Marzocchi Z3 QR20 Manual
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Marzocchi Z3 QR20 Manual

Marzocchi Z3 QR20 Manual

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KIT
Z3
10
Q
R
11
yyy
yyy
2
0
12
13
14
32
2
3
5
30
1
6A
42
7
6
8
9
9A
15
15A
15B
16
17
34
26
28
29
38
41
40
31
18
19
20
21
22
24
33
25
23
27
39
35
36
37

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Summary of Contents for Marzocchi Z3 QR20

  • 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: 95 c.c. BAM: Bomber Aerospace Material. 26.5 Special alloy developed from aerospace material. Z3 QR20 MY2000 cod.10211250...
  • Page 3 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 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 through the top of slider 1.

  • Page 5: Recommendations For Maintenance

    Installing the Z3 fork on a bicycle is a very REMOVING THE FORK LEGS delicate operation that should be carried FROM THE CROWN (Fig. A) MARZOCCHI forks are based on ad- out with extreme care. To remove the fork legs from the crown, vanced technology, supported by year-...

  • Page 6: Disc Brake System Assembly

    FRONT WHEEL ASSEMBLY (Fig. B) DISC BRAKE SYSTEM ASSEMBLY IMPORTANT: fixing the front Do not use any hub design other than that (Fig. C) wheel properly as specified in the specified here, as this would not ensure Assembling the brake caliper onto the instructions given below is essential for the proper fastening of the wheel and may slider is a very delicate operation that...
  • Page 7 ADJUSTMENT SPRING PRELOAD (Fig. D) REBOUND ADJUSTER ON INNER Spring preload determines COMPRES- PUMPING ROD (Fig. E) SION damping and can be adjusted by The adjuster controlling REBOUND damp- turning the adjuster knob (3) on top of the ing adjustment is accommodated inside 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 PILOT BUSHING AND SEAL FIG. 1 Push the stanchion tube into the slider and ASSEMBLY CHANGE Place the stanchion tube (14) in a vice remove the washers (9A/9B) and the FIG. 3 making sure it is not damaged or dented spring (10).
  • Page 10 FIG. 4 FIG. 5 FIG. 6 Withdraw the stanchion tube (14) com- Remove the dust seal (18) from the top of Remove the stop ring (19) from the slider plete with pumping rod from the slider. the slider using a small screwdriver. by placing the screwdriver bit in one of the three openings on the stop ring.
  • Page 11 FIG. 7 FIG. 8 FIG. 9 Fit the slider protector (A) onto the slider Remove the upper washer (21) from the Fit the bit of a small screwdriver into upper and remove the oil seal (20) with the help slider. edge slot of the pilot bushing (22) and lift of a large screwdriver.
  • Page 12 PUMPING ROD CHANGE VALVE ASSEMBLY CHANGE FIG. 10 FIG. 11 Remove the foot buffer (17) from the To check that the valve assembly is oper- pumping rod (12) end. ating correctly, it is necessary to work on Withdraw the pumping rod (12) and the the inside of the stanchion tube.
  • Page 13 REASSEMBLY FIG. 13 FIG. 14 Fit the upper washer (21) into the slider so Lubricate the oil seal (20) and place it onto CAUTION: before reassembling, that it touches the pilot bushing. the seal press (B) with the hollow side all metal components should be toward the slider.
  • Page 14 FIG. 15 VALVE AND PUMPING ROD FIG. 17 Insert the stop ring (19) making sure it is ASSEMBLY Reassemble the foot buffer (17) onto pump- properly seated into place. FIG. 16 ing rod (12) end. After having overhauled or replaced the valve unit and after having cleaned the inside of the stanchion, reassemble.
  • Page 15 FIG. 18 STANCHION TUBE ASSEMBLY FIG. 20 Fit this assembly into the stanchion tube FIG. 19 Grease the dust seal (18) and insert it in (14) and properly seat the valve assembly Fit the complete stanchion tube (14) gently the stanchion tube. (15).
  • Page 16 FIG. 21 HOW TO FILL WITH OIL SPRING AND CAP Grease the O-ring (28) on the foot nut (29) FIG. 22 FIG. 23 and screw the nut on the hydraulic car- Pour the oil little by little when the stan- Fit the spring (10) into the stanchion tube.
  • Page 17 FIG. 24 Lubricate the O-ring (5) on the cap (4). Turn the preload adjuster (6) until setting minimum preload and install the lower washers (9B / 9A). Fit the complete cap assembly into the stanchion tube and start cap into thread by hand.

  • 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 R 5085 Hexagon wrench: to set rebound adjuster...

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