Marzocchi Z1 CR Bedienungsanleitung

10A

10D

10B

10C

14 28

21 20

10E

10B

10F

10A

KIT

±2

+0.1

178

L.MAX=510.6 L.L.=500.6 L.MIN=370.6

TRAVEL 130

248.5

9.2

58.5

Z1 CR MY2000 cod.10211000

130

100

6.8 6.8

+0.5

348

442.1

±2

Ø30

4322

1°

GENERAL

• The fork is specifically designed for Downhill use and damped

by a coil spring and hydraulic cartridges.

• Rebound damping cartridge inside RH fork leg, compression

damping cartridge in LH fork leg.

• Spring pre-load and hydraulic damping adjustment controlled

via external top mount adjusters.

• Stanchion tubes feature full length 360º slider bushings giving

this fork an incredibly smooth stiction free stroke, in addition to

unmatched structural strength.

• Parts subjected to friction are cooled and lubricated by a

specially formulated oil.

• Stanchion tubes secured to crown so they will not become

separated accidentally.

Steer tube: in CrMo steel with variable butting. Several lengths

available in threaded and non threaded 1 1/8” diameters.

EASTON aluminum steer tubes available for 1 1/8”, threadless.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Forged and CNC-machined BAM

❊

aluminum alloy.

Stanchions: AnodizedEASTONaluminumwithvariablebutting.

Sliders: Cast and CNC-machined BAM

❊

aluminum alloy. Left

slider equipped with disc brake adapter.

Springs: Constant pitch springs.

Slider bushing: Fulllengthguidebushingcomposedofacopper

base and impregnated with an anti-friction coating.

Seals: Computer designed oil seals guarantee the highest quality

seals available.

Oil: Specially formulated oil which eliminates foaming and viscos-

itybreakdownwhile providingcompletestiction-free performance.

Fork leg oil: type EBH 16- SAE 7.5. 100 c.c.

❊

BAM: Bomber Aerospace Material.

Special alloy extracted from aerospace material.

GENERAL RULES FOR A

CORRECT OVERHAULING

AND MAINTENANCE

1. Where specified, assemble and disas-

semble the shock absorption system

using the MARZOCCHI special tools

only.

2. On reassembling the suspension sys-

tem, always use new seals.

3. Iftwoscrewsarecloseonetotheother,

alwaystightenusinga1-2-1sequence.

In short, screw the first screw just up to

thepointitiswelltightened,thentighten

the second screw and then go back to

the first one and screw it tighter.

4. Clean all metal parts with a special,

preferablybiodegradablesolvent,such

astrichloroethaneortrichloroethylene.

5. Beforereassembling,lubricateallparts

in contact with each other using sili-

cone fat spray.

6. Always grease the conic seal rings

before reassembling.

7. Use wrenches with metric size only.

Wrenches with inch size might dam-

age the fastening devices even when

theirsizeissimilartothatofthewrenches

in metric size.

INSTRUCTIONS

FAILURES, CAUSES AND REMEDIES

This 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 dam-

aged Replace the O-ring seal

Oil leaking through the top of slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on slider oil seal

1. Replace oil seal

2. Replace oil seal and stanchion tube

3. Clean the oil seal seat and replace oil

seal

Fork has not been used for some time and

is locked out Oil seals and dust seals tend to stick to

stanchion tube Raise dust seal and lubricate stanchion

tube, oil seal and dust seal

Forkcompressesand/orreboundstoofast

even though the adjuster is set to hardest

damping position

Cartridge is faulty Replace hydraulic cartridge

Excessiveplayofstanchionsintothesliders Main slider bushings are worn Replace main slider bushings

FAILURES CAUSES REMEDIES

RECOMMENDATIONS FOR

MAINTENANCE

MARZOCCHI forks are based on ad-

vanced technology, supported by year-

long experience in the field of profes-

sionalmountainbiking.Inordertoachieve

best results, we recommend to check and

cleantheareabelowthedustsealandthe

stanchion tube after each use and lubri-

cate with silicone oil.

Polishedforksmustbetreatedwithbody

workpolishat regularintervals in orderto

retain their finish.

INSTALLATION

InstallingtheZ1fork on abicycleisa very

delicate operation that should be carried

out with extreme care.

Always have the installation checked at

one of our Technical Service Centers.

WARNING: “A-Head Set” head-

set/Steer tube mounting and ad-

justment must be carried out in compli-

ance with the headset manufacturer’s in-

structions.Improperinstallationmayjeop-

ardize the safety of the rider.

Be sure to install correct steer type, (A-

HeadSetorthreadedsteertube)diameter

andlengthfortheframeonwhichitshould

be fitted. The steer tube is an interference

fit in the crown and must be installed at

one of our Technical Service Centers who

have the proper equipment.

WARNING: In case of improper

installationof thesteer tubeinto the

crown, the rider could lose control of his/

her bicycle, thus jeopardizing his/her

safety.

Checkthetorque ofthebolts fastening the

stanchion tubes to the crown and those

securing the brake arch to the sliders at

regularintervals.Recommendedtorqueis

11 Nm.

REMOVING THE FORK LEGS FROM

THE CROWN (Fig. A)

Installationproceduremayrequireremov-

ingtheforklegsfromtheslider.Whenthis

isthecase,loosenthescrews(28)andslip

off the safety ring (30). Aid removal by

slippingasmallscrewdriverbetweenring

and cap. Remove the complete fork legs.

IMPORTANT: Be sure to refit the

safety rings into the fork legs upon

reassembly so that the fork legs will not

become separated from the crown in the

event the fastening bolts become loose

accidentally.

DISC BRAKE SYSTEM ASSEMBLY

Assembling the brake caliper onto the

slider is a very delicate operation that

should be carried out with extreme care.

Improper assembly might overstress the

caliper supports, which might break.

Wheninstalling the discbrake system, be

sure to properly follow the instructions

given by the manufacturer.

ADJUSTMENTS

SPRING PRELOAD (Fig. B)

The spring preload for COMPRESSION

damping can be adjusted by turning the

knob (2) on top of fork legs. From the

factorytheZ1 forkis set withthe minimum

preload, i.e. the adjustment knob is com-

pletelyunscrewedcounterclockwise.How-

ever, the spring is slightly preloaded to

helpcounteractstaticloads.Byturningthe

adjustmentknobclockwise,thepreloadis

increasedup tothe maximumvalue equal

to 15 mm of spring preload. This adjust-

ment is essential in order to have the right

Z1 response for the rider weight and

riding style.

COMPRESSION DAMPING

ADJUSTMENT (Fig. C)

The l.h. fork leg is equipped with an

adjuster (C, BLACK) for COMPRESSION

dampingadjustment.Turningthisadjuster

clockwise into the cartridge rod, changes

thehydraulicsetting oftheinner valves. In

short, the amount of adjustment applied

on the piston in the fluid determines the

rate of compression damping.

To adjust, always start from the minimum

damping setting, i.e. unscrew completely

counterclockwise. About 8 turns - abt. 4

mm of the adjustment - are possible.

REBOUNDDAMPINGADJUSTMENT

(Fig. D)

The r.h. fork leg features an adjuster (D)

for REBOUND damping adjustment. Ad-

justment and setting range are the same

as for the compression damping adjuster

▲

DISASSEMBLY

GENERAL

– The reference numbers given in this section relate to the components shown in the fork exploded view.

– Operations refer to the fork legs already 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 disassembling

sequence. Start from the part to be disassembled and then follow the arrows to remove the other parts.

DISASSEMBLY DIAGRAM

STOP RING FIG. 2

STANCHION TUBE FIG. 7

DUST SEAL FIG. 8

SPRING FIG. 4

REBOUND SPRING FIG. 6

PRELOAD KNOB FIG. 1

HYDRAULIC CARTRIDGE

CHANGE

FOOT NUT FIG. 5

HYDRAULIC CARTRIDGE FIG. 6

GUIDE BUSHING AND SEAL

ASSEMBLY CHANGE

OIL SEAL FIG. 10

UPPER WASHER FIG. 11

GUIDE BUSHING FIG. 12

STANCHION TUBE CAP FIG. 3

SPRING CHANGE

STOP RING FIG. 9

FORK OIL CHANGE

SPRING CHANGE

FIG. 1

Set the knob (2) to the minimum preload

position.

Loosen the grub screw (3) fastening the

preload knob (2) by means of a 1.5 mm

Allen wrench. Remove grub screw from

cap assembly.

FIG. 2

Removethestopring(4)fromthetopofthe

preload knob support with a small screw-

driver.

FIG. 3

Place the stanchion tube (13) in a vice

makingsurenottodamageordentitinthe

processandunscrewthecap(5)witha26

mm open end wrench.

Remove the cap complete with O-ring (6)

from the stanchion tube.

FIG. 4

Pushthestanchion tubeintothe sliderand

remove the spring (9).

Let all the oil drain into the fork leg. By

following this procedure, there is no need

to check the oil level. Make all necessary

changes.

11-29

HYDRAULIC CARTRIDGE CHANGE

FIG. 5

Let all the oil drain out.

WARNING:Remembertoalways

recycle any used oil.

To change the fork leg oil follow the

procedure as described in section

“REASSEMBLY” from FIG. 21 to FIG. 26.

Turn the fork leg upside-down and un-

screw the foot nut (18) complete with O-

ring (17) by the use of a 15 mm socket

wrench.

FIG. 6

Pull the hydraulic cartridge (11) or (29)

complete with rebound spring (12) out of

the stanchion tube.

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 rebound

cartridgebythe BLACKendand theholes

in cartridge casing.

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