Marzocchi Z1 CR User manual

Z1
C
R
11
29
12
13
32
17
18
16
22
9
10A
10D
10B
10C
2
30
3
4
5
67
8
1
14 28
27
19
26
25
24
23
33
31
21 20
13
12
10E
10B
10F
10A
10
9
15
10
34
KIT

Z1
C
R
±2
+0.1
0
178
L.MAX=510.6 L.L.=500.6 L.MIN=370.6
TRAVEL 130
248.5
9.2
58.5
15
Z1 CR MY2000 cod.10211000
25
130
100
6.8 6.8
+0.5
0
4
80
82
348
442.1
±2
Ø30
4322
1°
GENERAL
• The fork is specifically designed for Downhill use and damped
by a coil spring and hydraulic cartridges.
• Rebound damping cartridge inside RH fork leg, compression
damping cartridge in LH fork leg.
• Spring pre-load and hydraulic damping adjustment controlled
via external top mount adjusters.
• Stanchion tubes feature full length 360º slider bushings giving
this fork an incredibly smooth stiction free stroke, in addition to
unmatched structural strength.
• Parts subjected to friction are cooled and lubricated by a
specially formulated oil.
• Stanchion tubes secured to crown so they will not become
separated accidentally.
Steer tube: in CrMo steel with variable butting. Several lengths
available in threaded and non threaded 1 1/8” diameters.
EASTON aluminum steer tubes available for 1 1/8”, threadless.
Crown: Forged and CNC-machined BAM
❊
aluminum alloy.
Arch: Forged and CNC-machined BAM
❊
aluminum alloy.
Stanchions: AnodizedEASTONaluminumwithvariablebutting.
Sliders: Cast and CNC-machined BAM
❊
aluminum alloy. Left
slider equipped with disc brake adapter.
Springs: Constant pitch springs.
Slider bushing: Fulllengthguidebushingcomposedofacopper
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 viscos-
itybreakdownwhile providingcompletestiction-free performance.
Fork leg oil: type EBH 16- SAE 7.5. 100 c.c.
❊
BAM: Bomber Aerospace Material.
Special alloy extracted from aerospace material.

Z1
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GENERAL RULES FOR A
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. Iftwoscrewsarecloseonetotheother,
alwaystightenusinga1-2-1sequence.
In short, screw the first screw just up to
thepointitiswelltightened,thentighten
the second screw and then go back to
the first one and screw it tighter.
4. Clean all metal parts with a special,
preferablybiodegradablesolvent,such
astrichloroethaneortrichloroethylene.
5. Beforereassembling,lubricateallparts
in contact with each other using sili-
cone fat spray.
6. Always grease the conic seal rings
before reassembling.
7. Use wrenches with metric size only.
Wrenches with inch size might dam-
age the fastening devices even when
theirsizeissimilartothatofthewrenches
in metric size.
INSTRUCTIONS

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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.
Oil leaking through the bottom of slider O-ring seal on the cartridge nut is dam-
aged Replace the O-ring seal
Oil leaking through the top of slider 1. Oil seal is worn out
2. Stanchion tube is scored
3. Excessive dirt on slider oil seal
1. Replace oil seal
2. Replace oil seal and stanchion tube
3. Clean the oil seal seat and replace oil
seal
Fork has not been used for some time and
is locked out Oil seals and dust seals tend to stick to stanchion tube Raise dust seal and lubricate stanchion tube, oil seal and dust seal
Forkcompressesand/orreboundstoofast
even though the adjuster is set to hardest
damping position
Cartridge is faulty Replace hydraulic cartridge
Excessiveplayofstanchionsintothesliders Main slider bushings are worn Replace main slider bushings
FAILURES CAUSES REMEDIES

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RECOMMENDATIONS FOR
MAINTENANCE
MARZOCCHI forks are based on ad-
vanced technology, supported by year-
long experience in the field of profes-
sionalmountainbiking.Inordertoachieve
best results, we recommend to check and
cleantheareabelowthedustsealandthe
stanchion tube after each use and lubri-
cate with silicone oil.
Polishedforksmustbetreatedwithbody
workpolishat regularintervals in orderto
retain their finish.
INSTALLATION
InstallingtheZ1fork on abicycleisa very
delicate operation that should be carried
out with extreme care.
Always have the installation checked at
one of our Technical Service Centers.
WARNING: “A-Head Set” head-
set/Steer tube mounting and ad-
justment must be carried out in compli-
ance with the headset manufacturer’s in-
structions.Improperinstallationmayjeop-
ardize the safety of the rider.
Be sure to install correct steer type, (A-
HeadSetorthreadedsteertube)diameter
andlengthfortheframeonwhichitshould
be fitted. The steer tube is an interference
fit in the crown and must be installed at
one of our Technical Service Centers who
have the proper equipment.
WARNING: In case of improper
installationof thesteer tubeinto the
crown, the rider could lose control of his/
her bicycle, thus jeopardizing his/her
safety.
Checkthetorque ofthebolts fastening the
stanchion tubes to the crown and those
securing the brake arch to the sliders at
regularintervals.Recommendedtorqueis
11 Nm.
REMOVING THE FORK LEGS FROM
THE CROWN (Fig. A)
Installationproceduremayrequireremov-
ingtheforklegsfromtheslider.Whenthis
isthecase,loosenthescrews(28)andslip
off the safety ring (30). Aid removal by
slippingasmallscrewdriverbetweenring
and cap. Remove the complete fork legs.
IMPORTANT: Be sure to refit the
safety rings into the fork legs upon
reassembly so that the fork legs will not
become separated from the crown in the
event the fastening bolts become loose
accidentally.
30
28

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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.
Wheninstalling the discbrake system, be
sure to properly follow the instructions
given by the manufacturer.

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ADJUSTMENTS
SPRING PRELOAD (Fig. B)
The spring preload for COMPRESSION
damping can be adjusted by turning the
knob (2) on top of fork legs. From the
factorytheZ1 forkis set withthe minimum
preload, i.e. the adjustment knob is com-
pletelyunscrewedcounterclockwise.How-
ever, the spring is slightly preloaded to
helpcounteractstaticloads.Byturningthe
adjustmentknobclockwise,thepreloadis
increasedup tothe maximumvalue equal
to 15 mm of spring preload. This adjust-
ment is essential in order to have the right
Z1 response for the rider weight and
riding style.
2
COMPRESSION DAMPING
ADJUSTMENT (Fig. C)
The l.h. fork leg is equipped with an
adjuster (C, BLACK) for COMPRESSION
dampingadjustment.Turningthisadjuster
clockwise into the cartridge rod, changes
thehydraulicsetting oftheinner valves. In
short, the amount of adjustment applied
on the piston in the fluid determines the
rate of compression damping.
To adjust, always start from the minimum
damping setting, i.e. unscrew completely
counterclockwise. About 8 turns - abt. 4
mm of the adjustment - are possible.
C
REBOUNDDAMPINGADJUSTMENT
(Fig. D)
The r.h. fork leg features an adjuster (D)
for REBOUND damping adjustment. Ad-
justment and setting range are the same
as for the compression damping adjuster
(C) above.
D

Z1
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▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
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. Start from the part to be disassembled and then follow the arrows to remove the other parts.
DISASSEMBLY DIAGRAM
STOP RING FIG. 2
STANCHION TUBE FIG. 7
DUST SEAL FIG. 8
SPRING FIG. 4
REBOUND SPRING FIG. 6
PRELOAD KNOB FIG. 1
HYDRAULIC CARTRIDGE
CHANGE
FOOT NUT FIG. 5
HYDRAULIC CARTRIDGE FIG. 6
GUIDE BUSHING AND SEAL
ASSEMBLY CHANGE
OIL SEAL FIG. 10
UPPER WASHER FIG. 11
GUIDE BUSHING FIG. 12
STANCHION TUBE CAP FIG. 3
SPRING CHANGE
STOP RING FIG. 9
FORK OIL CHANGE

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SPRING CHANGE
FIG. 1
Set the knob (2) to the minimum preload
position.
Loosen the grub screw (3) fastening the
preload knob (2) by means of a 1.5 mm
Allen wrench. Remove grub screw from
cap assembly.
FIG. 2
Removethestopring(4)fromthetopofthe
preload knob support with a small screw-
driver.
FIG. 3
Place the stanchion tube (13) in a vice
makingsurenottodamageordentitinthe
processandunscrewthecap(5)witha26
mm open end wrench.
Remove the cap complete with O-ring (6)
from the stanchion tube.
23
4
56
13

Z1
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FIG. 4
Pushthestanchion tubeintothe sliderand
remove the spring (9).
Let all the oil drain into the fork leg. By
following this procedure, there is no need
to check the oil level. Make all necessary
changes.
9
17
18
11-29
12
HYDRAULIC CARTRIDGE CHANGE
FIG. 5
Let all the oil drain out.
WARNING:Remembertoalways
recycle any used oil.
To change the fork leg oil follow the
procedure as described in section
“REASSEMBLY” from FIG. 21 to FIG. 26.
Turn the fork leg upside-down and un-
screw the foot nut (18) complete with O-
ring (17) by the use of a 15 mm socket
wrench.
FIG. 6
Pull the hydraulic cartridge (11) or (29)
complete with rebound spring (12) out of
the stanchion tube.
Replace the whole hydraulic cartridge.
IMPORTANT: The hydraulic car-
tridge accommodated in the l.h.
fork leg controls COMPRESSION damp-
ing. You can tell it from the rebound
cartridgebythe BLACKendand theholes
in cartridge casing.

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GUIDE BUSHING AND SEAL
ASSEMBLY CHANGE
FIG. 7
Pullthestanchiontube(13)completelyout
of the slider.
13
27
26
FIG. 8
Use a small screwdriver and remove the
dust seal (27) from the top of slider.
FIG. 9
Remove the stop ring (26) from the slider
byplacingthescrewdriverbitinoneofthe
three openings on the stop ring and care-
fully lifting the ring out of place.
IMPORTANT:whenremovingthe
stopring,makesurenottodamage
its seat.

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FIG. 10
Fit the slider protector (A) onto the slider
and remove the oil seal (25) with the help
of a large slot screwdriver.
IMPORTANT:whenremovingthe
oil seal, make sure not to damage
itsseat.Onceremovedtheoilsealsshould
not be used again.
25
A
24
23
FIG. 11
Remove the upper washer (24) from the
slider.
FIG. 12
Fit the bit of a small screwdriver into the
upper edge slot of the guide bushing (23)
and lift gently. Pull the bushing out of the
slider and make all necessary changes.

Z1
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REASSEMBLY
CAUTION: before reassembling,
all metal components should be
washed carefully with inflammable and
biodegradable solvent and dried with
compressed air.
GUIDE BUSHING AND SEAL
ASSEMBLY
FIG. 13
Check that no dirt or debris is between
slider and bushing. Insert the guide bush-
ing(23)intoplacesothatitadherestothe
slider.
23
24 25
B
FIG. 14
Fittheupper washer(24)into the sliderso
that it touches the guide bushing.
FIG. 15
Lubricatetheoilseal(25)andplaceitonto
the seal press (B) with the hollow side
toward the slider.
Press the oil seal into place until it touches
theupper washer byusing the aboveseal
press.

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FIG. 16
Insert the stop ring (26) making sure it is
properly seated into place in the slider.
26
13
27
STANCHION TUBE
FIG. 17
Fit the stanchion tube (13) gently into the
dust seal, from the non threaded end.
Rotatethestanchiontubewhileinsertingit
into the seal to facilitate installation and
reducethechanceofdamagingtheseals.
Checktoseethatthestanchiontubeslides
unrestricted by cycling the fork up and
down several times. The tube should slide
freely inside the seal assembly without
any side play. In the event it is too hard or
too soft, repeat the previous steps de-
scribed above and check components to
ensure they are not damaged.
FIG. 18
Lubricatethedustseal(27)andfititintoits
seat in the stanchion.
Fit it into the slider seat.

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HYDRAULIC CARTRIDGE
FIG. 19
Fit the rebound spring (12) into the hy-
draulic cartridge. Insert the complete hy-
draulic cartridge (11) or (29) with the
stanchion pressed fully down into the
slider.
IMPORTANT: The cartridge with
the BLACK adjuster goes into the
l.h. fork leg.
11-29
12
17
18
Nm 12
50
FIG. 20
GreasetheO-ring(17)onthefootnut(18)
and screw the nut on the hydraulic car-
tridge threaded end.
Tighten to 12 Nm.
Pump stanchion up and down several
timestomakesureitslidesproperlythrough
the stroke.
HOW TO FILL WITH OIL
FIG. 21
Pour the oil little by little when the stan-
chion tube is fully down and then pump
withthecartridge(11) or (29)rodsoas to
haveabetterfilling.Cartridgeisfullwhen
no air is detected when pumping, in the
fully compressed position.
Checkthat the oillevel is50 mm/1.97 in.
from the top of the stanchion tube in each
leg.

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SPRING AND CAP
FIG. 22
Fit the spring (9) into the stanchion tube.
Lubricate the O-ring (10) on the top of the
preload knob support and the O-ring (6)
on the cap (5).
910
68
5
11-29
5
Nm12
FIG. 23
Move the plunger (7), in the cap, to the
minimum preload position.
Screw the cap (5) complete with lower
washer (8) onto the cartridge (11) or (29)
rod. Screw cap all the way in.
FIG. 24
Takethe stanchiontubeand fitthe cap(5)
byhand.Placethestanchiontubeinavice
making sure it is not damaged or dented
in the process and tighten the cap to 12
Nm.

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FIG. 25
Fit the stop ring (4) of the preload knob
support and make sure it is properly
seated into place.
4
FIG. 26
Fit the preload knob (2) and secure it on
the support by tightening the grub screw
(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”.
Nm 1,5
23

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