Assembly; Disassembly - Marzocchi MAGNUM Handbuch

8
US UK

ASSEMBLY

IMPORTANT: MAGNUM fork should be assembled on the frame in compliance with
the motorcycle Manufacturer's specifications as far as the steering elements and the
wheel fastening are concerned. An unproper assembly can jeopardize both rider's safety
and life.
– Assemble the stanchion tubes in the steering base and head and position them at the
same height.
– Tighten the fastening screws of the stanchion tubes on the steering base and head
using a torque of 21.5-24.5 Nm, following the above 1-2-1 procedure.
– Tighten the fastening nuts of the wheel pin on the sliders using a torque of 21.5-24.5,
following the above 1-2-1 procedure.
DISASSEMBLY (see fig. on page 35)
The reference numbers of this chapter refer to the components of the exploded view of the
fork shown on page 37.
FIG. 1
Fix the stanchion tube (19) in a vice equipped with protection jaws. By means of a 36 mm
Allen wrench unscrew the upper plug (17-17A). Be sure not to damage the O-ring (4) when
removing it. Push the stanchion tube into the slider.
FIG. 2
Stop the plug by means of the above Allen wrench and loosen the check nut (145) by
means of a 19 mm Allen wrench. Unscrew completely and remove the plug (17-17A) from
the damper rod end. Withdraw the spring (18), the spring guides (62) and the pre-load
sleeve (28) from the inside of the stanchion tube.
FIG. 3
Empty the fork leg of oil. For an easier drainage of the oil contained in the damping unit
pump up and down pushing with the damper rod (29).
WARNING: pushing the l.h. damper rod and pulling the end of the l.h. damper rod, a
pressure oil jet will come out. Aim the rod end at a container in order to avoid any damage.
FIG. 4
Vice the slider and unscrew the foot screw (40) by means of a 8 mm Allen wrench. Remove
the screw and its seal (52).
Carefully slide the stanchion tube (19) out of the slider (24-25).
OIL SEALS AND PILOT BUSHING REPLACEMENT
FIG. 5
Remove the dust seal (20) by levering with a screwdriver (be sure not to damage the inner
sealing lip).