Marzocchi Z1 CR Manual
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Marzocchi Z1 CR Manual

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Table of Contents

KIT
12
Z1
C
R
13
32
30
2
4
3
34
5
10
6
10A
7
10D
8
10B
10C
11
9
27
22
16
21
20
19
17
18
1
9
15
14
28
10
10A
10F
10B
10E
26
25
24
23
29
31
12
13
33

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Summary of Contents for Marzocchi Z1 CR

  • Page 2 Oil: Specially formulated oil which eliminates foaming and viscos- ity breakdown while providing complete stiction-free performance. Fork leg oil: type EBH 16- SAE 7.5. 100 c.c. +0.1 +0.5 BAM: Bomber Aerospace Material. Z1 CR MY2000 cod.10211000 Special alloy extracted from aerospace material.

  • Page 3: General Rules For Acorrect Overhauling And Maintenance

    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. If two screws are close one to the other, always tighten using a 1-2-1 sequence.

  • Page 4: Failures, Causes And Remedies

    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. FAILURES CAUSES REMEDIES Oil leaking through the top of slider 1.

  • Page 5: Recommendations For Maintenance

    Installing the Z1 fork on a bicycle is a very Installation procedure may require remov- delicate operation that should be carried MARZOCCHI forks are based on ad- ing the fork legs from the slider. When this out with extreme care.

  • Page 6: Disc Brake System Assembly

    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. When installing the disc brake system, be sure to properly follow the instructions given by the manufacturer.
  • Page 7 ADJUSTMENTS SPRING PRELOAD (Fig. B) COMPRESSION DAMPING REBOUND DAMPING ADJUSTMENT The spring preload for COMPRESSION ADJUSTMENT (Fig. C) (Fig. D) damping can be adjusted by turning the The l.h. fork leg is equipped with an The r.h. fork leg features an adjuster (D) knob (2) on top of fork legs.

  • Page 8: Disassembly Diagram

    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.
  • Page 9 SPRING CHANGE FIG. 2 FIG. 3 FIG. 1 Remove the stop ring (4) from the top of the Place the stanchion tube (13) in a vice Set the knob (2) to the minimum preload preload knob support with a small screw- making sure not to damage or dent it in the position.
  • Page 10 FIG. 4 HYDRAULIC CARTRIDGE CHANGE FIG. 6 Push the stanchion tube into the slider and FIG. 5 Pull the hydraulic cartridge (11) or (29) remove the spring (9). Let all the oil drain out. complete with rebound spring (12) out of Let all the oil drain into the fork leg.
  • Page 11 GUIDE BUSHING AND SEAL FIG. 8 FIG. 9 ASSEMBLY CHANGE Use a small screwdriver and remove the Remove the stop ring (26) from the slider FIG. 7 dust seal (27) from the top of slider. by placing the screwdriver bit in one of the Pull the stanchion tube (13) completely out three openings on the stop ring and care- of the slider.
  • Page 12 FIG. 10 FIG. 11 FIG. 12 Fit the slider protector (A) onto the slider Remove the upper washer (24) from the Fit the bit of a small screwdriver into the and remove the oil seal (25) with the help slider. upper edge slot of the guide bushing (23) of a large slot screwdriver.
  • Page 13 REASSEMBLY CAUTION: before reassembling, FIG. 14 FIG. 15 all metal components should be Fit the upper washer (24) into the slider so Lubricate the oil seal (25) and place it onto washed carefully with inflammable and that it touches the guide bushing. the seal press (B) with the hollow side biodegradable solvent and dried with toward the slider.
  • Page 14 FIG. 16 STANCHION TUBE FIG. 18 Insert the stop ring (26) making sure it is FIG. 17 Lubricate the dust seal (27) and fit it into its properly seated into place in the slider. Fit the stanchion tube (13) gently into the seat in the stanchion.
  • Page 15 HYDRAULIC CARTRIDGE FIG. 20 HOW TO FILL WITH OIL FIG. 19 Grease the O-ring (17) on the foot nut (18) FIG. 21 Fit the rebound spring (12) into the hy- and screw the nut on the hydraulic car- Pour the oil little by little when the stan- draulic cartridge.
  • Page 16 SPRING AND CAP FIG. 23 FIG. 24 FIG. 22 Move the plunger (7), in the cap, to the Take the stanchion tube and fit the cap (5) Fit the spring (9) into the stanchion tube. minimum preload position. by hand. Place the stanchion tube in a vice Lubricate the O-ring (10) on the top of the Screw the cap (5) complete with lower making sure it is not damaged or dented...
  • Page 17 FIG. 25 FIG. 26 Fit the stop ring (4) of the preload knob Fit the preload knob (2) and secure it on support and make sure it is properly the support by tightening the grub screw seated into place. (3) to 1.5 Nm. Fit the brake arch to the fork leg, and then install fork legs into crown as specified in section “INSTALLATION”.

  • Page 18: Specific Tools

    SPECIFIC TOOLS Ref. Item. Description and use 536003 AB Slider protector: to remove the oil seal from the slider R 5068 Oil seal press: to press oil seal into the slider...

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