Marzocchi Z1 Free Ride User manual

Z1 Free Ride
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Features
TECHNICAL CHARACTERISTICS
Fork with Ø32 mm legs with spring and
hydraulic rebound damping.
Adjustment of the hydraulic rebound
braking through the knob on the top of the
right leg.
Adjustment of the air preload on the right
leg.
The ETA cartridge in the left leg makes it
possible to limit the extension blocking the
rebound of the fork.
The stanchion tubes are pressed into the
crown with a cryogenic process.
New sliding system to improve the stiffness
and operation.
Magnesium alloy cast one-piece assembly,
CNC machined for lighter weight and more
stiffness.
Components subjected to friction are
lubricated and cooled by means of a
special oil.
Steer tube: steel or reinforced aluminium,
1-1/8", threadless.
Crown: BAM® aluminium alloy forged and
CNC machined.
Stanchions: aluminium.
Springs: constant pitch.
Sliding bushes: made of friction free and
wear free material.
Seals: computer designed oil seals that
guarantee the maximum seal in any
condition.
Oil: special formulated oil that prevents
foam and keeps the viscosity unchanged
while offering high performance; free from
static friction.
Dropout type: Standard or (optional) QR20
Plus in the standard version or in the new
"With Bolt" version.
Disk brake mount: XC International
Standard for 6" disk.
Options: integrated fender.
BAM®: Bomber Aerospace Material:
special alloy coming from the aerospace
industry.

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Features

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Warning
INSTRUCTIONS FOR USE
GENERAL REGULATIONS
FITTING THE FORK ONTO THE FRAME
INSTALLING THE DISK BRAKE SYSTEM
ASSEMBLING THE FENDER
ASSEMBLING THE WHEEL ON FORKS WITH STANDARD DROPOUTS
ASSEMBLING THE WHEEL ON FORKS WITH QR20 PLUS DROPOUTS
ASSEMBLING THE WHEEL ON FORKS WITH QR20 "WITH BOLT" DROPOUTS

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Warning
INSTRUCTIONS FOR USE
MARZOCCHI forks are based on an
advanced technology coming from the
company’s years long experience in the
professional mountain bike industry.
For the best results, it is advisable to
inspect and clean the area below the dust
seal and the stanchion tube after every use
and to lubricate the parts with some
silicone oil.
MARZOCCHI forks usually offer the best
performances since the very first rides.
Notwithstanding this, a short running-in
period may be necessary (5-10 hours) to
adjust the internal couplings. This
precaution will lengthen your fork’s life and
guarantee its best performances.
Changing the oil every 100 hours is
recommended.
The forks with a polished finish must be
treated periodically with polishing paste to
keep the exterior shining like new.

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Warning
GENERAL REGULATIONS
· After a complete breakdown, always use
new MARZOCCHI seals when
reassembling.
· Before reassembly, wash all new and old
components and dry them with some
compressed air, making sure there are
neither breaks nor burrs.
· Never use flammable or corrosive
solvents to clean the parts as this could
damage the seals. If necessary use specific
detergents that are not corrosive, not
flammable or have a high flash point
compatible with the materials of the seals
and preferably biodegradable.
· Before reassembling, always lubricate the
parts of the fork in contact with some oil for
forks.
· Never pour lubricants, solvents or
detergents which are not completely
biodegradable in the environment; these
must be collected and kept in the relevant
special containers, then disposed of in
accordance with the regulations in force.
· Always grease the seal lips before
reassembling.
· Use only metric spanners and not
imperial. Imperial spanners may have
similar sizes to metric ones but they can
damage the bolts and screws making it
impossible to unscrew them.
· Use the right size and sort of screwdriver
to unscrew slotted or crosshead screws.
· When using a screwdriver to assemble or
dismantle metal stop rings, O-ring seals,
guide bushes or seal segments, avoid
scratching or cutting the components with
the tip of the screwdriver.
· Use only original spare parts.
· Before servicing the fork, we recommend
washing the fork thoroughly.
· Work in a clean, ordered and well-lit place.
· Carefully check there are no metal
shavings in the work area.

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Warning
FITTING THE FORK ONTO THE FRAME
The fork is supplied with “A-Head Set” steer
tube to be cut according to frame size it will
be used on.
Fitting the fork onto the bike frame is a very
delicate operation that must be carried out
at one of our service centres only.
The assembling on the frame and the
adjustment of the steer tube must be
carried out following the instructions of the
steering set manufacturer.
A wrong installation can be dangerous
for the rider.
Marzocchi does not guarantee the
assembly and accepts no liability for
damage and/or accidents arising from a
wrong installation.
The steer tube must be pressed into the
crown; its replacement must be carried
out by one of our service centres using
the adequate tools.
A wrong installation of the steer tube
into the crown may cause the rider to
lose the control of the bike and lead to
serious personal injury.

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Warning
INSTALLING THE DISK BRAKE SYSTEM
Installing the brake system is a very
delicate operation that must be carried out
at our specialised service centres only.
Marzocchi does not guarantee the
installation and accepts no liability for
damage and/or accidents arising from a
wrong installation
Improper installation of the disk brake
system can overstress the caliper
mountings, which may break. The
installation of the brake system must be
carried out following the instructions of
the brake system manufacturer.
Improper installation can be dangerous
for the rider.
Use only brake systems in accordance with
the fork’s specifications.
After installation always check that the
brake tube is correctly fixed to the
special mount (A).

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Warning
ASSEMBLING THE FENDER
The fender can be supplied with the fork or
purchased separately.
Assemble the fender (A) by inserting the
small support bush (C) between the screw
and the fender as shown, and by tightening
the screws (B) with an 8mm hexagonal
spanner to the required torque (8±1 Nm).

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Warning
ASSEMBLING THE WHEEL ON FORKS
WITH STANDARD DROPOUTS
Install the wheel following the
instructions of the bike’s manufacturer.
A good and reliable operation of the fork
and all of the parts linked to it mainly
depend on the correct fixing of the front
wheel.
For a correct operation of the fork, install
the wheel as explained below:
Check the correct fork-wheel alignment by
fully compressing the fork a few times.
Lift the front wheel above the ground; turn
the wheel a few times to verify the correct
alignment with the disk brake.

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Warning
ASSEMBLING THE WHEEL ON FORKS
WITH QR20 PLUS DROPOUTS
A good and reliable operation of the fork
and all of the parts linked to it mainly
depend on the correct fixing of the front
wheel.
For a correct operation of the fork, install
the wheel as explained below:
· Unlock the locking device on both legs
pushing levers (A) downwards and opening
the small flap (P).
· For quick-release hubs, open the release
lever (B).
· For hubs with threaded cap, loose cap (C)
as much as needed to insert the wheel axle
through the wheel axle clamps.
· Insert the wheel axle (D) into the wheel
axle clamps.
· Check that the wheel axle supporting
bushes (E) are centred in the slider’s seat.
· If the wheel axle is equipped with a
quick-release system, lock the wheel with
the quick-release lever (B); otherwise, with
a 6mm Allen wrench, tighten the cap to the
side of the wheel axle to the recommended
tightening torque (see table - Tightening
torques).
· Verify the supporting bushes (E) stay
correctly.
· Check the correct fork-wheel alignment by
fully compressing the fork a few times.
the wheel a few times to verify the correct
alignment with the disk brake.
· Lock the locking device pulling levers (A)
upwards and adjust the clearance with the
adjusters (H), if necessary.

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Warning
ASSEMBLING THE WHEEL ON FORKS
WITH QR20 "WITH BOLT" DROPOUTS
A good and reliable operation of the fork
and all of the parts linked to it mainly
depend on the correct fixing of the front
wheel.
For a correct operation of the fork, install
the wheel as explained below:
Using a 6mm Allen wrench, loosen both
screws (L) and open the locking device (M).
For quick-release hubs, open the release
lever (B).
For hubs with threaded cap, loose cap (C)
as much as needed to insert the wheel axle
through the wheel axle clamps.
Insert the wheel axle (D) into the wheel axle
clamps.
Check that the wheel axle supporting
bushes (E) are centred in the slider’s seat.
If the wheel axle is equipped with a
quick-release system, lock the wheel with
the quick-release lever (B); otherwise, with
a 6mm Allen wrench, tighten the cap to the
side of the wheel axle to the recommended
tightening torque (see table - Tightening
torques).
Verify the supporting bushes (E) stay
correctly.
Check the correct fork-wheel alignment by
fully compressing the fork a few times.
Lift the front wheel above the ground; turn
the wheel a few times to verify the correct
alignment with the disk brake.
Close the locking device (M) and tighten
both screws (L) with a 6mm Allen wrench.

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Diagnostic

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Disassembling
REMOVING THE TOP CAP – RIGHT LEG
REMOVING THE TOP CAP – LEFT LEG
DRAINING THE OIL
BREAKING DOWN THE CROWN-STANCHION UNIT / ARCH-SLIDER ASSEMBLY
REMOVING THE CARTRIDGE – LEFT LEG
REMOVING THE ETA CARTRIDGE - LEFT LEG
REMOVING THE SEALS
REMOVING THE GUIDE BUSHES

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Disassembling
REMOVING THE TOP CAP - RIGHT LEG
· With a 2mm Allen wrench loosen screw (1
).
· Remove first the screw (1), then the
adjusting knob (3).
· Fully unscrew the lock cap (4), using a
21mm socket spanner.
· Lift out the lock cap (4).

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Disassembling
Push washer (6) and the preload tube (7)
downwards so you can reach locknut (5)
with a 10mm spanner.
· Holding locknut (5) with the 10mm
spanner, use the 21mm spanner to
unscrew the lock cap (4) completely.
· Remove the lock cap (4).

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Disassembling
REMOVING THE TOP CAP – LEFT LEG
· With a 2mm Allen wrench loosen screw (1
).
· Remove first the screw (1), then the ETA
control knob (3).
· Fully unscrew the lock cap (4) using a
21mm socket spanner.
· Lift out the lock cap (4).

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Disassembling
Push washer (6) and the preload tube (7)
downwards so you can reach locknut (5)
with a 10mm spanner.
· Holding locknut (5) with the 10mm
spanner, use the 21mm spanner to
unscrew the lock cap (4) completely.
· Remove the lock cap (4).

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Disassembling
DRAINING THE OIL
· Remove washer (3), the preload tube (1)
and spring (2) from the right leg.
· Remove washer (13), the preload tube (11
), and spring (12) from the left leg.
· Free the fork from the vice and tip it into a
container of a suitable size to drain the oil;
compress the fork a few times to help the
oil flow out.
Do not pour used oils on the ground.

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Disassembling
BREAKING DOWN THE
CROWN-STANCHION UNIT /
ARCH-SLIDER ASSEMBLY
Use the special spanner to remove the
bottom nuts. Do not use other tools.
Using the special 12mm spanner (A),
loosen the two bottom nuts (1).
Remove the bottom nuts (1) and the
O-rings (2).
Pull the complete hydraulic cartridge (10)
off the right leg.
Pull the complete ETA cartridge (9) off the
left leg.

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Disassembling
· Pull the crown-stanchion unit (3) off the
arch-slider assembly (4).