Marzocchi MARATHON User Manual

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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M ARZOCCHI special tools only.
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
in contact with each other using silicone
fat spray or a specific oil for seals.
5. Always grease the lip seal rings before
reassembling.
6. Use wrenches with metric size only.
Wrenches with inch size might damage
the fastening devices even when their
size is similar to that of the wrenches in
metric size.

Marzocchi MARATHON Specifications

General

Wheel Size	26", 27.5", 29"
Spring Type	Air
Stanchion Diameter	32mm
Brake Compatibility	Disc
Intended Use	Cross Country
Adjustments	Rebound, Air Pressure
Travel	100mm, 120mm
Type	Suspension Fork
Steerer Tube Diameter	1 1/8"
Axle Type	QR (Quick Release)

Summary

INSTRUCTIONS

GENERAL RULES

Key guidelines for assembling and maintaining the suspension system, emphasizing specific tools and cleaning.

FAILURES, CAUSES AND REMEDIES

FAILURES, CAUSES AND REMEDIES

Table detailing common fork failures, their potential causes, and recommended solutions for repair.

RECOMMENDATIONS FOR MAINTENANCE

RECOMMENDATIONS FOR MAINTENANCE

Advice on checking, cleaning, and lubricating the fork for optimal performance and longevity.

INSTALLATION

ADJUSTMENTS

FORK LEG PRESSURIZATION

Procedure for setting compression damping by adjusting air pressure using the specialized pump.

REBOUND ADJUSTMENT (r.h. fork leg)

Details on adjusting rebound damping on the right fork leg using knob (28) for different riding conditions.

NEGATIVE AIR CARTRIDGE ADJUSTMENT (LH fork leg)

Instructions for adjusting compression damping on the left fork leg via the air cartridge valve.

DISASSEMBLY

DISASSEMBLY DIAGRAM

Flowchart illustrating the sequence and interdependencies for various disassembly and component change procedures.

REMOVING UPPER CAP

REMOVING CARTRIDGES

FIG. 6

Procedure for unscrewing foot nuts to remove cartridges from the fork legs.

REMOVING GUIDE BUSHING AND SEAL ASSEMBLY

REPLACING AIR VALVE

FIG. 15

AIR-OPERATED CARTRIDGE OVERHAUL

REASSEMBLY

RE-ASSEMBLING AIR-OPERATED CARTRIDGE

PILOT BUSHING AND SEAL ASSEMBLY

CROWN AND STANCHIONS ASSEMBLY

FIG. 24

REASSEMBLING CARTRIDGES

FIG. 26

HOW TO FILL WITH OIL

FIG. 27

Procedure for filling the fork legs with oil, cycling the stanchions, and checking quantity.

REASSEMBLING UPPER CAP

FIG. 29