Marzocchi Z1 FR 1 2005 Technical Instructions Download Page 27 | Manualshive

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© Marzocchi Suspension

2005

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Z1 FR 1

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Summary of Contents for Z1 FR 1 2005

Page 1: ...2005 Z1 FR 1 Technical instructions Marzocchi Suspension 2005 Z1 FR 1 ...

Page 2: ...28243 1 28 703692KM C 1 29 547640 1 29 547637 1 29 547636 1 30 522387 1 31 523300 1 32 5181224 1 33 5181181 1 36 522403 A 2 38 509145 1 39 5141123 C 1 40 703737LA C 1 41 521142IW A 2 42 850939 C 1 44 520313 1 45 549081AQ 1 46 525007 1 47 5141137 A 1 48 520220AA 1 49 701275 C 1 50 523231 1 51 535112 1 52 528180 1 53 5321188 1 54 531076 1 55 850760 C 1 56 526143RX 2 57 520342AR 2 60 526145AA 2 61 52...

Page 3: ...1 19 5321261RR R A FLAT BLACK TA MONOLITE UNIT 1 19 5321261ST R A MAGNUM GREY FL TA MONOL UNIT 1 19 5321261SR R A SILVER DUST TA MONOLITE UNIT 1 20 547611 RH LH LABELS Z1 FR 1 2005 1 22 528046 O RING 2 23 5321130 B FOOT NUT UNIT 2 27 528243 O RING 1 28 703692KM C ETA CARTRIDGE Z1FR04 TRAVEL130 1 29 547640 ETA 2005 EXTERNAL LABEL 1 29 547637 ETA 2005 LABELS TOP 1 29 547636 replaces 547585 REBOUND A...

Page 4: ...3 5321188 ADJUSTER PIN 1 54 531076 AIR RUBBER 1 55 850760 C FENDER UNIT 1 56 526143RX FENDER BUSHINGS 2 57 520342AR FENDER SCREW 2 60 526145AA BUSHING 2 61 520178PN SCREW 2 62 850777 C QR 20 AXLE SCREW KIT 1 63 520349LA AXLE SCREW QR 20 1 Marzocchi Suspension 2005 Z1 FR 1 ...

Page 5: ...28243 1 28 703700KM C 1 29 547640 1 29 547637 1 29 547636 1 30 522387 1 31 523300 1 32 5181224 1 33 5181181 1 36 522403 A 2 38 509145 1 39 5141123 C 1 40 703737LA C 1 41 521142IW A 2 42 850954 C 1 44 520313 1 45 549081AQ 1 46 525007 1 47 5141137 A 1 48 520220AA 1 49 701275 C 1 50 523231 1 51 535112 1 52 528180 1 53 5321188 1 54 531076 1 55 850760 C 1 56 526143RX 2 57 520342AR 2 60 526145AA 2 61 52...

Page 6: ...IT 1 19 5321261RR R A FLAT BLACK TA MONOLITE UNIT 1 19 5321261ST R A MAGNUM GREY FL TA MONOL UNIT 1 19 5321261SR R A SILVER DUST TA MONOLITE UNIT 1 20 547611 RH LH LABELS Z1 FR 1 2005 1 22 528046 O RING 2 23 5321130 B FOOT NUT UNIT 2 27 528243 O RING 1 28 703700KM C ETA CARTRIDGE Z150 04 1 29 547640 ETA 2005 EXTERNAL LABEL 1 29 547637 ETA 2005 LABELS TOP 1 29 547636 replaces 547585 REBOUND ADJUSTE...

Page 7: ...3 5321188 ADJUSTER PIN 1 54 531076 AIR RUBBER 1 55 850760 C FENDER UNIT 1 56 526143RX FENDER BUSHINGS 2 57 520342AR FENDER SCREW 2 60 526145AA BUSHING 2 61 520178PN SCREW 2 62 850777 C QR 20 AXLE SCREW KIT 1 63 520349LA AXLE SCREW QR 20 1 Marzocchi Suspension 2005 Z1 FR 1 ...

Page 8: ...m alloy forged and CNC machined Stanchions anodised aluminium One piece assembly made of magnesium alloy cast and CNC machined for lighter weight and more stiffness Sliding bushings made of friction free and wear free material Springs constant pitch Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents foam and keeps the viscosity...

Page 9: ... components of Marzocchi forks require the use of metric tools Use only metric tools Imperial US tools may have similar sizes but can damage the bolts making them impossible to loosen or tighten When using a screwdriver to assemble or disassemble metal stop rings O rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Do not carry out any maint...

Page 10: ...the proper fork wheel alignment To do this begin by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Then lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake The wheel should not wobble from side to side or up and down Check the owner s manual of the brake system for t...

Page 11: ...lock cap 2 Push washer 7 and the pre load tube 8 only on models with 150mm travel downwards so you can reach locknut 6 with the 10mm key Holding locknut 6 with the 10mm key use the 21mm key to unscrew the lock cap 2 completely Remove lock cap 2 Dismantling Removing the top left cap With a 2mm Allen wrench loosen screw 4 Remove first the screw 4 then the ETA control knob 5 Marzocchi Suspension 2005...

Page 12: ...ap 2 completely Remove lock cap 2 Dismantling Draining the oil Remove washer 1 the preload tube 2 only for models with 150mm travel and spring 3 from the right leg Remove washer 11 the preload tube 12 and spring 13 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 oil...

Page 13: ... the special 12mm spanner A loosen the bottom nuts 1 of both legs Pull the bottom nuts 1 complete with O rings 2 out of both legs Pull the complete ETA cartridge 9 off the left leg Pull the crown stanchion unit 3 off the arch slider assembly 4 Dismantling Dismantling the right pumping element and valve Using the special round nose pliers remove stop ring 2 Marzocchi Suspension 2005 Z1 FR 1 ...

Page 14: ...ube Remove the complete hydraulic cartridge 5 from the stanchion tube Loosen and remove nut 1 with a 10mm fixed spanner The hydraulic cartridge 5 has been sealed through machining and cannot be overhauled In the case of faults or a malfunctioning this cartridge must be replaced Marzocchi Suspension 2005 Z1 FR 1 ...

Page 15: ...dge must be replaced Dismantling Removing the seals Prize the dust seal 1 off its seat with a small flat tip screwdriver Take great care not to damage the internal surfaces of the one piece assembly while removing the dust seal With the same screwdriver prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the one piece assembly while removing the stop ring Marzocc...

Page 16: ...the extractor keeping the side with larger diameter towards the edge opposite to striker D Fit the extraction washer B with a black finish to the extractor During use remove the non used washer from the extractor Remove first the top bushes then the bottom bushes Fit the extraction washer keeping the blunt side towards the threaded grubscrew C fixed crosswise on to the main rod as shown The slot i...

Page 17: ...bush A in the seat of the sealing ring While holding the main rod in position the aluminium bush will drive the guide bushes during extraction Using striker D knock out and extract the guide bush 1 Remove the guide bush 1 from the extractor Repeat the steps above to remove the bottom guide bush Marzocchi Suspension 2005 Z1 FR 1 ...

Page 18: ...ther tools Fit first the bottom bushes then the top bushes Using the long introducer A fit the bottom bush 1 Using a hammer knock the introducer A into the arch slider assembly Using the short introducer B fit the top bush 2 Using a hammer knock the introducer B into the arch slider assembly Assembling Assembling the seals Insert the spring cup 4 in its seat Marzocchi Suspension 2005 Z1 FR 1 ...

Page 19: ... damage the internal surfaces of the one piece assembly when fitting the stop ring The dust seals shall be refitted when reassembling the crown stanchion unit arch slider assembly Assembling During the assembly of the pumping unit strictly obey the instructions below Do not at any times reverse the position of the pumping elements in the fork legs if you are unsure about anything please refer to t...

Page 20: ...und nose pliers mount the stop ring 2 and check it fits perfectly into its groove Assembling Assembling the ETA cartridge Screw down nut 1 without tightening Assembling Reassembling the steering crown unit arch slider assembly A special spanner shall be used to assemble the bottom nuts Do not at any times use other tools Fit both dust seals 11 to the stanchions Marzocchi Suspension 2005 Z1 FR 1 ...

Page 21: ... complete ETA cartridge 9 in the left leg Using the special 12mm spanner A tighten the bottom nuts 1 complete with O rings 2 of both legs to the recommended tightening torque 10 Nm 1 Using introducer A insert the dust seals 11 in their seats Marzocchi Suspension 2005 Z1 FR 1 ...

Page 22: ...stanchion then pump the fork a few times to eliminate any traces of air Pour the rest of oil in A lower or higher volume or a type of oil other than the one recommended can change the behaviour of the fork in every phase Lift the crown stanchion unit on the arch slider assembly Remove spring 3 the preload tube 2 only for models with 150mm travel and washer 1 from the right leg Remove spring 13 the...

Page 23: ...to damage the O ring Push washer 7 and the preload tube 8 only on models with 150mm travel downwards so you can reach locknut 6 with a 10mm key Using the 10mm and 21mm keys tighten locknut 6 on cap 2 to the recommended tightening torque 6 Nm 1 With the 21mm socket spanner tighten the lock cap 2 on the steering crown to the recommended tightening torque 10 Nm 1 Assembling Assembling the top left ca...

Page 24: ...eload tube 8 downwards so you can reach locknut 6 with a 10mm spanner Using the 10mm and 21mm spanners tighten locknut 6 on cap 2 to the recommended tightening torque 6 Nm 1 With the 21mm socket spanner tighten the lock cap 2 on the steering crown to the recommended tightening torque 10 Nm 1 Fit the ETA control knob 5 and screw 4 Using a 2mm Allen wrench tighten the knob fixing screw 4 to the reco...

Page 25: ...jury or death Once the correct setting has been found we recommend noting the number of clicks or turns of the adjuster with respect to the fully closed position adjuster fully clockwise for a faster re setting of your fork in case of need Setting SAG SAG means the fork bottoming under the biker s weight How to measure the SAG Follow these simple steps to measure the SAG On the leg portion of the ...

Page 26: ... one obstacle and the next Turning adjuster A clockwise increases the hydraulic damping making the fork slower during the rebound phase Turning adjuster A counter clockwise decreases the hydraulic damping making the fork more reactive during the rebound phase Do not force the adjuster beyond its limit of travel Setting ETA Left fork leg The ETA cartridge lets you adjust the rebound damping on the ...

Page 27: ... Marzocchi Suspension 2005 Z1 FR 1 ...

Page 28: ...djustment knob fixing screws 2 0 5 Wheel axle Allen screws 6 1 Wheel axle screws 15 1 User weight Air pressure kg lb bar psi 55 70 121 154 2 00 2 900 00 70 80 154 176 2 00 2 75 2 900 00 3 987 50 80 95 176 209 2 75 3 40 3 987 50 4 930 00 95 110 209 242 4 20 6 090 00 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 130 Left fork leg SAE 7 5 550013 155 Position Oil type Quantity cc Right f...

Page 29: ...an the maximum preload Oil is too fluid Check oil levels Fork is too soft needs more than the maximum preload Spring rate too soft Change to stiffer spring rate Fork stays down or packs up during multiple impacts Rebound damping is too high Decrease rebound damping with the relevant register Front wheel tends to tuck under while turning left or right Rebound damping is too high Decrease rebound da...

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