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Z3 Air
(80)
175
+0.05
Ø30
0
80
+0.5
100
0
130
GENERAL
18
• Special air/oil damped cross-country fork: each leg uses pressu-
rized air blown through a special valve on stanchion caps as
damping medium.
• Rebound damping is controlled by pumping rods fixed to the
bottom of each slider; it can also be adjusted through an adjuster
on rh slider bottom.
• Stanchions fitted into lower Crown by cryofit technique. Full length
bushings guarantee superior rigidity.
• Sliders and arch are an integral assembly for reduced weight and
improved rigidity.
• Parts subjected to friction are cooled and lubricated by a specially
Ø30
formulated oil.
Steer tube: stainless steel or, on request, EASTON aluminum steer
tube available for 1 1/8" diameter, threadless.
Crown: Forged and CNC-machined BAM aluminum alloy.
Arch: Cast magnesium alloy.
Stanchions: anodized aluminum with variable butting.
0
15
-0.1
Sliders: Forged and CNC-machined BAM aluminum alloy. Left
+1
20
0
slider comes with supports for disc brake caliper.
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 viscosity
breakdown while providing complete stiction-free performance.
Fork leg oil: 85 cc (each leg), type EBH 16 - SAE 7.5.
+0.1
9.2
0
25
BAM: Bomber Aerospace Material.
Special alloy developed from aerospace material.
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Summary of Contents for Marzocchi Z3 Air
- Page 1 • Stanchions fitted into lower Crown by cryofit technique. Full length bushings guarantee superior rigidity. • Sliders and arch are an integral assembly for reduced weight and Z3 Air improved rigidity. • Parts subjected to friction are cooled and lubricated by a specially Ø30...
- Page 2 • Stanchions fitted into lower Crown by cryofit technique. Full length bushings guarantee superior rigidity. • Sliders and arch are an integral assembly for reduced weight and Z3 Air improved rigidity. • Parts subjected to friction are cooled and lubricated by a specially formulated oil.
-
Page 3: General Rules
4. Before reassembling, lubricate all parts Z3 Air in contact with each other using sili- cone fat spray or a specific oil for seals. 5. Always grease the lip seal rings before reassembling. -
Page 4: 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 Z3 Air Oil leaking through the top of the slider 1. Oil seal is worn out 1. Replace oil seal 2. Stanchion tube is scored 2. -
Page 5: Recommendations For Maintenance
ARZOCCHI installation may jeopardize the safety of performance from the start. However, in as spare parts. Z3 Air the rider. some cases a short running-in period is Tighten the above screws to 15 Nm. To replace it, contact one of our Technical required (5-10 hours) for inner adjust- Service Centers with the required tools. -
Page 6: Fork Leg Pressurization
IMPORTANT: do not force the adjuster tial in order to have the right fork response knob (D) over its limit. Z3 Air for the rider’s weight and riding style. The fork is pre-loaded at the factory to a standard value of 3 bar. -
Page 7: Disassembly Diagram
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 CROWN AND STANCHIONS STANCHION TUBE CAP FIG. 1 ASSEMBLY CHANGE Z3 Air BOTTOM ADJUSTER FIG. 3 PUMPING ROD CHANGE FORK OIL CHANGE FOOT NUT FIG. 4 FOOT BUFFER FIG. 11... - Page 8 Remove adjuster assembly (28) from the WARNING: Remember to always slider. recycle any used oil. To change the fork leg oil follow the procedure as described in section “REASSEMBLY” from Fig. 27 to Fig. 29. Z3 Air...
- Page 9 Remove foot nuts (26) and (7) with a Withdraw the crown and stanchions as- Remove the dust seal (19) from the top of 15 mm socket wrench. sembly (1) from the sliders. the sliders using a small screwdriver. Z3 Air...
- Page 10 IMPORTANT: when removing the stop IMPORTANT: when removing the oil ring, make sure not to damage its seat. seal, make sure not to damage its seat. Once removed the oil seals should not be used again. Z3 Air...
- Page 11 Pull the bushing out of the slider Remove the foot buffer (18) complete from the stanchion tube top. Replace the and make all necessary changes. with ring (25) from the pumping rod ends seal ring (13) if damaged or worn out. (14) and (12). Z3 Air...
- Page 12 (A) and screw inner rod until adjuster Pull the valve assembly (16) out of the threaded end is disengaged from pump- tube with one finger in the same sequence ing element. as in the figure. Remove inner rod and replace O-ring (3) if damaged. Z3 Air...
- Page 13 PILOT BUSHING AND SEAL ASSEMBLY FIG. 15 Check that no dirt or debris is between slider and bushing. Insert the pilot bushing Z3 Air (23) into place so that it adheres to the slider.
- Page 14 Turn inner rod clockwise so that threaded into the slider. end can be seen the into pumping element and stop ring seat (4), marked during disassembly. Fit stop ring (4) into inner rod seat and ring (A) into pumping element seat. Z3 Air...
- Page 15 Insert the stop ring (17). inside of the tube, reassemble. Assemble valve components (16), in correct se- quence. Then fit pumping elements (12) and (14) with seal ring (13) and rebound spring (15) into the valve assembly (16). Z3 Air 12-14...
- Page 16 Press the crown and stanchions assembly fully down and check that threaded ends of pumping elements (14) and (12) are com- Z3 Air ing out through the bottom of the sliders. Check to see that the stanchions slide unrestricted by cycling the fork up and down several times.
- Page 17 JUSTING. crown so as to have a better filling. Check that the oil level is 40 mm from the top of the stanchion tube, in both legs. Z3 Air...
-
Page 18: Specific Marzocchi Tools
SPECIFIC MARZOCCHI TOOLS R e f . I t e m . Description and use R 5089 AB Slider protector: to remove the oil seal from the slider R 5090 Oil seal press: to press oil seal into the slider...
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