Marzocchi Roco WC Coil Rebuild:

INTRODUCTION
This guide will show you how to take apart, service and rebuild a Marzocchi Roco WC coil shock. The procedures covered include Disassembling the shock Cleaning and inspecting the internals Replacing Internal O-Rings Reassembling Final Bleeding

MODELS COVERED
The shock used is a 2011 model, but the procedure is the same for all Roco WC Coils from 2006 to 2011, the only difference between them is that the 2006 model has a steel shaft and the others have alloy shafts. The guide should also provide a solid foundation for the Roco TST R Coil and the Coil R (With external IFP Chamber). The TST R compression system is designed to be interchangeable with the HSCV in the WC, simply remove one and reinstall the other. The Coil R will be near identical, minus the compression internals.

DISCLAMER:
Unlike other brands of shocks, the Marzocchi Roco series is designed to be user serviceable, hence working on the shock shouldnt void any remaining warranty, however, this wont apply to damaged caused during the repair, be careful with the tools and ensure not to round off parts or slip with the spanner and damage the shaft. I AM NOT RESPONSIBLE FOR ANY DAMAGE CAUSED TO YOUR SHOCK, BIKE, PERSONA, SURROUNDINGS OR OTHERS, YOU PERFORM THIS REPAIR AT YOUR OWN RISK. THE REPAIR WORKS IF YOU USE COMMON SENSE WHEN PERFORMING THIS REPAIR AND TAKE YOUR TIME. BASIC MECHANICAL INCLINATION IS NEEDED TO PERFORM THIS REPAIR, IF YOU DAMAGE YOUR SHOCK, YOU WILL HAVE TO PAY FOR REPAIR. A PROPANE TORCH IS REQUIRED TO HEAT CERTAIN PARTS OF THE SHOCK TO SOFTEN INTERNAL LOCTITE. BE VERY GENTLE WITH THE HEAT, ONLY HEAT UNTIL HOT TO TOUCH.

WARNING!
Read all instructions twice before commencing work to ensure you fully understand its procedures.

Preliminaries:
TOOL LIST:
18mm Spanner or shifter 27mm Spanner or shifter Blue Loctite medium thread lock Bench vice O-Ring/Dental picks Clean Rags Clean Work bench Oil Drip Pan Small Breaker Bar 2.5mm Allen Key

PARTS LIST:
Suspension Oil, stock oil weight is 5wt Seal kit

Kits can be purchase through me on my Ebay account, MTBMechanics, or from Marzocchi directly, however these kits direct from Marzocchi can be expensive as they include a brand new piston. I was quoted at $120 AUD for one of these kits. Also included however in the kit is a new dust wiper and main seal. Unlike a Fox DHX, the main seal is a special quad ring seal. However these rarely need to be replaced unless your shock is gushing from the main shaft. I am currently sourcing replacements for these items (minus the piston). Otherwise a local Engineering or Auto supply store should be able to provide you with the necessary o-rings

Note: Main Quad ring can be removed using a 14mm Allen key on the retaining ring after the dust seal is removed. I have not sourced replacements for these yet so it is not covered in this version of the guide, but will be included in future releases Bleed procedure does not take use of the bleed screw and syringe, however it shall be included in future releases once I have refined the technique. The bleed procedure covered will give a proper bleed if done with care and slowly

Repair Guide:

1. Remove the shock from the frame; it will be different for every bike, so if you dont know how to remove your shock, put the tools down NOW. 2. Assemble your tools together.

3. Remove the Rebound Adjuster using a 2.5mm allen key 4. Remove the Compression Adjuster using a 2.5mm allen key

5. Deflate the IFP Chamber 6. Using a shifter or a 27mm wrench, undo the piston shaft end cap, be careful not to slip with the shifter/spanner and damage the shaft

7. Carefully remove the piston assembly, allow oil to drain, then place aside 8. Drain oil in main chamber into a container

9. Return Shock body to vice, then carefully undo IFP Chamber end cap using 27mm spanner or shifter 10.Remove cap and place aside

11.Using shifter or spanner, undo the IFP Chamber 12. Remove chamber

13.Press the IFP out of the chamber and set aside 14.Drain remaining oil form HSCV valve

15.Using a sharp pick, carefully remove the o-ring seated on the HSCV 16.With the o-ring removed, pull out the HSCV, and set it aside

17.Drill a 12mm hole into a block of hardwood, the cut in half to create shaft clamps. (Wood must be a hardwood) 18.Clamp the shaft in the clamps in a vice, the GENTLY heat with a propane torch to soften Loctite. ONLY HEAT UNTIL HOT TO TOUCH! (Tip: Spraying Isopropyl Alcohol on the clamping surface of the shaft clamps will greatly increase their grip)

19.Using 18mm ring spanner, undo the piston bolt 20.Carefully remove the piston/shim assembly, being carefully no to muck up the shims

21.Remove shaft seal housing assembly and set aside 22. Flip the shaft over in the clamps, then GENTLY heat the base of the rebound eyelet until hot to touch

23.Place a long allen key or breaker bar in the eyelet, and unscrew the eyelet 24.Remove the eyelet and place aside

25.Press the Rebound needle out of the shaft 26.Using a sharp pick, carefully remove the rebound needle o-ring

27.Replace the Rebound needle, making sure its properly seated in the groove 28.Using a open ended spanner, carefully remove the dust wiper

29.Clean the inside of the dust wiper and the internal shaft seal 30.Using a sharp pick, remove the bottom out o-ring from the base of the shaft seal housing

31.Remove the seal at the base of the shaft seal housing 32.With all 3 seals removed, replace the o-rings and press the dust wiper back into the housing

33.Remove the IFP o-ring, replace with a new one 34.You have now successfully disassembled the Roco WC

35.Lightly grease the rebound needle with suspension grease, then reinsert back into shaft 36.Ensure all dry Loctite has been cleaned from the threads inside the eyelet

37.Place a small drop of medium strength blue Loctite on the base of the threads on the shaft, ensure it does not drip onto the base of the rebound needle 38.Hand tighten the eyelet onto the shaft

39.Return the Shaft to the shaft clamps, using a allen key/Breaker bar, tighten up the eyelet 40.Grease the internal seal and the inside of the wiper with suspension grease, the reinsert it onto the shaft, taking care not to force it, forcing may cause damage to the shaft, seals or bushing on the inside of the housing

41.Place a small drop of Loctite on the tip of the threads of the piston 42.Flip the shaft in the clamps, and using a 18mm spanner or wrench, retighten the piston assembly. Only tighten till snug, over tightening will crush the shim stack, prevent the shock from rebound and compressing correctly

43.The shaft and piston assemblies have now been rebuild 44.Return the main body of the shock to the vice

45.Reinstall the HSCV spring into the base of the shock bridge, ensure the wider part of the spring goes in first 46.Reinstall the HSCV assembly into the bridge

47.Reinstall a new o-ring into the groove above the HSCV assembly, ensuring that it is correctly seated in the groove 48.Replace the o-ring on the threaded end of the IFP chamber

49.Ensure that a high quality synthetic racing suspension oil is used, stock oil is 5 wt 50.Fill both the main chamber and the IFP chamber with the oil, ensure to fill one side first and allow it to bleed through to the other chamber first

51.Place a rag at the base of the shock, and place the IFP with the bleed screw removed into the chamber. Use caution, as oil will shoot through the bleed hole. Make sure that oil is at the brim of the chamber, then insert piston into the main chamber 52.Using a spanner or shifter, tighten the piston assembly, taking care not to slip with the tool and damaging the shaft

53.Wipe the excess oil from the main chamber 54.Using a measuring device, press the IFP into the chamber, use caution, as oil will shoot out of the bleed hole. The IFP depth on Rocos is between 35mm and 40mm. A shallower depth will give a more progressive stroke, a deeper depth will give a more linear stroke

55.With the IFP inserted, reinstall the bleed screw, drain the excess oil from the chamber, reinstall the chamber end cap and reinflate the IFP chamber to between 170-210 psi 56.Reinstall the adjusters, clean shock of excess oil and cycle the shock to ensure smooth operation. Test all adjusters to ensure correct function 57.Congratulations, you have successfully rebuilt your Roco 58.SUCCESS = BEER!

Troubleshooting:
Answers to common problems: 1. Q.) Shock will not compress or rebound, or is very slow and sticky A.) - Check that piston bolt is not over tightened, over tightening will crush shim stack and prevent proper operation. - Oil used is to thick, use thinner oil - Loctite has seeped into rebound needle, check and clean rebound needle - Check that main dust seal is installed correctly and greased 2. Q.) Oil leaks from shock A.) - O-ring was damaged during assembly, inspect and replace if needed - O-ring was not installed correctly; check all o-rings for correct installation - Inspect shock for damage on sealing surfaces, any significant scratches or gouges will either have to be filled with o-ring sealant or replace 3. Q.) Shock extends very quickly, rebound has no effect and leaks from adjuster A.) Ensure that piston has not been installed upside down Ensure that rebound needle is correctly inserted and has o-ring installed 4. Q.) Compression/Rebound stroke feels different, but same Wt oil used A.) - Shim stack has likely been altered, consult below chart for stock stack 5. Q.) Shock has Squelching noises during compression/rebound stroke A.) Shock has become aerated, repeat bleed procedure

Shim Tuning Tips:

PERFORM AT YOUR OWN RISK!! When altering shims on the main piston, the total number and thickness of the shims combined must not change The following chart shows the stock configuration of a Roco WC, use this for reference during tuning or if the shim stack was mucked up during rebuilding

Compression shim stack

22mm x 0.15mm thick 20mmx 0.15mm thick 19mm x 0.15mm thick 17mm x 0.15mm thick 15mm x 0.15mm thick 11mm x 0.15mm thick Top Out Washer

Qty

Rebound shim stack

18mm x 0.15mm thick 11mm x 1.5mm thick -

Qty

Piston bolt shim

16mm x 0.15mm thick Cir-clip

6-9

Acknowledgments: This guide was compiled by me; Nick_M2r on December 22nd 2010 I hope you found it useful and please leave feedback on the threads I shall read all constructive critisim and update accordingly in future versions of this guide Happy Trails! Version 1