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Marzocchi Z1 CR, Manual

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Marzocchi Z1 CR Manual Download Page 6

Z1

C

R

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.
When installing the disc brake system, be
sure to properly follow the instructions
given by the manufacturer.

Summary of Contents for Z1 CR

Page 1: ...Z1 C R 11 29 12 13 32 17 18 16 22 9 10A 10D 10B 10C 2 30 3 4 5 6 7 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 ...

Page 2: ...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 Anodized EASTON aluminum with variable butting Sliders Cast and CNC mac...

Page 3: ...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 as trichloroethane or trichloroethylene 5 Before reassembling lubricate all parts in contact with each other using sili cone fat spray 6 Always grease the conic seal rings before reassembling 7 Use wrenches wi...

Page 4: ...ube 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 Fork compresses and or rebounds too fast even though the adjuster ...

Page 5: ...teer type A Head Set or threaded steer tube diameter and length for the frame on which it should 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 installation of the steer tube into the crown the rider could lose control of his her bicycle thus jeopardizing his her sa...

Page 6: ...o 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 When installing the disc brake system be sure to properly follow the instructions given by the manufacturer ...

Page 7: ... 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 damping adjustment Turning this adjuster clockwise into the cartridge rod changes the hydraulic setting of the inner valves In short the amount of adjustment applied on the piston in the fluid determines the rate of compression damping To adjust always...

Page 8: ...ickest 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...

Page 9: ...ench Remove grub screw from cap assembly FIG 2 Remove the stop ring 4 from the top of the preload knob support with a small screw driver FIG 3 Place the stanchion tube 13 in a vice making sure not to damage or dent it in the process and unscrew the cap 5 with a 26 mm open end wrench Remove the cap complete with O ring 6 from the stanchion tube 2 3 4 5 6 13 ...

Page 10: ...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 accommodate...

Page 11: ...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 by placing the screwdriver bit in one of the three openings on the stop ring and care fully lifting the ring out of place IMPORTANT when removing the stop ring make sure not to damage its seat ...

Page 12: ... removing the oil seal make sure not to damage its seat Once removed the oil seals should 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 ...

Page 13: ... no dirt or debris is between slider and bushing Insert the guide bush ing 23 into place so that it adheres to the slider 23 24 25 B FIG 14 Fit the upper washer 24 into the slider so that it touches the guide bushing FIG 15 Lubricate the oil seal 25 and place it onto the seal press B with the hollow side toward the slider Press the oil seal into place until it touches the upper washer by using the...

Page 14: ...te installation and reduce the chance of damaging the seals Check to see that the stanchion tube slides 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 Lubricate the dust ...

Page 15: ...he foot nut 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 with the cartridge 11 or 29 rod so as to have a better filling Cartridge is full when no air is detected when pum...

Page 16: ...0 6 8 5 11 29 5 Nm 12 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 Take the stanchion tube and fit the cap 5 by hand Place the stanchion tube in a vice making sure it is not damaged or dented in the process and tighten the cap to 12 Nm ...

Page 17: ... 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 2 3 ...

Page 18: ...Z1 C R 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 ...

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