Marzocchi Z3 QR20 Manual de usuario

QR20

(110)

TRAVEL 110

+0.5

175

426 55

L.MAX=491 L.L.=481 L.MIN=371

248.5

26.5

130

110

Ø30

±2

-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.

QR20

(130)

TRAVEL 130

+0.5

175

446 55

L.MAX=511 L.L.=501 L.MIN=371

248.5

26.5

130

110

Ø30

±2

Ø30

+0.05

-0.1

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

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

QR20

(100)

TRAVEL 100

+0.5

175

426 55

L.MAX=481 L.L.=471 L.MIN=371

248.5

26.5

130

110

Ø30

±2

-0.1

Ø30

+0.05

SPECIALIZED

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.

QR20

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system

usingtheM

ARZOCCHI

special toolsonly.

2. On reassembling the suspension sys-

tem, always use new seals.

3. Clean all metal parts with a special,

preferablybiodegradablesolvent,such

as trichloroethane or trichloroethylene.

4. Beforereassembling,lubricate allparts

in contact with each other using sili-

conefat sprayor aspecificoil forseals.

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

theirsizeissimilartothatofthewrenches

in metric size.

QR20

FAILURES, CAUSES AND REMEDIES

Thisparagraph reports somefailuresthatmay occurwhenusingthe fork.It alsoindicatespossible causes andsuggestsa remedy.Always

refer to this table before doing any repair work.

Oil leaking though the top of slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on oil seal

1. Replace oil seal

2. Replace crown/stanchions assembly,

oil seals and dust 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 the sliders Pilot bushings are worn Replace pilot bushings

Adjuster position does not affect fork op-

eration 1. Dirt inside legs

2. O-ringintopumpingelement damaged. 1. Clean carefully and change oil

2. Replace O-ring.

QR20

RECOMMENDATIONS FOR

MAINTENANCE

ARZOCCHI

forks are based on advanced

technology,supported byyear-long expe-

rience in the field of professional moun-

tain biking. In order to achieve best re-

sults, we recommend to check and clean

the area below the dust seal and the

stanchion tube after each use and lubri-

cate with silicone oil.

In general, M

ARZOCCHI

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 with

bodywork polish at regular intervals in

order to preserve their original finish.

QR20

DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake sys-

tem is installed, it is absolutely

forbidden to loosen and remove original

brake supports fixing pins. In fact, apart

from retaining Cantilever or V-brake le-

vers, they also play an important role in

securingsliderbottom toslider-arch mono-

lith. If needed, replace these pins with

screws (part no. 532979QF) available

as spare parts.

Tighten the above screws to 15 Nm.

IMPORTANT: screw and pin threading

is treated to ensure hydraulic seal. Never

reuse screws and pins which have been

removed.

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.

INSTALLATION

Installing the fork on a bicycle is a very

delicate operation that should be carried

out with extreme care. The installation

should always be checked by one of our

Technical Service Centers.

WARNING: Steer 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 jeopardizing his/her

safety.

FRONT WHEEL ASSEMBLY

IMPORTANT:fixingthefrontwheelprop-

erly as specified in the instructions given

belowis essential fortheproperoperation

of this fork and all related devices, and

therefore for safe riding. You are advised

to follow these instructions closely.

Slacken the lock nut of the quick release

lever so the hub will fit between the fork

sliders.

Make sure the quick release bushings (A)

are centered to the recesses in the sliders.

Lock the quick release lever (B) and make

sure the bushings (A) are properly seated

in the sliders.

Fit bolt end (C) in suitable slider groove

and tighten the screw (D) to specified

torque.

WARNING: Theseslidersare spe-

cifically 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.

QR20

ADJUSTMENT

SPRING PRELOAD

Spring preload determines COMPRES-

SION damping and is adjusted by turning

the adjustment knob (3) on the top of the

fork legs. From the factory the fork is set at

minimumpreload,i.e.theadjustmentknob

completely unscrewed counterclockwise.

However, springs are slightly preloaded

to counteract static loads. 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 fully

turned counterclockwise. Each adjusting

position can be identified by a click.

IMPORTANT: do not force the adjuster

knob (C) over its limit.

QR20

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FORK LEG OIL CHANGE

CHANGING PUMPING

ELEMENT SEALS

FOOT NUT FIG. 4

SPRING FIG. 2

DUST SEAL FIG. 6

STOP RING. 7

OIL SEAL FIG. 8

PUMPING ROD FIG. 12

REBOUND SPRING FIG. 12

VALVE ASSEMBLY

CHANGE

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 11

CROWN AND STANCHIONS

ASSEMBLY FIG. 5

SPRING CHANGE

BOTTOM 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 you need to remove in the diagram, then look at the arrows to determine which other parts you need to

remove first.

DISASSEMBLY DIAGRAM

QR20

SPRING CHANGE

FIG. 1

Unscrew the caps (4) with a 21 mm

socket wrench.

Remove the caps complete with O-ring

(5) from the stanchions.

FIG. 2

Push the stanchions into the sliders and

remove the lower washer (11) and the

spring (34) from each fork leg.

Drain all oil from the fork legs.

WARNING: Rememberto 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-

sembly (28) from the slider.

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