Rebuilding Marzocchi Forks

mightyi

I've just got some Marzocchi Marathon LR forks quite cheaply new, and i want to increase the fork travel to 120mm from the current 100mm. This is possible using the space provided with the forks, but I cannot find any information anywhere on their site or anywhere else about how to go about stripping down the forks to fit the new spacer. I also am unable to find any servicing details for them; something that would be useful to have (exploded diagrams, oil type and quantity etc)

Can anyone help? I prefer to do all my servicing myself, so don't want to take it in for servicing/changing travel somewhere!

mrmonkfinger

What model year are they?

mightyi

hi mrmonkfinger - they are 2011 model

bornagainbiker

Hi,
I have the same fork and the same 'problem' extending the length to 120mm. I couldn't find any info on the web either.

I took it to a chap down Plymouth who did the travel adjust ( which is REMOVING the spacer already in the fork )

and oil change and regrease, all in for £30.

http://www.mountainbikesuspension-rsf.co.uk/index.html if you're interested give Dave a ring, decent bloke knows his stuff and did the job there and then for me after I driven down to see him.

mightyi

@bornagainbiker cheers for the link mate - unfortunately i'm up in Liverpool, so a bit of a trek..

cobba

Look at the following links, they should give you some idea on how to pull the fork apart.

* The Manuals link only goes up to 2006 forks but there shouldn't be too much difference between a 2006 Marathon and a 2011 Marathon.

2011 Marathon LR Exploded Diagram: http://marzocchi.ru/resources/forks/PDF/PDF%202011/MY2012%20-%20MARATHON%20LR%20-%20100_R00-01.pdf

Marzocchi Service Manuals: http://my-sport.spb.ru/manual_1/index-16.htm

Butterd2

I did this work on my Marathon's a couple of months ago, it was easy enough based on the exploded diagram and the clip on YouTube from Windwave (http://www.youtube.com/watch?v=bDP6X4nmp9c) on how to refil the damper properly.
As posted above you just need to take out the spacer to extend to 120mm travel.
As I remember;
1. let the air out
2. undo both of the plugs on the tops of the stantions (big spanner or adjustables required)
3. Extract the parts you can
4. undo allen bolts on bottoms of legs and the legs should then pull off the stantions exposing all the parts you need to reach. (At this point oil goes everywhere and the Mrs gets pissed off)

The service manual will give you the oil volumes to put back in each leg when you reassemble.

Good luck, it was worth doing for me.

(PS Windwave were really helpful if you get stuck)