Marzocchi Z1 Free Ride Manual Download | Manualshive

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Z1 Free Ride

21/45

Disassembling

REMOVING THE HYDRAULIC
CARTRIDGE - RIGHT LEG

· Loosen and remove nut (

1

)

with a 10mm

spanner with fixed jaws.

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.

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Summary of Contents for Z1 Free Ride

Page 1: ...ess 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 form...

Page 2: ...Z1 Free Ride 2 45 Features ...

Page 3: ...LATIONS 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 ...

Page 4: ...fter 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 ...

Page 5: ...e 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 th...

Page 6: ... 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 to...

Page 7: ...cidents 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 a...

Page 8: ...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 ...

Page 9: ...ation 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 ...

Page 10: ...ough 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 t...

Page 11: ...l 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...

Page 12: ...Z1 Free Ride 12 45 Diagnostic ...

Page 13: ... 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 ...

Page 14: ...45 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 ...

Page 15: ...assembling 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 ...

Page 16: ...5 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 ...

Page 17: ...assembling 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 ...

Page 18: ...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 ...

Page 19: ...BLY 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 ...

Page 20: ...Z1 Free Ride 20 45 Disassembling Pull the crown stanchion unit 3 off the arch slider assembly 4 ...

Page 21: ...HYDRAULIC CARTRIDGE RIGHT LEG Loosen and remove nut 1 with a 10mm spanner with fixed jaws 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 ...

Page 22: ...G THE ETA CARTRIDGE LEFT LEG Loosen and remove nut 1 with a 10mm spanner with fixed jaws The ETA cartridge 5 has been sealed through machining and cannot be overhauled In the case of faults or a malfunctioning this cartridge must be replaced ...

Page 23: ...emove the dust seal 1 from its seat using a small flat tip screwdriver With the same screwdriver prize off the metal stop ring 2 Take great care not to damage the internal surfaces of the arch slider assembly when removing the dust seal and the stop ring ...

Page 24: ...pecial tool A With a screwdriver prize the sealing ring 3 off Remove the sealing ring 3 Take great care not to damage the internal surfaces of the arch slider assembly when removing the sealing ring The old sealing rings and dust seals must not be used again Remove the spring cup 4 ...

Page 25: ...pecial tool A With a screwdriver prize the sealing ring 3 off Remove the sealing ring 3 Take great care not to damage the internal surfaces of the arch slider assembly when removing the sealing ring The old sealing rings and dust seals must not be used again Remove the spring cup 4 ...

Page 26: ...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 in the rod lets the extraction washer swing inside the rod itself Insert the extractor in the arch slider assembly from the side of washer B...

Page 27: ...Z1 Free Ride 27 45 Assembling ASSEMBLING THE GUIDE BUSHES ...

Page 28: ...pecial introducers short type for the top bush and long type for the bottom bush both with a white finish Do not use other 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 ...

Page 29: ...Z1 Free Ride 29 45 Assembling Using the short introducer B fit the top bush 2 Using a hammer knock the introducer B into the arch slider assembly ...

Page 30: ...S Fit the dust seal 4 in its seat Smear the dust seal and the sealing ring with some grease Refit the sealing ring 3 using the special introducer A Using a hammer knock in the introducer A and drive the sealing ring home into the arch slider assembly ...

Page 31: ...t the stop ring 2 and check it fits perfectly into its groove Take great care not to damage the internal surfaces of the arch slider assembly when fitting the stop ring The dust seals shall be refitted when reassembling the crown stanchion unit arch slider assembly ...

Page 32: ...Z1 Free Ride 32 45 Assembling MOUNTING THE HYDRAULIC CARTRIDGE RIGHT LEG Screw down nut 1 without tightening ...

Page 33: ...Z1 Free Ride 33 45 Assembling ASSEMBLING THE ETA CARTRIDGE LEFT LEG Screw down nut 1 without tightening ...

Page 34: ...BLING THE CROWN STANCHION UNIT ARCH SLIDER ASSEMBLY A special spanner shall be used to assemble the bottom nut Do not use other tools Fit the dust seals 11 to the stanchions Insert the crown stanchion unit 3 in the arch slider assembly 4 ...

Page 35: ...it the complete hydraulic cartridge 10 in the right leg Fit the complete ETA cartridge 9 in the left leg With the special 12mm spanner A tighten the bottom nut 1 with O ring 2 of both legs to the recommended tightening torque 11 Nm 1 ...

Page 36: ...Z1 Free Ride 36 45 Assembling Re assemble the dust seals 11 in their seats using the special introducer A ...

Page 37: ...ly 1 3 of the oil required into each stanchion then pump the fork a few times to remove any traces of air Pour the rest of the oil in Lower again the crown stanchion unit on the arch slider assembly Wait for a few minutes and check the volume of the air h if necessary refill to the right level A lower or higher volume of air or a type of oil other than the recommended type can change the behaviour...

Page 38: ...ide 38 45 Assembling Lift the crown stanchion unit on the arch slider assembly Insert spring 2 the preload tube 1 and washer 3 in the right leg Insert spring 12 the preload tube 11 and washer 13 in the left leg ...

Page 39: ...own on the cartridge rod without tightening being very careful not to damage the O ring Push washer 6 and the preload tube 7 downwards so you can reach locknut 5 with a 10mm spanner Using the 10mm and 21mm spanners tighten locknut 5 on cap 4 to the recommended tightening torque 6 Nm 1 ...

Page 40: ...he 21mm socket spanner tighten the lock cap 4 on the steering crown to the recommended tightening torque 20 Nm 1 Fit the adjusting knob 3 and screw 1 Using the 2mm Allen wrench tighten screw 1 to the recommended tightening torque 2 Nm 0 5 ...

Page 41: ... on the ETA cartridge rod without tightening being very careful not to damage the O ring Push washer 6 and the preload tube 7 downwards so you can reach locknut 5 with a 10mm spanner Using the 10mm and 21mm spanners tighten locknut 5 on cap 4 to the recommended tightening torque 6 Nm 1 ...

Page 42: ... 21mm socket spanner tighten the lock cap 4 on the steering crown to the recommended tightening torque 20 Nm 1 Fit the ETA control lever 3 and screw 1 Using the 2mm Allen wrench tighten screw 1 to the recommended tightening torque 2 Nm 0 5 ...

Page 43: ...Z1 Free Ride 43 45 Settings REBOUND ADJUSTMENT ETA TRAVEL LIMITING DEVICE ...

Page 44: ...ulic configuration of the internal valves and lets more or less oil flow through Turning the adjuster clockwise increases the hydraulic damping making the fork slower during the rebound phase Turning the adjuster counter clockwise decreases the hydraulic damping making the fork more responsive during the rebound phase Do not force the adjuster A beyond its limit stops ...

Page 45: ...ing the fork travel to 30 mm Turning the control A clockwise activates the ETA cartridge function Turning the control A counter clockwise brings the fork back to normal function and deactivates the limiting device Do not use the ETA devices when riding on steep downhills The fork would not react safely enough when hitting an obstacle ...

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