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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M
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
Z1
in contact with each other using silicone
fat spray or a specific oil for seals.
Wedge
5. Always grease the lip seal rings before
reassembling.
ext.
6. Use wrenches with metric size only.
Wrenches with inch size might damage
Preload
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
special tools only.
ARZOCCHI
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Table of Contents
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Summary of Contents for Marzocchi Z1 Wedge ext. Preload
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing the M special tools only. ARZOCCHI 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.
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Page 2: Failures, Causes And Remedies
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. FAILURES CAUSES REMEDIES Oil leaking though the top of slider 1. -
Page 3: Recommendations For Maintenance
RECOMMENDATIONS FOR INSTALLATION MAINTENANCE Installing the fork on a bicycle is a very DISC BRAKE SYSTEM ASSEMBLY delicate operation that should be carried forks are based on advanced WARNING: If a disc brake system ARZOCCHI out with extreme care. The installation should technology, supported by year-long experi- is installed, it is absolutely forbidden always be checked by one of our Technical... -
Page 4: Spring Preload
ADJUSTMENT SPRING PRELOAD REBOUND ADJUSTMENT VIA Spring preload determines COMPRESSION INNER PUMPING ROD damping and is adjusted by turning the The adjuster controlling REBOUND damp- adjustment knob (3) on the top of the fork ing adjustment is accommodated inside legs. From the factory the fork is set at pumping rod (10) inside each fork leg. -
Page 5: Disassembly Diagram
DISASSEMBLY GENERAL – The reference numbers given in this section relate to the components shown in the fork exploded view. – 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. - Page 6 SPRING CHANGE FIG. 2 PILOT BUSHING AND SEAL FIG. 1 Push the stanchions into the sliders and ASSEMBLY CHANGE Unscrew the caps (4) with a 21 mm socket remove the lower washer (33) and the FIG. 3 wrench. spring (8) from each fork leg. Turn the fork leg upside-down and unscrew Remove the caps complete with O-ring (5) Drain all oil from the fork legs.
- Page 7 FIG. 4 FIG. 5 FIG. 6 Withdraw the crown and stanchions as- Remove the dust seal (15) from the top of Remove the stop ring (16) from the sliders sembly (1) from the sliders (20). the sliders using a small screwdriver. by placing the screwdriver bit in one of the three openings on the stop ring.
- Page 8 FIG. 7 FIG. 8 FIG. 9 Fit the slider protector (A) onto the slider Remove the upper washer (18) from the Fit the bit of a small screwdriver into upper and remove the oil seal (17) with the help slider. edge slot of the pilot bushing (19) and lift of a large screwdriver.
- Page 9 PUMPING ROD CHANGE VALVE ASSEMBLY CHANGE FIG. 10 FIG. 11 Remove the foot buffer (14) with the o-ring To check that the valve assembly is operat- (27) from the pumping rod (10) end. ing correctly, it is necessary to work on the Withdraw the complete pumping rod (10) inside of the stanchion tube.
- Page 10 REASSEMBLY CAUTION: before reassembling, all metal FIG. 13 FIG. 14 components should be washed carefully Fit the upper washer (18) into the slider so Lubricate the oil seal (17) and place it onto with inflammable, preferably biodegrad- that it touches the pilot bushing. the seal press (B) with the hollow side able, solvent and dried with compressed toward the slider.
- Page 11 FIG. 15 FIG. 16 VALVE AND PUMPING ROD Insert the stop ring (16) into the slider Lubricate the dust seals (15) and fit them ASSEMBLY making sure it is properly seated into place. into the stanchions from the spring end. FIG.
- Page 12 FIG. 18 FIG. 19 CROWN AND STANCHIONS Lubricate O-rings (27) and (26) and reas- Fit this assembly into the stanchion tube and ASSEMBLY semble the foot buffer (14) onto the end properly seat the valve assembly (D). FIG. 20 Fit the crown and stanchions assembly (1) part of pumping rod (10).
- Page 13 FIG. 21 HOW TO FILL WITH OIL SPRING AND CAP Screw the foot nut (22) onto the pumping FIG. 22 FIG. 23 rod threaded end (10). Pour oil little by little when the stanchions Fit the spring (8) and lower washer (33) Tighten to 11 Nm.
- Page 14 FIG. 24 Lubricate the O-ring (5) on the cap (4). Turn the preload adjuster (31) counter- clockwise until it is at its minimum setting (see section ADJUSTMENT). Start the complete cap assembly into the stanchion tube thread by hand. Tighten the cap (4) to 20 Nm.
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