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Discussion Starter · #1 ·
I'm looking for help in servicing the Marzochi EXR Pro Air that came on my 2005 Giant Rainier. This fork has positive air springs in both legs. Feel free to provide tips/links or read on for what I've found and questions unanswered.

The 2005 Zoch manual includes the EXR Pro Air and provides air pressure specs, shows internal adjustments for most fork but not for the EXR Pro Air, and implies that the EXR Pro Air has an 'SSV damping rod' in each leg*.

The Fork Service Thread led me to more info (links below). The first link shows three different procedures for servicing Zochs. The middle one includes a picture of an air cap plug that looks similar those on my EXR Pro Air, though there is no crown shown, which is confusing b/c the air plugs one the EXR Pro Air are at the top of the stanchion sticking out of the crown. It suggests two steps: 1) Release air, 2) Using 21mm wrench remove air plug. Is it really this easy? Is there nothing I have to do with the 'SSV damping rod' or the bolt on the bottom of each leg?

It also specifies using SAE 7.5w oil. Where's the most affordable place to get that?

The next link shows oil levels for a variety of older Zochs including the 2004 EXR Pro Air (EXR does not appear in 2005). It seems to suggests 130cc+. Would that be 130 cubic centimeters per fork leg? How do I get the oil in the fork? Just poor it in after removing the air cap plug?

http://www.windwave.co.uk/documents/techinfo/oilchange&springremoval.pdf
http://www.windwave.co.uk/documents/techinfo/oil level charts.pdf

*--Table 2.2 shows damping by leg for a bunch of models with one column for left leg and another for the right. For the EXR Pro Air these columns are combined and it just says 'SSV damping rod' once.
+--The first column across from the 2004 EXR Pro Air is labeled '55-80 kg'-which I assume is rider weight-and lists '130cc'. The second column labeled '80-90kg' is blank. I interpret this to mean I should put 130cc of oil in each leg of my EXR Pro Air regardless of rider weight.
 

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tenbsmith said:
I'm looking for help in servicing the Marzochi EXR Pro Air that came on my 2005 Giant Rainier. This fork has positive air springs in both legs. Feel free to provide tips/links or read on for what I've found and questions unanswered.

The 2005 Zoch manual includes the EXR Pro Air and provides air pressure specs, shows internal adjustments for most fork but not for the EXR Pro Air, and implies that the EXR Pro Air has an 'SSV damping rod' in each leg*.

The Fork Service Thread led me to more info (links below). The first link shows three different procedures for servicing Zochs. The middle one includes a picture of an air cap plug that looks similar those on my EXR Pro Air, though there is no crown shown, which is confusing b/c the air plugs one the EXR Pro Air are at the top of the stanchion sticking out of the crown. It suggests two steps: 1) Release air, 2) Using 21mm wrench remove air plug. Is it really this easy? Is there nothing I have to do with the 'SSV damping rod' or the bolt on the bottom of each leg?

It also specifies using SAE 7.5w oil. Where's the most affordable place to get that?

The next link shows oil levels for a variety of older Zochs including the 2004 EXR Pro Air (EXR does not appear in 2005). It seems to suggests 130cc+. Would that be 130 cubic centimeters per fork leg? How do I get the oil in the fork? Just poor it in after removing the air cap plug?

http://www.windwave.co.uk/documents/techinfo/oilchange&springremoval.pdf
http://www.windwave.co.uk/documents/techinfo/oil level charts.pdf

*--Table 2.2 shows damping by leg for a bunch of models with one column for left leg and another for the right. For the EXR Pro Air these columns are combined and it just says 'SSV damping rod' once.
+--The first column across from the 2004 EXR Pro Air is labeled '55-80 kg'-which I assume is rider weight-and lists '130cc'. The second column labeled '80-90kg' is blank. I interpret this to mean I should put 130cc of oil in each leg of my EXR Pro Air regardless of rider weight.
I'd buy the oil from a local moto shop - 5 or 7wt. Call Marzocchi for oil level height spec's as the manuals are almost useless.
 

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Discussion Starter · #3 ·
O.k., I've got an e-mail in to Zoch, I'll be interested to see what I get back from them and will post back here with results. In the mean time, I'm still interested in any other advice on this.
 
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