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 Post subject: Marzocchi XC 400 Rebuild
PostPosted: Tue Jul 07, 2009 3:44 pm 
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Joined: Tue Jul 07, 2009 3:38 pm
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Does anyone have a parts list or instructions for rebuilding a Marzocchi XC 400 suspension fork made in 1993? Any info is greatly appreciated!


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 Post subject:
PostPosted: Tue Jul 07, 2009 6:52 pm 
Deputy National AEC
Deputy National AEC
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Joined: Wed Jun 04, 2008 4:43 pm
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Location: Cumbria, England.
I'm pretty sure you'll find the manual on the Marzocchi website. I serviced some xc 600's (think thats the correct number) a while back and got the manual from there. I had to purchase a special schrader top plug puller from CRC also in order to get to the internals. CRC had a service kit stock for them which was good value and included all the seals etc.


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PostPosted: Wed Jul 08, 2009 1:49 pm 
Devout Dirtbag

Joined: Fri Jan 18, 2008 10:23 pm
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retrorider wrote:
Does anyone have a parts list or instructions for rebuilding a Marzocchi XC 400 suspension fork made in 1993? Any info is greatly appreciated!


I just downloaded the manual from the Marzocchi site yesterday. It's actually the 1994 XC600 manual. That is the earliest one they have available. My fork is stamped 1993, and has no decals. I can't be sure if it is an XC600. It has a 4 position adjuster and the internals are essentially identical to the parts shown in the exploded diagram.

Rebuilding it with the parts I have should not be a problem. My only concern is the quality of the seals and bushings. All the seals are basically o-rings, with the exception of the conical oil seal. I don't know if this seal is supposed to be a tight fit, or if it is designed to allow some oil to flow past it during fork activation. I suspect that it is the latter. I hope so, because replacing this seal may be very difficult. It looks custom made.


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 Post subject:
PostPosted: Wed Jul 08, 2009 3:38 pm 
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Joined: Tue Jul 07, 2009 3:38 pm
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I found the XC 400 manual here: http://manualer.happymtb.org/marzocchi/ ... MANUAL.pdf

The XC 400 is also listed in this manual: http://www.marzocchi.com/admin/download ... getto=2879

From what I have found the seals are 32mm, but there are two types according to this site: http://www.enduroforkseals.com/id261.html

I am guessing the oil is supposed to be 7.5w.


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 Post subject:
PostPosted: Wed Sep 02, 2009 5:17 pm 
Retro Guru
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Joined: Tue Aug 25, 2009 5:35 pm
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Location: Germany
I do have a manual for the XC400, a ServiceManual.

There is a simple reason, the manuel is not downloadable from marzocchi: they startet later with creationg pdf manuals ;-)

A fork which is adjustable in 4 steps ist must be a xc500.
the xc400 is not adjustable.

xc400 and xc500 need 24mm seals. I have some oft them, original.

And of course I have almost every spare part, steering tubes and forksm some are coloured ;-)

==> http://dr-marzocchi.projectweb.de/repar ... chi-xc400/


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