Marzocchi Z2 Atom Race Bedienungsanleitung

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GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system us-

ing the M

ARZOCCHI

special tools only, as

shown in the table below.

2. On reassembling the suspension system,

always use new seals.

3. Clean all metal parts with a special,

preferably biodegradable solvent, such

as trichloroethane or trichloroethylene.

4. Before reassembling, lubricate all parts

in contact with each other using silicone

fat spray.

5. Always grease the conic seal rings be-

fore reassembling.

6. Use wrenches with metric size only.

Wrenches with inch size might damage

the fastening devices even when their

size is similar to that of the wrenches in

metric size.

INSTRUCTIONS

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FAILURES, CAUSES AND REMEDIES

This paragraph reports some failures 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 on the cartridge seal nut damaged Replace the O-ring

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

2. Stanchion tube is scored

3. Excessive dirt on oil seal

1. Replace oil seal

2. Replace oil seal and stanchions and

crown assembly

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, dust seal and oil seal with silicone

grease

Fork rebounds too fast even though the

adjuster is set to hardest damping position

Right leg cartridge is faulty Replace hydraulic cartridge

Excessive play of stanchions in the sliders Pilot bushings are worn Replace pilot bushings

FAILURES CAUSES REMEDIES

Fork does not react to adjustments Legs inner parts are dirty Carefully clean and replace oil

Fork does not react to rebound lock LH fork cartridge faulty Replace hydraulic cartridge

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DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake system

is installed, it is absolutely forbidden

to loosen and remove original brake sup-

ports fixing pins. In fact, apart from retain-

ing Cantilever or V-brake levers, they also

play an important role in securing slider

bottom to slider-arch monolith. If needed,

replace these pins with screws (part no.

532979QF) available as spare parts.

Tighten the above screws to 10 Nm.

IMPORTANT: screw and pin threading is

treated to ensure hydraulic seal. Never

reuse screws and pins which have been

removed.

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.

When installing the disc brake system, be

sure to properly follow the instructions given

by the manufacturer.

RECOMMENDATIONS FOR

MAINTENANCE

ARZOCCHI

forks are based on advanced

technology, supported by year-long experi-

ence in the field of professional mountain

biking. In order to achieve best results, we

recommend to check and clean the area

below the dust seal and the stanchion tube

after each use and lubricate with silicone

oil.

In general, M

ARZOCCHI

forks can offer top

performance from the start. However, in

some cases a short running-in period is

required (5-10 hours) for inner adjustments.

This running-in period will make fork life

longer and ensure fork top performance

over time.

IMPORTANT: change oil at least every

100 working hours.

Polished forks should be cleaned with

bodywork polish at regular intervals in

order to preserve their original finish.

INSTALLATION

Installing the fork on a bicycle is a very

delicate operation that should be carried

out with extreme care. The installation should

always be checked by one of our Technical

Service Centers.

WARNING: Steer tube/headset

mounting and adjustment must be

carried out in compliance with the headset

manufacturer’s instructions. Improper in-

stallation may jeopardize the safety of the

rider.

To replace it, contact one of our Technical

Service Centers with the required tools.

WARNING: In case of improper

installation of the steer tube into the

crown, the rider might lose control of his/

her bicycle, thus jeopardizing his/her safety.

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ADJUSTMENTS

SPRING PRELOAD

The spring preload determines COMPRES-

SION damping and can be adjusted by

turning the knob (4) on top of the fork legs.

From the factory the fork is set at minimum

preload, i.e. the adjustment knob com-

pletely unscrewed counterclockwise. How-

ever, the springs are slightly preloaded to

help counteract static loads. By turning the

adjustment knob clockwise, the preload is

increased up to the maximum value equal

to 15 mm’s of spring preload. This adjust-

ment is essential in order to have the right

fork response for the rider’s weight and

riding style.

REBOUND ADJUSTMENT

(only right leg)

The right fork leg is equipped with an

adjuster screw (A) for REBOUND damp-

ing. Turning this adjuster clockwise into the

cartridge rod, changes the hydraulic set-

ting of the inner valves. In short, the amount

of adjustment applied on the piston in the

fluid determines the rate of 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.

REBOUND LIMITER

(only left leg)

In case of hard uphill path, fork leg rebound

can be locked for improved behavior.

Position the knob (3) on l.h. fork leg top to

“LOCK” to lock rebound limit in this posi-

tion; this also allows to decrease fork leg

height for optimal attitude uphill, thus sup-

porting suspension compression operation.

Reposition the knob to its original position

so that the fork will rebound and restart to

work as before.

WARNING: do not position to

“LOCK” when riding downhill as

available travel might not be enough, thus

jeopardizing rider’s safety

LOCK

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DISASSEMBLY

GENERAL

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

– Before starting any operation, please read the diagram below. It shows the quickest procedure and the exact sequence in which it should

be disassembled. Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you will

need to remove first.

DISASSEMBLY DIAGRAM

▲

FOOT NUT FIG. 7

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

CARWON AND STANCHIONS ASSEMBLY

FIG. 9

SPRING CHANGE

PRELOAD KNOB FIG. 2

STANCHION TUBE CAP FIG. 4/5

SPRING FIG. 6

FORK OIL CHANGE

STOP RING FIG. 3

DUST SEAL FIG. 10

STOP RING FIG. 11

OIL SEAL FIG. 12

UPPER WASHER FIG. 13

PILOT BUSHING FIG. 14

COMPLETE HYDRAULIC CARTRIDGE FIG. 8

HYDRAULIC CARTRIDGE CHANGE

“LOCK” KNOB FIG. 1 (left leg)

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SPRING CHANGE

FIG. 1 (only left leg)

Loosen screw (2) and remove rebound

limiting knob (3).

FIG. 2

Set knob (4) of both legs to minimum

preload.

Loosen dowels (6) fastening the preload

knobs by means of a 1.5 mm Allen wrench.

Remove the knobs from the caps.

FIG. 3

Remove preload knob support stop rings

(5) from the top of the cap with a small

screwdriver.

WARNING: never use the fork with-

out upper cap otherwise the stan-

chion might detach from its slider.

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FIG. 4

Unscrew the caps (7) with a 21 mm socket

wrench.

Remove the caps complete with O-ring (8)

from the stanchions.

FIG. 5

Lock the check nuts (39) and remove the

caps (7) from hydraulic cartridges end

(12) and (28).

FIG. 6

Push the stanchions into the sliders.

Remove the lower washer (10) and the

spring (11) in both fork legs.

(only for travel of 80)

In LH fork leg, between lower washer (10)

and spring (11) there is a preload tube

(31).

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.

12-28

Dx. Sx.

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HYDRAULIC CARTRIDGE CHANGE

FIG. 7

Drain all oil from the fork legs.

WARNING: Remember to always

recycle any used oil.

To change the fork leg oil follow the proce-

dure as described in section “REASSEMBLY”

from Fig. 23 to Fig. 29.

Turn the fork leg upside-down and unscrew

the foot nut (20) complete with O-ring (19)

by the use of a 15 mm socket wrench.

FIG. 8

Remove hydraulic cartridges (12) and (28)

and keep the rebound spring.

IMPORTANT: cartridges fitted to forks

with a travel of 100 feature a rebound

spring (26) that is the same fitted in both

fork legs.

Rebound springs in forks with a travel of

80 are different: rebound spring (26) is in

the LH fork leg, while rebound spring (34)

is in the RH fork leg.

Remove the bottom washers (23, see ex-

ploded view) from inside the stanchions.

Replace the whole hydraulic cartridges.

NOTE: the hydraulic cartridge is supplied

with gaskets and lock nut (39). This model

features both support (40) for the preload

knob and spring guide (32).

These parts can be also ordered separately

(see exploded view).

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 9

Pull the crown and stanchions assembly (1)

completely out of the sliders (18).

34-26 26

Dx. Sx.

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FIG. 10

Use a small screwdriver and remove the

dust seal (13) from the top of the slider.

FIG. 11

Remove the stop ring (14) from the slider

by placing the screwdriver bit in one of the

three openings on the stop ring and care-

fully lifting the ring out of place.

IMPORTANT: when removing the stop

ring, make sure not to damage its seat.

FIG. 12

Fit the slider protector (A) onto the slider

and remove the oil seal (15) with the help

of a large slot screwdriver.

IMPORTANT: when removing the oil seal,

make sure not to damage its seat. Once

removed the oil seals should not be used

again.

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FIG. 13

Remove the upper washer (16) from the

slider.

FIG. 14

Fit the bit of a small screwdriver into the

upper edge slot of the pilot bushing (17)

and lift gently. Pull the bushing out of the

slider and make all necessary changes.

Dieses Handbuch passt für folgende Modelle

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