Reassembly - Marzocchi MAGNUM Handbuch

10
US UK
REASSEMBLY (see figures on page 36)
WARNING: before reassembling all components, they should be carefully washed
and dried with compressed air. Clean the upper plug and the foot screw paying
particular attention.
FIG. 1
After performing all necessary overhaul operation, reassemble the piston-rod unit in the
damper body (117-117A).
FIG. 2
Fit the foot valve (157) and the new O-ring (86) at the body bottom (117-117A) and push
it beyond the stop ring seat.
Fit the stop ring (38N) into the body seat and push the foot valve by means of the rod until
it leans on the ring.
FIG. 3
Tighten the check nut (145) on the rod until the end of the thread is reached and
reassemble the foot pad (39) at the body lower end.
Reassemble the damping unit into the stanchion tube.
FIG. 4
Before reassembling the stanchion tube (19) into the slider (24-25), make sure that upper
pilot bushing (56) is assembled on it.
Fit the lower sliding bushing (58) into its seat on the stanchion tube.
Fit the stanchion tube (19) into the slider (24-25) and push it down to the counterboring.
FIG. 5
Screw the foot screw (40) with seal (52) and tighten at 50 Nm (36.8 ft.lb).
FIG. 6
Fit the retaining cup (139) and the oil seal (22), well lubricated, in the stanchion tube. Use
the proper fitter B (Ref. R5050) and push the oil seal into the slider down to the
counterboring. Then assembly the stop ring (23) and the dust seal (20).
FIG. 7
Pour "MARZOCCHI SAE 7.5" oil (Ref. 55 00 09) into the stanchion tube making sure that
also ducts inside the damper are full. Check that an air volume of 190 mm is left between
the top of the stanchion tube and the oil level, with the stanchion tube at its end of stroke.