Marzocchi Z3 QR20 User manual

Z3
Q
R
2
0
,,,
,,,
yyy
yyy
30
89
9A
6
7
6A
5
3
2
32
10
11
12
13
14
34
15A
15B
15
16
17 24
25 23
28
26 27
29
31
1
18
19
20
21
22
33
40
41
35
39
38 37
36
42
KIT

Z3
Q
R
2
0
Z3 QR20 MY2000 cod.10211250
TRAVEL 130
178
248.5
348
43 22
442
L.MAX=510.5 L.L.=500.5 L.MIN=370.5
15
1°
58.5
26.5
±2
±2
20
110
130
10
10
82
80
Ø30
GENERAL
• The Z3 fork is sprung by a mechanical spring system and
damped by hydraulic rebound damping.
• Spring pre-load adjustment controlled via external top mount
adjuster, rebound damping adjustment controlled by adjuster
inside each fork leg.
• Stanchions and full length bushings for superior rigidity.
• Stanchions designed with a special safety feature to eliminate
any chance of the stanchions becoming separated from the
crown.
• Parts subjected to friction are cooled and lubricated by a
specially formulated oil.
Steer tube: in CrMo steel with variable butting. Several lengths
availableinthreadedornonthreaded11/8”diameters.EASTON
aluminum steer tubes available in non threaded 1 1/8” diameter.
Crown: Forged and CNC-machined BAM
❊
aluminum alloy.
Arch: Forged and CNC-machined BAM
❊
aluminum alloy.
Stanchions: Anodized EASTON aluminum.
Springs: Constant pitch springs.
Sliders: Forged and CNC-machined BAM
❊
aluminum alloy.
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 viscos-
itybreakdown whileproviding completestiction-free performance.
Fork leg oil: type EBH 16- SAE 7.5: 95 c.c.
❊
BAM: Bomber Aerospace Material.
Special alloy developed from aerospace material.

Z3
Q
R
2
0
GENERAL RULES FOR
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. Alwaysgrease thelip sealringsbefore
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

Z3
Q
R
2
0
FAILURES, CAUSES AND REMEDIES
Thisparagraphreportssomefailuresthatmayoccurwhenusingthefork.Italsoindicatespossiblecausesandsuggestsaremedy.Always
refer to this table before doing any repair work.
Oil leaking through the bottom of slider O-ringonthepumpingrodnutisdamaged Replace the O-ring
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 tubes Raise dust seal and lubricate stanchion tube, dust seal and oil seal
Excessive play of stanchions in the sliders Pilot bushings are worn Replace pilot bushings
FAILURES CAUSES REMEDIES

Z3
Q
R
2
0
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.
INSTALLATION
InstallingtheZ3forkon abicycleis avery
delicate operation that should be carried
out with extreme care.
Theinstallationshouldalwaysbechecked
by one of our Technical Service Centers.
WARNING: Steer tube/headset
mounting and adjustment must be
carried out in compliance with the head-
setmanufacturer’sinstructionseitherwhen
a threaded steer tube or an “A-Head Set”
steer tube is installed. Improper installa-
tion may jeopardize the safety of the
rider.
If you have the steer tube replaced, be
sure to select the correct steer type (A-
Head Set or threaded), diameter and
length for the frame on which it should be
fitted. Contact one of our Technical Serv-
ice Centers to have steer tube installed.
WARNING: In case of improper
installationof the steertube into the
crown, the rider could lose control of his/
her bicycle, thus jeopardizing his/her
safety.
Checkthe torqueof theboltsfasteningthe
stanchionsto the crownand attaching the
brake arch to the sliders at regular inter-
vals (11 Nm).
REMOVING THE FORK LEGS
FROM THE CROWN (Fig. A)
To remove the fork legs from the crown,
loosen the bolts (31) and remove the
safetyring(32).Foreasierremoval,insert
a small screwdriver between the ring and
itsseatandthenremovethecompletefork
legs.
WARNING: Be sure to install the
fork legs safety rings when reas-
sembling, so that the fork legs do not
become separated from the crown even
though the bolts have become loose.
31
32

Z3
Q
R
2
0
Do not use any hub design other than that
specified here, as this would not ensure
proper fastening of the wheel and may
lead to breakdown of the assembly com-
ponents.
FRONT WHEEL ASSEMBLY (Fig. B)
IMPORTANT: fixing the front
wheel properly as specified in the
instructionsgivenbelowisessentialforthe
proper operation of this fork and all re-
lated devices, and therefore for safe rid-
ing. You are advised to follow these
instructions closely.
Slackenthelocknutofthequickreleaselever
so the hub will fit between the fork sliders.
Make sure the quick release bushings (D)
are centered to the recesses in the sliders.
Lock the quick release lever (E) and check
on both sides to make sure the bushings
(D) are properly seated in the sliders.
WARNING:Theseslidersarespe-
cifically designed to fit this type of
hub.
D
E
DISC BRAKE SYSTEM ASSEMBLY
(Fig. C)
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.
Screwthecalipersupport(36)totheslider
(27)using the screws (37)and plate (38).
IMPORTANT: Clean the mating
surfaces inside and outside slider,
otherwise dirt may affect caliper position
orcausethescrews(37)tobecomeloose.
Tighten the screws (37) to 9 Nm.
Wheninstallingthe disc brakesystem,be
sure to properly follow the instructions
given by the manufacturer.
Nm9
27
38
37
36

Z3
Q
R
2
0
ADJUSTMENT
SPRING PRELOAD (Fig. D)
Spring preload determines COMPRES-
SION damping and can be adjusted by
turning the adjuster knob (3) on top of the
fork legs. From the factory the Z3 is set
with the minimum preload, i.e. the adjust-
ment knob is completely unscrewed
counterclockwise. However, the springs
are slightly preloaded to help counteract
static loads. By turning the adjustment
knob clockwise, the preload is increased
up to the maximum value equal to 15
mm’sofspringpreload.Thisadjustmentis
essential in order to have the right Z3
response for the rider’s weight and riding
style.
3
REBOUND ADJUSTER ON INNER
PUMPING ROD (Fig. E)
TheadjustercontrollingREBOUNDdamp-
ing adjustment is accommodated inside
pumping rod (12) inside each fork leg.
To access the adjuster, unscrew the top
cap (30) and push the stanchion tubes
fully down (see Fig. 1).
Fit the supplied hexagon rod (C) into the
stanchion tube and into the adjuster inner
hole. Rotate the adjuster clockwise for
harderdamping,counterclockwise to sof-
ten it.
Refit the cap (30) and tighten it to the
specified torque (see Fig. 24).
WARNING: Do not remove the
springs or this will alter the amount
of oil inside the fork legs.
C
12

Z3
Q
R
2
0
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
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. 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
FORK OIL CHANGE
PUMPING ROD CHANGE
FOOT NUT FIG. 3
SPRING FIG. 2
DUST SEAL FIG. 5
STOP RING. 6
OIL SEAL FIG. 7
PUMPING ROD FIG. 10
REBOUND SPRING FIG. 10
VALVE ASSEMBLY CHANGE
PILOT BUSHING AND SEAL
ASSEMBLY CHANGE
STANCHION TUBE CAP FIG. 1
FOOT BUFFER FIG. 10
STANCHION TUBE FIG. 4
SPRING CHANGE
UPPER WASHER FIG. 8 STOP RING FIG. 11
PILOT BUSHING FIG. 9 VALVE ASSEMBLY FIG. 11

Z3
Q
R
2
0
SPRING CHANGE
FIG. 1
Place the stanchion tube (14) in a vice
making sure it is not damaged or dented
in the process and unscrew the cap (4)
with a 26 mm wrench.
Remove the cap complete with O-ring (5)
from the stanchion tube.
FIG. 2
Pushthe stanchiontube intothe sliderand
remove the washers (9A/9B) and the
spring (10).
Drain all oil from the fork leg.
WARNING:Remembertoalways
recycle any used oil.
To change the fork leg oil follow the
procedure as described in section
“REASSEMBLY” from Fig. 22 to Fig. 24.
PILOT BUSHING AND SEAL
ASSEMBLY CHANGE
FIG. 3
Turn the fork leg upside-down and un-
screw the foot nut (29) complete with O-
ring (28) by the use of a 15 mm socket
wrench.
45
14
10
29
28

Z3
Q
R
2
0
FIG. 4
Withdraw the stanchion tube (14) com-
plete with pumping rod from the slider.
14
18 19
FIG. 5
Remove the dust seal (18) from the top of
the slider using a small screwdriver.
FIG. 6
Remove the stop ring (19) from the slider
byplacingthescrewdriverbitinoneofthe
three openings on the stop ring.
IMPORTANT:whenremovingthe
stopring,makesurenotto damage
its seat.

Z3
Q
R
2
0
FIG. 7
Fit the slider protector (A) onto the slider
and remove the oil seal (20) with the help
of a large screwdriver.
IMPORTANT:whenremovingthe
oil seal, make sure not to damage
itsseat.Onceremovedtheoilsealsshould
not be used again.
20
A
21
22
FIG. 8
Remove the upper washer (21) from the
slider.
FIG. 9
Fitthebitofasmallscrewdriverintoupper
edge slot of the pilot bushing (22) and lift
gently. Pull the bushing out of the slider
and make all necessary changes.

Z3
Q
R
2
0
PUMPING ROD CHANGE
FIG. 10
Remove the foot buffer (17) from the
pumping rod (12) end.
Withdraw the pumping rod (12) and the
rebound spring (13) from the stanchion
tube opposite side. Replace the seal ring
(11) if damaged or worn out.
11
13
17 12
16
15
VALVE ASSEMBLY CHANGE
FIG. 11
To check that the valve assembly is oper-
ating correctly, it is necessary to work on
the inside of the stanchion tube.
Slip off the stop ring (16) using pointed
pliers.
Pull the valve assembly (15) out of the
stanchiontubewithonefingerinthesame
sequence as in the figure.

Z3
Q
R
2
0
REASSEMBLY
CAUTION: before reassembling,
all metal components should be
washed carefully with inflammable, pref-
erably biodegradable, solvent and dried
with compressed air.
PILOT BUSHING AND SEAL
ASSEMBLY
FIG. 12
Check that no dirt or debris is between
sliderandbushing.Insertthepilotbushing
(22) into place so that it adheres to the
slider.
22
21
20
B
FIG. 13
Fitthe upperwasher (21)intothesliderso
that it touches the pilot bushing.
FIG. 14
Lubricatetheoilseal(20)andplaceitonto
the seal press (B) with the hollow side
toward the slider.
Press the oil seal until it touches the upper
washer by using the above seal press.

Z3
Q
R
2
0
FIG. 15
Insert the stop ring (19) making sure it is
properly seated into place.
19
VALVE AND PUMPING ROD
ASSEMBLY
FIG. 16
After having overhauled or replaced the
valve unit and after having cleaned the
inside of the stanchion, reassemble. As-
semble valve components (15), in correct
sequence.
Then fit pumping rod (12), seal ring (11)
and rebound spring (13) into the valve
assembly (15).
13
11
12
15
FIG. 17
Reassemblethefootbuffer(17)ontopump-
ing rod (12) end.
17 12

Z3
Q
R
2
0
14
16
15
14
FIG. 18
Fit this assembly into the stanchion tube
(14)andproperlyseatthevalveassembly
(15).
Insert the stop ring (16).
STANCHION TUBE ASSEMBLY
FIG. 19
Fitthecompletestanchiontube(14)gently
into the oil seal (20).
Rotatethestanchiontubewhileinsertingit
into the seal to facilitate installation and
reducethechanceofdamagingthe seals.
Turn the slider over and check that the
pumping rod (12) is sticking out through
the hole at slider bottom. If not so, use the
hexagon rod (C) to push pumping rod.
FIG. 20
Grease the dust seal (18) and insert it in
the stanchion tube.
Then fit onto the stop of slider.
18

Z3
Q
R
2
0
29
28
Nm 12
45
FIG. 21
GreasetheO-ring(28)onthefootnut(29)
and screw the nut on the hydraulic car-
tridge threaded end.
Tighten to 12 Nm.
Check to verify that the stanchion tube
slidesproperlythroughthestrokebypump-
ing it up and down several times.
HOW TO FILL WITH OIL
FIG. 22
Pour the oil little by little when the stan-
chion tube is fully down and then pump
with the stanchion tube so as to have a
better filling. Check that the oil level is
45 mm/1.77 in. from the top of the
stanchion tube in each leg.
SPRING AND CAP
FIG. 23
Fit the spring (10) into the stanchion tube.
10

Z3
Q
R
2
0
Nm12
45
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. Tighten the cap (4) to 12 Nm.
The brake arch can now be installed on
the fork leg, which should then be in-
stalled into the crown as specified in
section “INSTALLATION”.

Z3
Q
R
2
0
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
C R 5085 Hexagon wrench: to set rebound adjuster
B
AC