Marzocchi Z3 QR20 Bedienungsanleitung

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15A

15B

17 24

25 23

26 27

38 37

KIT

Z3 QR20 MY2000 cod.10211250

TRAVEL 130

178

248.5

348

43 22

442

L.MAX=510.5 L.L.=500.5 L.MIN=370.5

1°

58.5

26.5

±2

110

130

Ø30

GENERAL

• The Z3 fork is sprung by a mechanical spring system and

damped by hydraulic rebound damping.

• Spring pre-load adjustment controlled via external top mount

adjuster, rebound damping adjustment controlled by adjuster

inside each fork leg.

• Stanchions and full length bushings for superior rigidity.

• Stanchions designed with a special safety feature to eliminate

any chance of the stanchions becoming separated from the

crown.

• Parts subjected to friction are cooled and lubricated by a

specially formulated oil.

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

availableinthreadedornonthreaded11/8”diameters.EASTON

aluminum steer tubes available in non threaded 1 1/8” diameter.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Forged and CNC-machined BAM

❊

aluminum alloy.

Stanchions: Anodized EASTON aluminum.

Springs: Constant pitch springs.

Sliders: Forged and CNC-machined BAM

❊

aluminum alloy.

Slider bushing: Full length guide bushings composed of a

copper 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-

itybreakdown whileproviding completestiction-free performance.

Fork leg oil: type EBH 16- SAE 7.5: 95 c.c.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

GENERAL RULES FOR

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. Alwaysgrease thelip sealringsbefore

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

Thisparagraphreportssomefailuresthatmayoccurwhenusingthefork.Italsoindicatespossiblecausesandsuggestsaremedy.Always

refer to this table before doing any repair work.

Oil leaking through the bottom of slider O-ringonthepumpingrodnutisdamaged 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 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 tubes Raise dust seal and lubricate stanchion

tube, dust seal and oil seal

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

INSTALLATION

InstallingtheZ3forkon abicycleis avery

delicate operation that should be carried

out with extreme care.

Theinstallationshouldalwaysbechecked

by one of our Technical Service Centers.

WARNING: Steer tube/headset

mounting and adjustment must be

carried out in compliance with the head-

setmanufacturer’sinstructionseitherwhen

a threaded steer tube or an “A-Head Set”

steer tube is installed. Improper installa-

tion may jeopardize the safety of the

rider.

If you have the steer tube replaced, be

sure to select the correct steer type (A-

Head Set or threaded), diameter and

length for the frame on which it should be

fitted. Contact one of our Technical Serv-

ice Centers to have steer tube installed.

WARNING: In case of improper

installationof the steertube into the

crown, the rider could lose control of his/

her bicycle, thus jeopardizing his/her

safety.

Checkthe torqueof theboltsfasteningthe

stanchionsto the crownand attaching the

brake arch to the sliders at regular inter-

vals (11 Nm).

REMOVING THE FORK LEGS

FROM THE CROWN (Fig. A)

To remove the fork legs from the crown,

loosen the bolts (31) and remove the

safetyring(32).Foreasierremoval,insert

a small screwdriver between the ring and

itsseatandthenremovethecompletefork

legs.

WARNING: Be sure to install the

fork legs safety rings when reas-

sembling, so that the fork legs do not

become separated from the crown even

though the bolts have become loose.

Do not use any hub design other than that

specified here, as this would not ensure

proper fastening of the wheel and may

lead to breakdown of the assembly com-

ponents.

FRONT WHEEL ASSEMBLY (Fig. B)

IMPORTANT: fixing the front

wheel properly as specified in the

instructionsgivenbelowisessentialforthe

proper operation of this fork and all re-

lated devices, and therefore for safe rid-

ing. You are advised to follow these

instructions closely.

Slackenthelocknutofthequickreleaselever

so the hub will fit between the fork sliders.

Make sure the quick release bushings (D)

are centered to the recesses in the sliders.

Lock the quick release lever (E) and check

on both sides to make sure the bushings

(D) are properly seated in the sliders.

WARNING:Theseslidersarespe-

cifically designed to fit this type of

hub.

DISC BRAKE SYSTEM ASSEMBLY

(Fig. C)

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.

Screwthecalipersupport(36)totheslider

(27)using the screws (37)and plate (38).

IMPORTANT: Clean the mating

surfaces inside and outside slider,

otherwise dirt may affect caliper position

orcausethescrews(37)tobecomeloose.

Tighten the screws (37) to 9 Nm.

Wheninstallingthe disc brakesystem,be

sure to properly follow the instructions

given by the manufacturer.

Nm9

ADJUSTMENT

SPRING PRELOAD (Fig. D)

Spring preload determines COMPRES-

SION damping and can be adjusted by

turning the adjuster knob (3) on top of the

fork legs. From the factory the Z3 is set

with the minimum preload, i.e. the adjust-

ment knob is completely unscrewed

counterclockwise. However, 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’sofspringpreload.Thisadjustmentis

essential in order to have the right Z3

response for the rider’s weight and riding

style.

REBOUND ADJUSTER ON INNER

PUMPING ROD (Fig. E)

TheadjustercontrollingREBOUNDdamp-

ing adjustment is accommodated inside

pumping rod (12) inside each fork leg.

To access the adjuster, unscrew the top

cap (30) and push the stanchion tubes

fully down (see Fig. 1).

Fit the supplied hexagon rod (C) into the

stanchion tube and into the adjuster inner

hole. Rotate the adjuster clockwise for

harderdamping,counterclockwise to sof-

ten it.

Refit the cap (30) and tighten it to the

specified torque (see Fig. 24).

WARNING: Do not remove the

springs or this will alter the amount

of oil inside the fork legs.

▲

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

remove first.

DISASSEMBLY DIAGRAM

FORK OIL CHANGE

PUMPING ROD CHANGE

FOOT NUT FIG. 3

SPRING FIG. 2

DUST SEAL FIG. 5

STOP RING. 6

OIL SEAL FIG. 7

PUMPING ROD FIG. 10

REBOUND SPRING FIG. 10

VALVE ASSEMBLY CHANGE

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 10

STANCHION TUBE FIG. 4

SPRING CHANGE

UPPER WASHER FIG. 8 STOP RING FIG. 11

PILOT BUSHING FIG. 9 VALVE ASSEMBLY FIG. 11

SPRING CHANGE

FIG. 1

Place the stanchion tube (14) in a vice

making sure it is not damaged or dented

in the process and unscrew the cap (4)

with a 26 mm wrench.

Remove the cap complete with O-ring (5)

from the stanchion tube.

FIG. 2

Pushthe stanchiontube intothe sliderand

remove the washers (9A/9B) and the

spring (10).

Drain all oil from the fork leg.

WARNING:Remembertoalways

recycle any used oil.

To change the fork leg oil follow the

procedure as described in section

“REASSEMBLY” from Fig. 22 to Fig. 24.

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 3

Turn the fork leg upside-down and un-

screw the foot nut (29) complete with O-

ring (28) by the use of a 15 mm socket

wrench.

FIG. 4

Withdraw the stanchion tube (14) com-

plete with pumping rod from the slider.

18 19

FIG. 5

Remove the dust seal (18) from the top of

the slider using a small screwdriver.

FIG. 6

Remove the stop ring (19) from the slider

byplacingthescrewdriverbitinoneofthe

three openings on the stop ring.

IMPORTANT:whenremovingthe

stopring,makesurenotto damage

its seat.

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