Marzocchi Z3 QR20 Manual Download

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QR20

(110)

TRA

VEL 110

+0.5

175

426

L.MAX=491

L.L.=481 L.MIN=371

248.5

26.5

130

110

Ø30

-0.1

Ø30

+0.05

GENERAL

• The fork is sprung by a mechanical coil system and uses hydraulic

rebound damping.

• Spring pre-load adjustment controlled via external top mount

adjuster, rebound damping adjustment controlled by bottom
adjuster of right fork leg.

• Stanchions fitted into lower Crown by cryofit technique. Full length

bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weight and

improved rigidity.

• Parts subjected to friction are cooled and lubricated by a specially

formulated oil.

• QR20 wheel shaft retaining system for special hubs (110-mm stop)

and wheel shafts with 20-mm diameter.

Steer tube:

stainless steel or, on request, EASTON aluminum steer

tube available for 1 1/8” diameter, threadless.

Crown:

Forged and CNC-machined BAM

❊

aluminum alloy.

Arch:

Cast magnesium alloy.

Stanchions:

anodized EASTON aluminum with variable butting.

Springs:

Constant pitch springs.

Sliders:

Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

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 viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil:

85 cc (each leg), type EBH 16 - SAE 7.5.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

Summary of Contents for Z3 QR20

Page 1: ... hubs 110 mm stop and wheel shafts with 20 mm diameter Steer tube stainless steel or on request EASTON aluminum steer tube available for 1 1 8 diameter threadless Crown Forged and CNC machined BAM aluminum alloy Arch Cast magnesium alloy Stanchions anodized EASTON aluminum with variable butting Springs Constant pitch springs Sliders Forged and CNC machined BAM aluminum alloy Left slider comes with...

Page 2: ... hubs 110 mm stop and wheel shafts with 20 mm diameter Steer tube stainless steel or on request EASTON aluminum steer tube available for 1 1 8 diameter threadless Crown Forged and CNC machined BAM aluminum alloy Arch Cast magnesium alloy Stanchions anodized EASTON aluminum with variable butting Springs Constant pitch springs Sliders Forged and CNC machined BAM aluminum alloy Left slider comes with...

Page 3: ...pecial hubs 110 mm stop and wheel shafts with 20 mm diameter Steer tube stainless steel or on request EASTON aluminum steer tube available for 1 1 8 diameter threadless Crown Forged and CNC machined BAM aluminum alloy Arch Cast magnesium alloy Stanchions anodized EASTON aluminum with variable butting Springs Constant pitch springs Sliders Forged and CNC machined BAM aluminum alloy Left slider come...

Page 4: ... with a special preferablybiodegradablesolvent such as trichloroethane or trichloroethylene 4 Before reassembling lubricate all parts in contact with each other using sili cone fat spray or a specific oil for seals 5 Always grease the lip seal rings before reassembling 6 Use wrenches with metric size only Wrenches with inch size might dam age the fastening devices even when theirsizeissimilartotha...

Page 5: ... seals 3 Cleantheoilsealseatandreplaceoilseal FAILURES CAUSES REMEDIES Oil leaking through the bottom of slider O rings at pumping element bottom and adjusting rod damaged Replace the O rings Fork has not been used for some time and is locked out Oil seals and dust seals tend to stick to stanchions Raise dust seal and lubricate stanchion tube dust seal and oil seal Excessive play of stanchions in ...

Page 6: ...on tube after each use and lubri cate with silicone oil In general MARZOCCHI forks can offer top performance from the start However in some cases a short running in period is required 5 10 hours for inner adjust ments This running in period will make fork life longer and ensure fork top per formance over time IMPORTANT change oil at least every 100 working hours Polished forks should be cleaned wi...

Page 7: ...teer tube headset mounting and adjustment must be carried out in compliance with the head set manufacturer s instructions Improper installation may jeopardize the safety of the rider To replace it contact one of our Technical Service Centers with the required tools WARNING In case of improper installation of the steer tube into the crown the rider might lose control of his her bicycle thus jeopard...

Page 8: ...By turning the adjustment knob clockwise the preload is increased up to the maximum value equal to 15 mm spring preload This adjustment is essential in order to have the right fork response for the rider s weight and riding style REBOUND ADJUSTMENT Right slider botom is equipped with an adjuster screw C for REBOUND damp ing To adjust always start from the minimum damping setting i e with the screw...

Page 9: ...OM ADJUSTER FIG 3 PUMPING ELEMENT INNER O RING FIG 13 STOP RING FIG 14 UPPER WASHER FIG 9 PILOT BUSHING FIG 10 VALVE ASSEMBLY FIG 14 DISASSEMBLY GENERAL The reference numbers given in this section relate to the components shown in the fork exploded view Before starting any operation please read the diagram below It shows the quickest procedure and the exact disassembling sequence Locate the part y...

Page 10: ...d the spring 34 from each fork leg Drain all oil from the fork legs WARNING Remember to always recycle any used oil To change the fork leg oil follow the procedure as described in section REASSEMBLY from Fig 27 to Fig 29 PILOT BUSHING AND SEAL ASSEMBLY CHANGE FIG 3 only right leg Turn fork legs upside down and press adjuster retainer 28 with a small screw driver to release it Remove adjuster as se...

Page 11: ...x Sx 1 19 FIG 4 Remove foot nuts 26 and 29 with a socket wrench FIG 5 Withdraw the crown and stanchions as sembly 1 from the sliders FIG 6 Remove the dust seal 19 from the top of the sliders using a small screwdriver ...

Page 12: ...TANT when removing the stop ring make sure not to damage its seat FIG 8 Fit the slider protector A onto the slider and remove the oil seal 21 with the help of a large screwdriver IMPORTANT when removing the oil seal make sure not to damage its seat Once removed the oil seals should not be used again FIG 9 Remove the upper washer 22 from the slider ...

Page 13: ... Pull the bushing out of the slider and make all necessary changes REPLACING PUMPING ELEMENT SEALS FIG 11 Remove the foot buffer 18 complete with ring 25 from the pumping rod ends 14 and 12 FIG 12 Withdraw the pumping elements 14 and 12 and the rebound spring 15 from the stanchion tube top Replace the seal ring 13 if damaged or worn out ...

Page 14: ...ng A and screw inner rod until adjuster threaded end is disengaged from pump ing element Remove inner rod and replace O ring 27 if damaged VALVE ASSEMBLY CHANGE FIG 14 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 17 using pointed pliers Pull the valve assembly 16 out of the tube with one finger in the sa...

Page 15: ...BLY FIG 15 Check that no dirt or debris is between slider and bushing Insert the pilot bushing 23 into place so that it adheres to the slider FIG 16 Fit the upper washer 22 into the slider so that it touches the pilot bushing FIG 17 Lubricate the oil seal 21 and place it onto the seal press B with the hollow side toward the slider Press the oil seal until it touches the lower washer by using the a...

Page 16: ...em into the stanchions from the spring end PUMPING ROD ASSEMBLY FIG 20 only right leg Lubricate the O ring 27 and fit inner rod threaded end into pumping element 14 Turn inner rod clockwise so that threaded end can be seen the into pumping element and stop ring seat 33 marked during disassembly Installez la bague de butée 33 dans le logement sur la tige interne et la bague A dans le logement sur l...

Page 17: ...he tube reassemble Assemble valve components 16 in correct se quence Then fit pumping elements 12 and 14 with seal ring 13 and rebound spring 15 into the valve assembly 16 FIG 22 Lubricate the O rings 24 25 and reas semble the foot buffer 18 onto pumping element ends 14 and 12 FIG 23 Fit this assembly into the stanchion tube and properly seat the valve assembly 16 Insert the stop ring 17 ...

Page 18: ...rs Check to see that the stanchions slide unrestricted by cycling the fork up and down several times The tube should slide freely inside the seal assemblywithoutanysideplay Intheevent it is too hard or too soft repeat the previous steps described above and check compo nents to ensure they are not damaged Seat the dust seals 19 on top of the sliders FIG 25 Screw the foot nuts 26 and 29 on the threa...

Page 19: ...ling Ensure proper oil level H from the top of the stanchion tube in both legs SPRING AND CAP FIG 28 Fit the springs 34 into each stanchion tube FIG 29 Lubricate the O ring 5 on the cap 4 Turn the preload adjuster 9 counterclockwise until it is at its minimum setting and install the lower washer 11 Start the caps with the O ring 5 in place into the stanchion tube threads by hand Tighten caps 4 to ...

Page 20: ...Z3 QR20 A B SPECIFIC MARZOCCHI TOOLS Ref Item Description and use A R 5089 AB Slider protector to remove the oil seal from the slider B R 5090 Oil seal press to press oil seal into the slider ...

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