MONSTER T

12

181716

39

14

3

7

15

32

33

32

13

2

8

1

9

8A

11

30

20

30

27

27

26

28

28

29

31

29

31

29

25

24

19

34

2921

22

23

46 5

35

1010A10F10B

10E

3738

36

40

41

1010A10D10B10C

MONSTER T

35

8

L.M

AX

=728

L.

L.=718 L

.MIN

=5

43

55

0.5

513.5

192.5

15

5.5

267

142.5

25 17

.4

38

TRAV

EL 1

75

37

±2

±2

175

Ø22

112.5

Ø20

+0.50 27

Monster Triple MY2000 cod.10211450

GENERAL• The double plate fork is specifically designed for Downhill use.

Damped by hydraulic cartridges and sprung by a mechanicalcoil spring system.

• Rebound damping cartridge inside RH fork leg, compressiondamping cartridge in LH fork leg.

• Spring pre-load and rebound damping adjustment controlledvia external top mount adjusters.

• Stanchion tube secured to the crown and upper plate. The systemgives the fork unmatched structural strength.

• Parts subjected to friction are cooled and lubricated by speciallyformulated oil.

• Left slider comes with brake caliper adapter.• Axle support is the same drop-out design as in motorbikes, with

shaft threaded.• Wheel shaft (20 mm diam.) available on request.• Adapter kit for 3" wheel installation available on request.

Steer tube: EASTON aluminum steer tubes available for 1 1/8”x267 mm, threadless.Crown: Forged and CNC-machined “BAM” aluminum alloy.Upper plate: CNC-machined T6-6082 alloy. Two versionsavailable for different frame sizes.Arch: CNC-machined ERGAL alloy.Stanchions: Anodized EASTON aluminum with variable butting.Springs: with variable pitch.Sliders: Forged and CNC-machined aluminum alloySlider bushing: composed of a copper base and impregnatedwith an anti-friction coating.Seals: Computer designed oil seals guarantee the highest qualityseals available.Oil: Specially formulated oil which eliminates foaming and viscos-ity breakdown while providing complete stiction-free performance.Fork leg oil: 380 cc, type EBH 16- SAE 7.5.

MONSTER T

GENERAL RULES1. Where specified, assemble and disas-

semble the shock absorption systemusing MARZOCCHI special tools only.

2. On reassembling the suspension sys-tem, always use new seals.

3. If two screws are close one to the other,always tighten using a 1-2-1 sequence.In short, screw the first screw just up tothe point it is well tightened, then tightenthe second screw and then go back tothe first one and screw it tighter.

4. Clean all metal parts with a special,preferably biodegradable solvent, suchas trichloroethane or trichloroethylene.

5. Before reassembling, lubricate all partsin contact with each other using sili-cone fat spray or a specific oil for oilseals.

6. Always grease the conic seal ringsbefore reassembling.

7. Use wrenches with metric size only.Wrenches with inch size might dam-age the fastening devices even whentheir size is similar to that of the wrenchesin metric size.

INSTRUCTIONS

MONSTER T

FAILURES, CAUSES AND REMEDIESThis paragraph reports some troubles that may occur when using the fork. It also indicates possible causes and suggests a remedy.Always refer to this table before doing any repair work.

Oil leaking through the bottom of slider O-ring seal on the cartridge nut is damaged Replace the O-ring seal

Fork has not been used for some time andis locked out

Oil seals and dust seals tend to stick tostanchion tube

Raise dust seal and lubricate stanchiontube, oil seal and dust seal

Fork compresses and/or rebounds too fasteven though the adjuster is set to hardestdamping position

Cartridge is faulty Replace hydraulic cartridge

Excessive play of stanchions into the sliders Main slider bushings are worn Replace main slider bushings

1. Oil seal is worn out2. Stanchion tube is scored3. Excessive dirt on slider oil seal

1. Replace oil seal2. Replace oil seal and stanchion tube3. Clean the oil seal seat and replace oil

seal

Excessive oil build up on stanchions

FAILURES CAUSES REMEDIES

MONSTER T

RECOMMENDATIONS FORMAINTENANCEMARZOCCHI forks are based on ad-vanced technology, supported by year-long experience in the field of profes-sional mountain biking. In order to achievebest results, we recommend to check andclean the area below the oil seal and thestanchion tube after each use and lubri-cate with silicone oil.

INSTALLATIONInstalling the MONSTER T fork on a bicy-cle is a very delicate operation that shouldbe carried out with extreme care.A threadless steer tube is pre-installed onthe fork from the factory. It will need to becut to the required length for a proper fit.Always have the installation checked atone of our Technical Service Centers.

WARNING: “A-Head Set” head-set/steer tube mounting and adjust-

ment must be carried out in compliancewith the headset manufacturer’s instruc-tions. Improper installation may jeopard-ize the safety of the rider.

After any installation always check for thefollowing:– proper torque of bolts fastening stan-

chion tube onto lower crown and up-per plate;

– proper torque of bolts fastening brakearch onto slider

– proper torque of bolts fastening shaft todrop out

MOUNTING THE FORKON THE FRAMEFIG. ARemove the upper plate (28) from steertube and fork legs by loosening the fasten-ing screws (29) and (31).

28

29

31

29

MONSTER T

FIG. BAssemble the fork to the frame completewith headset. Fit the upper plate (28) intothe upper stanchions and the steer tube.

28

FIG. CThe stanchions edge (13) must be alignedwith or slightly lower than the upper plate(28). If fork legs overprotrude, fit somespacers (C) to the plate close to the steertube.In case of frame with higher steer tube, usethe optional plate supplied on request.

28

13

C

FIG. DFit the handlebar support and the A-HeadSet cap over the upper plate (28)and then adjust the steering.Now finally tighten the screws (29) and(31) on the upper plate to 11 Nm.

IMPORTANT: Loosen the screws(29) and (31) on the upper plate

before adjusting the steering. Tighten theabove bolts to the required torque whenfinished.

31

29 Nm11

MONSTER T

FIG. EIf the crown (26) position with respect tothe stanchion tubes (13) has been changedfor any reason, adjust the original dis-tance.– Distance “H” between crown and tyre

edge (when inflated) should not belower than total travel (175 mm) + 3mm.

WARNING: If steering crown isimproperly matched with stan-

chions, it may touch the tyre and causesevere injuries to the rider.

26

H

FIG. FTighten the 4 stanchions fastening screws(27) onto the crown to 11 Nm.

WARNING: do not overtightenthe screws holding the stanchions

to the crown as this may distort the stan-chion tubes and weaken the whole struc-ture.

Nm11

27

13

MONSTER T

FIG. HTighten the wheel shaft (23) counter clock-wise from the opposite end with a 8-mmAllen wrench. Tighten to 20 Nm.

Nm20

23

FIG. ICompress the fork several times so thesliders will become properly seated ontothe wheel shaft. Lock the pinch bolt (29) onthe r.h. lug to 6 Nm.

DISASSEMBLYTo remove the wheel proceed as follows:– loosen the bolt (29) on the r.h. drop-out

(see Fig. I);– screw the wheel shaft (23) clockwise

onto the l.h. drop-out (see Fig. H);– remove the shaft (23) from the opposite

side.

23

Nm6

FRONT WHEEL FIXINGIMPORTANT: for a safe andproper performance of this fork and

all related devices, the front wheel shouldbe absolutely secured as specified in theinstructions given below.

FIG. GInsert the complete wheel assembly be-tween the sliders and fit the wheel shaft(23) into the slider that accommodates thewheel shaft pinch bolt (29) from the righthand side.Rotate wheel shaft clockwise to start it intothe LH slider.

29

23

MONSTER T

FORK CONFIGURATION FOR 3"WHEEL INSTALLATION(Fig. L)Before you can install a 3" wheel, you willneed to:– replace standard arch with oversized

arch (38). Reuse the fastening bolts(25).

– Fit the spacers (36) to hydraulic car-tridges ends (11) and (35).

– Replace the standard foot nuts with thespecial nuts (37).

WARNING: Unless fork is prop-erly configured as detailed above,

tyre will touch the arch when a 3" wheelis installed.

25 38

21

36

37

11-35

DISC BRAKE SYSTEM ASSEMBLYAssembling the brake caliper onto theslider is a very delicate operation thatshould be carried out with extreme care.Improper assembly might overstress thecaliper supports, which might break.This system should be assembled by spe-cialized technicians in a position to fullyunderstand and properly follow the in-structions given by the manufacturer.

MONSTER T

COMPRESSION DAMPING AD-JUSTMENT (Fig. N)The l.h. fork leg is equipped with anadjuster (D, BLACK) for COMPRESSIONdamping adjustment. Turning this adjusterclockwise into the cartridge rod, changesthe hydraulic setting of the inner valves. Inshort, the amount of adjustment appliedon the piston in the fluid determines therate of compressionrebound damping.To adjust, always start from the minimumdamping setting, i.e. unscrew completelycounterclockwise. About 8 turns - abt. 4mm of the adjustment - are possible.

D

ADJUSTMENTSSPRING PRELOAD (Fig. M)The spring preload for COMPRESSIONdamping can be adjusted by turning theknob (2) on top of fork legs. From thefactory the MONSTER T is set with theminimum preload, i.e. the adjustment knobis completely unscrewed counterclockwise.However, springs are slightly preloadedto help counteract static loads duringCOMPRESSION. By turning the adjust-ment knob clockwise, the preload is in-creased up to the maximum value equal to15 mm of spring preload. This adjustmentis essential in order to have the rightMONSTER T response for the rider weightand riding style.

2

REBOUND DAMPING ADJUSTMENT(Fig. O)The r.h. fork leg features an adjuster (E) forREBOUND damping adjustment. Adjust-ment and setting range are the same as forthe COMPRESSION damping adjuster(D) above.

E

MONSTER T

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

▲

DISASSEMBLYGENERAL– The reference numbers given in this section relate to the components shown in the forks exploded view.– These operations refer to the fork legs having already been removed from the crown and disassembled from the brake arch.– Before starting any operation, please read the diagram below. It shows the quickest procedure and the exact sequence in which

it should be disassembled. Start from the part first to be disassembled and then follow the arrows to remove the remaining parts.

DISASSEMBLY DIAGRAM

GUIDE BUSHINGS ANDSEAL ASSEMBLY

CHANGE

DUST SEAL FIG. 7

SLEEVE FIG. 9STOP RING FIG. 10

OIL SEAL FIG. 11

LOWER WASHER FIG. 12

SLIDER BUSHING FIG. 13

CIRCLIP FIG. 9STANCHION TUBE FIG. 8

HYDRAULICCARTRIDGE CHANGE

FOOT NUT FIG. 5

REBOUND SPRING FIG. 6

STANCHION BUSHINGFIG. 9

HYDRAULIC CARTRIDGEFIG. 6

SPRING CHANGE

PRELOAD KNOB FIG. 1

STANCHION TUBE CAPFIG. 3

UPPER WASHER - PRELOADSLEEVE - SPRING - LOWER

WASHER FIG. 4

FORK OIL CHANGE

STOP RING FIG. 2

MONSTER T

SPRING CHANGEFIG. 1Set knob (2) to minimum preload value.Loosen the grub screw (3) fastening thepreload knob (2) by means of a 1.5 mmAllen wrench. Remove grub screw fromcap assembly.

FIG. 2Remove the stop ring (4) from the top of thepreload knob support with a small screw-driver.

FIG. 3Place the stanchion tube in a vice. Be surenot to damage or dent it in the process.Unscrew the cap (5) with a 26 mm endwrench.Remove the cap complete with O-ring (6)from the stanchion tube.

23

45 6

MONSTER T

FIG. 4Push the stanchion tube into the slider andremove the upper washer (8), the preloadsleeve (1) and the spring (9).Let all the oil drain into the fork leg. Byfollowing this procedure, there is no needto check the oil level. Make all necessarychanges.

91

8

22

21

11-35

12

8A

HYDRAULIC CARTRIDGE CHANGEFIG. 5Let all the oil drain out.

WARNING: Remember to alwaysrecycle any used oil.

To change the fork leg oil follow theprocedure as described in REASSEMBLYfrom FIG. 23 to FIG.28.Turn the fork leg upside-down and un-screw the foot nut (22) complete with O-ring (21) by the use of a 15 mm socketwrench.

FIG. 6Pull the hydraulic cartridge (11) or (35)complete with lower washer (8A) andrebound spring (12) out of the stanchiontube.Replace the whole hydraulic cartridge.

IMPORTANT: The hydraulic car-tridge accommodated in the l.h.

fork leg controls COMPRESSION damp-ing. You can tell it from the reboundcartridge by the BLACK inner rod and theholes in cartridge casing.

MONSTER T

GUIDE BUSHINGS AND SEALASSEMBLY CHANGEFIG. 7Use a small screwdriver and remove thedust seal (14) from the top of the slider.Pull the dust seal out of the stanchion tube.

14

13

13 32

13 34

FIG. 8Pull the stanchion tube (13) completely outof the slider.Pull strongly to overcome the resistance ofthe guide bushing (34) of the stanchiontube to slide through the slider bushing(18).

IMPORTANT: the seal unit will bepermanently damaged by the guide

bushing (34).Always change the oil seals after theabove procedure.

FIG. 9A sleeve (33) is located inside the stan-chion tube. Remove the outer snap ring(32) to remove the sleeve (33). Should theguide bushing (34) be damaged, removeit from the stanchion (13) inserting a smallscrewdriver into the bushing slot.

MONSTER T

FIG. 10Remove the stop ring (15) from the sliderby placing the screwdriver bit in one of thethree openings on the stop ring and care-fully lifting the ring out of place.

IMPORTANT: when removing thestop ring, make sure not to damage

its seat.

15

16

A17

FIG. 11Fit the slider protector (A) onto the sliderand remove the oil seal (16) with the helpof a large slot screwdriver.

IMPORTANT: when removing theoil seal, make sure not to damage

its seat. Once removed, the oil sealsshould not be used again.

FIG. 12Remove the upper washer (17) from theslider.

MONSTER T

FIG. 13To remove the guide bushing (18), beatpowerfully the slider edge on a woodensurface. Perform this operation with ex-treme care and try to keep the sliderperpendicular to the wooden surface.

MONSTER T

32

33

13

1617 18

REASSEMBLYCAUTION: before reassembling,all metal components should be

washed carefully with inflammable andbiodegradable solvent and dried withcompressed air.

FIG. 14Fit the sleeve (33), with its completelyopen side facing outwards, on the stan-chion edge (13). Fit the outer snap ring(32). Make sure it is fully seated in thetube.

FIG. 15Stick some adhesive tape onto the stan-chion bottom (13) to protect it. Insert theoil seal (16), duly lubricated, the bushingwasher (17) and the slider guide bushing(18) into the stanchion. Remove the adhe-sive tape and clean the stanchion.

FIG. 16Insert the bit of the flat screwdriver into theguide bushing slot (34) to fit it on thestanchion tube. Ease it into the tube seatby hand.

34

MONSTER T

18

16

13

17 16

B

FIG. 17Gently insert the stanchion tube (13) intothe slider from the bushing side.Fit the guide bushing (18) and the bushingwasher (17) into the slider seat by hand.

FIG. 18Press the oil seal (16) into place until ittouches the lower washer (17) by usingthe seal press (B).

FIG. 19Insert the stop ring (15) making sure it isproperly seated into place.

15

MONSTER T

14

11-35

12

8A

FIG. 20Lubricate the dust seal (14) and insert itinto the top of the slider.Fit it into the slider seat.

HYDRAULIC CARTRIDGEFIG. 21Fit the rebound spring (12) and the lowerwasher (8A) into the hydraulic cartridge.Insert the complete hydraulic cartridge(11) or (35) with the stanchion tube pressedfully down.

IMPORTANT: The cartridge withthe BLACK inner rod goes into the

l.h. fork leg.

FIG. 22Grease the O-ring (21) on the foot nut (22)and screw the nut onto the hydrauliccartridge thread.Tighten to 12 Nm.Pump stanchion up and down severaltimes to make sure it slides properly throughthe stroke.

Nm12

22

21

MONSTER T

100

91

86

HOW TO FILL WITH OILFIG. 23Pour the oil little by little when the stan-chion tube is fully down and then pumpthe cartridge rod (11 and 35) up anddown so as to have a better filling. Car-tridge is full when no air is detected whenpumping, in the fully compressed posi-tion. Check that oil level is 100 mm/3.9in. from the top of the stanchion tube ineach leg.

SPRING AND CAPFIG. 24Fit the spring (9), the preload sleeve (1)and the upper washer (8) into the stan-chion tube.Lubricate the O-ring (10) on the top of thepreload knob support and the O-ring (6)on the cap (5).

FIG. 25Position the plunger (7), into the cap, tothe minimum preload value.Screw the complete plug (5) fully onto thecartridge rod (11) or (35).

56

11-35

MONSTER T

5

Nm12

4

FIG. 26Lift the stanchion tube and fit the plug (5)by hand. Place the stanchion tube in vice.Make sure not to damage or squeeze it.Tighten to 12 Nm.

FIG. 27Fit the stop ring (4) of the preload knobsupport and make sure it is fitted properlyinto its seat.

FIG. 28Fit the preload knob (2), secure it on thesupport and tighten the Allen bolt (3) to1.5 Nm.Fit the brake arch to the fork leg, and theninstall fork legs into crown and upperplate as specified in section “INSTALLA-TION”.

Nm1,52

3

MONSTER T

SPECIFIC MARZOCCHI TOOLS

Ref. Item. Description and use A 536064 GG Slider protector: to remove oil seal from the slider B R 5083 AC Oil seal press: to press oil seal into the slider

B

A