Marzocchi Z1 FR 1 2005 Technical Instructions
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Marzocchi Z1 FR 1 2005 Technical Instructions

Marzocchi Z1 FR 1 2005 Technical Instructions

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© Marzocchi Suspension
2005 - Z1 FR 1
2005 - Z1 FR 1
Technical instructions

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Summary of Contents for Marzocchi Z1 FR 1 2005

  • Page 1 © Marzocchi Suspension 2005 - Z1 FR 1 2005 - Z1 FR 1 Technical instructions...
  • Page 2 © Marzocchi Suspension 2005 - Z1 FR 1 Exploded view - Z1 FR 1 130 TA Rif. Code Quantity 1 818223/E 1 818223/R 4 528226 5 701255/C 6 520363 7 549077AQ 8 528149 9 508995/C 10 520341 11 5321153>A 12 533297 13 523261 14 528230>A...
  • Page 3 ECO BLACK- TA MONOLITE UNIT 5321261RR/R>A FLAT BLACK-TA MONOLITE UNIT 5321261ST/R>A MAGNUM GREY FL-TA MONOL.UNIT 5321261SR/R>A SILVER DUST- TA MONOLITE UNIT 547611 RH+LH LABELS Z1 FR 1 2005 528046 O-RING 5321130>B FOOT NUT UNIT 528243 O-RING 703692KM/C ETA CARTRIDGE Z1FR04 TRAVEL130...
  • Page 4 © Marzocchi Suspension 2005 - Z1 FR 1 523231 STOP RING 535112 528180 OR 2015 (D3.69 S1.78) 5321188 ADJUSTER PIN 531076 AIR RUBBER 850760/C FENDER UNIT 526143RX FENDER BUSHINGS 520342AR FENDER SCREW 526145AA BUSHING 520178PN SCREW 850777/C QR 20 AXLE+SCREW KIT...
  • Page 5 © Marzocchi Suspension 2005 - Z1 FR 1 Exploded view - Z1 FR 1 150 TA Rif. Code Quantity 1 818223/E 1 818223/R 4 528226 5 701255/C 6 520363 7 549077AQ 8 528149 9 508995/C 10 520341 11 5321153>A 12 533297 13 523261 14 528230>A...
  • Page 6 ECO BLACK- TA MONOLITE UNIT 5321261RR/R>A FLAT BLACK-TA MONOLITE UNIT 5321261ST/R>A MAGNUM GREY FL-TA MONOL.UNIT 5321261SR/R>A SILVER DUST- TA MONOLITE UNIT 547611 RH+LH LABELS Z1 FR 1 2005 528046 O-RING 5321130>B FOOT NUT UNIT 528243 O-RING 703700KM/C ETA CARTRIDGE Z150/04...
  • Page 7 © Marzocchi Suspension 2005 - Z1 FR 1 523231 STOP RING 535112 528180 OR 2015 (D3.69 S1.78) 5321188 ADJUSTER PIN 531076 AIR RUBBER 850760/C FENDER UNIT 526143RX FENDER BUSHINGS 520342AR FENDER SCREW 526145AA BUSHING 520178PN SCREW 850777/C QR 20 AXLE+SCREW KIT...
  • Page 8 © Marzocchi Suspension 2005 - Z1 FR 1 Technical characteristics: Technical characteristics Single-crown fork with ø 32mm legs. Available travels: 130mm, 150 mm. Right fork leg damping element: spring (air pre-load). Left fork leg damping element: spring. Right fork leg damping system: HSCV cartridge with external rebound adjustment.
  • Page 9 Always grease the seal lips before reassembling. All of the components of Marzocchi forks require the use of metric tools. Use only metric tools. Imperial (US) tools may have similar sizes, but can damage the bolts, making them impossible to loosen or tighten.
  • Page 10 © Marzocchi Suspension 2005 - Z1 FR 1 Warnings: Assembling the wheel For a correct operation of the fork, install the wheel as explained below: Align the center of the wheel with each wheel axle clamp. Insert the wheel axle (1) through the right dropout, the wheel and the left dropout.
  • Page 11 © Marzocchi Suspension 2005 - Z1 FR 1 Dismantling: Removing the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. Dismantling: Removing the top right cap Fully unscrew lock cap (2) using a 21mm socket spanner.
  • Page 12 © Marzocchi Suspension 2005 - Z1 FR 1 Fully unscrew lock cap (2) using a 21mm socket spanner. Lift out lock cap (2). Push washer (7) and the preload tube (8) downwards so you can reach locknut (6) with the 10mm spanner.
  • Page 13 © Marzocchi Suspension 2005 - Z1 FR 1 Dismantling: Breaking down the steering crown unit / arch-slider assembly Use the special spanner to remove the bottom nuts. Do not use other tools. Turn the arch-slider assembly upside down. Using the special 12mm spanner (A), loosen the bottom nuts (1) of both legs.
  • Page 14 © Marzocchi Suspension 2005 - Z1 FR 1 Remove bushing (4), the preload tube (9) ( only for models with 130mm travel ) and rebound spring (7) from the stanchion tube. Remove the complete hydraulic cartridge (5) from the stanchion tube.
  • Page 15 © Marzocchi Suspension 2005 - Z1 FR 1 Dismantling: Dismantling the ETA cartridge Loosen and remove nut (1) with a 10mm fixed spanner. The ETA cartridge (5) has been sealed through machining and cannot be overhauled. In the case of faults or a malfunctioning, this cartridge must be replaced.
  • Page 16 © Marzocchi Suspension 2005 - Z1 FR 1 Protect the upper part of the slider with the special tool (A). With a screwdriver, prize off the sealing ring (3). Remove the sealing ring (3). Take great care not to damage the internal surfaces of the one-piece assembly while removing the sealing ring.
  • Page 17 © Marzocchi Suspension 2005 - Z1 FR 1 Pull the extractor rod so that the upper face of the washer stops against the lower face of the guide bush. Insert the aluminium bush (A) in the seat of the sealing ring.
  • Page 18 © Marzocchi Suspension 2005 - Z1 FR 1 Assembling: Assembling the guide bushes Insert the guide bushes using the special introducers (short type for the top bush and long type for the bottom bush, both with a white finish). Do not use other tools.
  • Page 19 © Marzocchi Suspension 2005 - Z1 FR 1 Smear the dust seal and the sealing ring with some grease. Insert the sealing ring (3) in its seat with the special introducer (A). Using a hammer, knock in introducer (A) and drive the sealing ring home into the arch-slider assembly.
  • Page 20 © Marzocchi Suspension 2005 - Z1 FR 1 Insert the complete hydraulic cartridge (5) into the stanchion. Insert the rebound spring (7), the preload tube (9) ( only for models with 130mm travel ) and bushing (4) into the stanchion.
  • Page 21 © Marzocchi Suspension 2005 - Z1 FR 1 Insert the crown-stanchion unit (3) in the arch-slider assembly (4). Insert the complete ETA cartridge (9) in the left leg. Using the special 12mm spanner (A), tighten the bottom nuts (1) complete with O-rings (2) of both legs to the recommended tightening torque (10 Nm ±...
  • Page 22 © Marzocchi Suspension 2005 - Z1 FR 1 Assembling: Filling with oil Block the fork in the vice, in perfectly vertical position. Lower the crown-stanchion unit on the arch-slider assembly. In a graduated recipient, prepare the quantity of oil to pour into the fork leg (see table).
  • Page 23 © Marzocchi Suspension 2005 - Z1 FR 1 Assembling: Mounting the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. Assembling: Assembling the top right cap Screw the lock cap (2) down on the cartridge rod without tightening being very careful not to damage the O-ring.
  • Page 24 © Marzocchi Suspension 2005 - Z1 FR 1 Screw the lock cap (2) down on the rod of the ETA cartridge without tightening being very careful not to damage the O-ring. Screw the lock cap (2) down on the rod of the ETA cartridge without tightening being very careful not to damage the O-ring.
  • Page 25 During setting don't force the adjusters beyond their limit of travel and don't exceed the max recommended air pressure. To keep the pressure inside the fork’s legs, only use the special MARZOCCHI pump with pressure gauge. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.
  • Page 26 © Marzocchi Suspension 2005 - Z1 FR 1 The pressure values in the table are given as a mere example and can be changed to meet the biker’s riding style and the track condition. Setting: Rebound adjustment Right fork leg: With the rebound adjuster you can control the return speed of the fork after compression.
  • Page 27 © Marzocchi Suspension 2005 - Z1 FR 1...
  • Page 28 © Marzocchi Suspension 2005 - Z1 FR 1 Tightening torques Components Tightening torque (Nm) Cap locknut 6±1 ETA knob fixing screws 2±0,5 Fender fixing screws 6±1 Fork leg top caps 10±1 Pumping element/cartridge bottom nuts 10±1 Rebound adjustment knob fixing screws 2±0,5...
  • Page 29 © Marzocchi Suspension 2005 - Z1 FR 1 Diagnostics Finding the problem Finding the possible cause Possible solutions proposed Anomalous noise from TAS cartridge TAS cartridge damaged Overhaul or replace the TST cartridge Fork doesn't get full travel Oil level too high...

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