hazards. The optimal setting is influenced by the geometry of the frame of the mountain bike, the weight of the cyclist, the type of terrain the bike will be used on and the type of obstacles you have to deal with, but also by subjective factors associated with your riding style; therefore it is impossible to provide objective data on the desired settings. Nevertheless by carefully following the instructions below you will soon be able to find the optimal setting for you. The shock absorber must be calibrated simply by using one adjuster at a time, following the order explained, noting the operations and any result step-by-step. During setting don't force the adjusters beyond their limit of travel and don't exceed the max recommended air pressure. To keep the pressure inside the forks legs, only use the special MARZOCCHI pump with pressure gauge. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.

Once the correct setting has been found, we recommend noting the number of clicks or turns of the adjuster with respect to the "fully closed" position (adjuster fully clockwise) for a faster re-setting of your fork in case of need.

Setting: SAG

SAG means the fork bottoming under the biker's weight. How to measure the SAG: Follow these simple steps to measure the SAG. On the leg portion of the fork, measure the distance between the lower crown and the dust seal (see Picture A). Note this value as H1. While sitting on the bike, repeat the measurement (see picture B). Note this value as H2". SAG = H1 - H2 How to find the best percent SAG: The best percent SAG is 15-20% for Cross-country and All Mountain forks and 25-30% for Freeride and Downhill forks. In order to calculate the best SAG for your own fork, you will need to make the following calculation: SAG = T x S (T = total travel; S = suggested sinking percentage).
Setting: Rebound adjustment
Right fork leg: With the rebound adjuster you can control the return speed of the fork after compression. The right rebound speed setting makes the bike stable letting it follow the variations in the terrain and any obstacles. If the fork setting is too reactive this will make the rear suspension instable and the mountain bike will have a tendency to snake. A too slow setting however will cause problems when dealing with multiple obstacles where the suspension can't return to its fully extended position fast enough between one obstacle and the next. Turning adjuster (A) clockwise increases the hydraulic damping making the fork slower during the rebound phase. Turning adjuster (A) counter-clockwise decreases the hydraulic damping making the fork more reactive during the rebound phase.
Do not force the adjuster beyond its limit of travel.
Setting: Compression adjustment
Left fork leg: With the compression adjuster you can control the compression speed. The compression setting is at the user's discretion and must be set to prevent the suspension bottoming out. A "hard" compression setting gives you more stability and lets you ride more aggressively making the mountain bike more reactive, vice versa a "soft" setting means less stability but also a less "nervous" ride. Turning adjuster (A) clockwise increases the hydraulic braking during compression and, under the same load conditions, reduces the fork travel. Turning adjuster (A) counter-clockwise decreases the hydraulic compression damping making the fork more reactive on harsh grounds.

Tightening torques

Components Adjuster locking screws Bottom crown fixing screws Fender fixing screws Fork leg top caps Handlebar fixing screws Pumping element/cartridge bottom nuts Top crown fixing screws Wheel axle Allen screws Wheel axle screws Tightening torque (Nm) 20,151

888 VF2 - 200 -

Diagnostics
Finding the problem Fork doesn't get full travel Fork extends too quickly; harsh top-out after impacts Fork extends too quickly; harsh top-out after impacts Fork has too much sag Fork is sticky; fork does not perform as new Fork is too soft, but the sag is the one recommended Fork is too soft, needs more than the maximum preload Fork stays down or "packs up" during multiple impacts Front wheel tends to tuck under while turning left or right Heavy amount of oil on stanchions; oil dripping down legs Heavy amount of oil on stanchions; oil dripping down legs Knocking sound during rebound, but no harsh topout Loss of sensitivity Loss of sensitivity Oil leaking from the bottom of the fork leg Oil ring on stanchions Finding the possible cause Oil level too high Rebound damping is not enough Rebound damping is not enough Oil is too fluid Dirty sealing rings; fork needs to be serviced Compression damping is not enough Oil is too fluid Rebound damping is too high Rebound damping is too high Sealing rings damaged The stanchion tubes could be damaged Rebound damping is too high Old oil Sliding bushes worn Bottom nut/screw loose Sealing rings dirty Possible solutions proposed Check oil levels Increase rebound damping Replace the oil (SAE 7.5) with one of higher viscosity index Check oil levels Renew all seals Increase compression damping by changing oil volumes Check oil levels Decrease rebound damping with the relevant register Decrease rebound damping with the relevant register Renew all seals Have the stanchions be checked Decrease rebound damping with the relevant register Change the oil Renew the sliding bushes Tighten the nut or screw Renew all seals