Marzocchi fork Travel change – MY2010+ air sprung forks

Marzocchi fork Travel change – MY2010+ air sprung forks
Most air sprung forks between 2010 and 2014 can be set to different travel settings by changing
internal spacers. These allow the travel to be adjusted in 20mm increments very easily.
Common forks that apply (maximum travel in brackets)–
2010 44 TST2 and 2011/12 29” (140mm, 100mm for some OE)
2011-2012 44 TST2 (150mm, 100 for some OE)
2010 44 TST Micro and 2011/12 29” (140mm)
2011-2012 44 TST Micro (150mm)
2010-2012 Corsa SL 26” (100mm)
2011-2014 Corsa SL LR 26 (120mm)
2012-2014 Corsa 29” (120mm)
2010 – 2012 55 TST Micro (160mm)
2012-2014 55 CR (170mm)
This procedure can be done with only a few tools, there are some minor variations to the footnut
and air piston design of some forks but the routine is always the same.
Start by removing all air pressure
Flip fork upside down, use the shaft of a screwdriver to pull rebound knob straight up and out
Loosen both footnuts by about 3 or 4 turns
Keep driver bit in the bolt and carefully strike with a soft hammer to break the fit with the lowers
Turn fork right way up and collect oil that drains from the bottom (you can reuse it if still clean)
Fork upside down again, slide lowers up and off
Remove the circlip on the spring side stanchion leg
Pull out the air spring assembly
From the top - Bottom out bumper, circlip, stanchion plug, negative spring (with top out bumper
inside, 20mm travel spacer, air piston.) Some forks will have a small ”foot” on the end of the shaft
which is easily pulled off with pliers before you can slide the other parts off.
Hold the negative spring and strike the bottom of the shaft against the bench to unclip it from the
top of the assembly. Slide all the parts off and lay them out in order.
Air spring parts laid out, this Corsa has 1 spacer installed currently for the 100mm travel setting.
The spacers fit by clipping to the spring or each other, and since we are taking this fork to 120mm we
will remove the spacer.
Slide the parts back on, clipping the spring in to the black retainer at the top.
Before fitting air spring back in to the stanchion, make sure this circlip is present and seated in the
second groove inside the stanchion. It may have been knocked when removing the piston. Grease
the air piston, push the assembly in to the stanchion and fit the circlip. Turn the circlip to make sure
it is home, then give the piston a tug to test it.
Before installing the lowers, pull the spring off the dust wipers then carefully lever them out with a
large tyre lever or similar. Be very careful not to nick the oil seal underneath! If there is a foam ring
present, throw it away.
Wipe some silicone grease on both seals, slide the dust wipers on to the stanchions then carefully fit
the lowers, making sure not to fold the oil seals over.
Add oil to the lowers on each side, check www.marzocchi.com for the correct levels. Then tighten
the footnuts.
Oil the sides of the dust wipers then use a clamshell press to seat the seals. They should sit square
and close to flush with the lowers.
Inflate fork until it extends fully
Measure the exposed stanchion to confirm you have the desired amount of travel.