Marzocchi Z1 QR20 Manual Download Page 4

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FAILURES, CAUSES AND REMEDIES

This paragraph reports some troubles that may occur when using the fork. It also indicates possible causes and suggests a remedy.
Always refer to this table before doing any repair work.

Oil leaking through the bottom of slider

O-ring seal on the cartridge nut is dam-
aged

Replace the O-ring seal

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 tube

Raise dust seal and lubricate stanchion
tube, oil seal and dust seal

Fork compresses and/or rebounds too fast
even though the adjuster is set to hardest
damping position

Cartridge is faulty

Replace hydraulic cartridge

Excessive play of stanchions into the sliders

Main slider bushings are worn

Replace main slider bushings

FAILURES

CAUSES

REMEDIES

Summary of Contents for Z1 QR20

Page 1: ...Z1 Q R 2 0 11 29 12 13 32 17 18 16 22 9 2 30 3 4 5 6 7 8 28 1 14 15 27 19 26 25 24 23 33 31 21 20 37 13 12 10E 10B 10F 10A 10 9 36 34 35 10 10A 10D 10B 10C 38 KIT ...

Page 2: ...oil Stanchion tubes secured to crown so they will not become separated accidentally Brake caliper adapter available fits onto LH slider Steer tube EASTON aluminum steer tubes available on request 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 machine...

Page 3: ...t 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 ...

Page 4: ... 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 tube Raise dust seal and lubricate stanchion tube oil seal and dust seal Fork compresses and or rebounds too fast even though the adjuste...

Page 5: ...with the headset manufacturer s in structions Improper installation may jeop ardize the safety of the rider 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 s...

Page 6: ...designed to fit this type of hub 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 components 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 sup...

Page 7: ...Fig D The spring preload for COMPRESSION damping can be adjusted by turning the knob 2 on top of fork legs From the factory the Z1 fork is set with the minimum preload i e the adjustment knob is com pletelyunscrewedcounterclockwise How ever the spring is slightly preloaded to help counteract static loads By turning the adjustment knob clockwise the preload is increased up to the maximum value equa...

Page 8: ...quickest 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 UPP...

Page 9: ...wrench 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: ...e 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 accommoda...

Page 11: ...6 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: ...en 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: ...at 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 t...

Page 14: ...tate 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 dus...

Page 15: ... the 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 p...

Page 16: ... 10 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: ...nd 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 Q R 2 0 SPECIFIC MARZOCCHI 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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