GENERAL

18

175

+0.05
0

80

15 -0.1
+1

20 0

248.5

(110)

TRAVEL 110

30

426 2

Z1
Drop-Off

L.MAX=491 L.L.=481 2 L.MIN=371

55

30

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

9.2 +0.1
0
+0.5

100 0

130

25

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

175

GENERAL

18

+0.05
0

80

15 -0.1
+1

20 0

248.5

(130)

TRAVEL 130

30

446 2

Z1
Drop-Off

L.MAX=511 L.L.=501 2 L.MIN=371

55

30

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 on each 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.

+0.5

9.2 +0.1
0

100 0

130

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.

25

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

INSTRUCTIONS
GENERAL RULES

Z1
Drop-Off

1. Where specified, assemble and disassemble the shock absorption system

using the MARZOCCHI special tools only.
2. On reassembling the suspension system, always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
in contact with each other using silicone 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 damage the fastening devices even when
their size is similar to that of the wrenches
in metric size.

FAILURES, CAUSES AND REMEDIES

This paragraph reports some failures 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.

Z1
Drop-Off

FAILURES

CAUSES

REMEDIES

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. Clean the oil seal seat and replace oil seal

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 operation

1. Dirt inside legs

2. O-ring into pumping element damaged.

1. Clean carefully and change oil

2. Replace O-ring.

RECOMMENDATIONS FOR
MAINTENANCE

Z1
Drop-Off

MARZOCCHI forks are based on advanced

technology, supported by year-long experience in the field of professional mountain biking. In order to achieve best results, we recommend to check and clean
the area below the dust seal and the
stanchion tube after each use and lubricate 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 adjustments. This running-in period will make
fork life longer and ensure fork top performance 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.

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 headset manufacturers 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.

DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake system is installed, it is absolutely forbidden to loosen and remove original
brake supports fixing pins. In fact, apart
from retaining Cantilever or V-brake levers, they also play an important role in
securing slider bottom to slider-arch monolith. 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.

ADJUSTMENT

Z1
Drop-Off

SPRING PRELOAD
Spring preload determines COMPRESSION 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
minimum preload, i.e. the adjustment knob
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 riders weight and riding
style.

REBOUND ADJUSTMENT
Each fork leg is equipped with an adjuster
screw (C) for REBOUND damping at
slider bottom.
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.

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

FOOT BUFFER FIG. 11

FOOT NUT FIG. 4

PUMPING ROD FIG. 11

REBOUND SPRING FIG. 11

CROWN AND STANCHIONS

ASSEMBLY FIG. 5

DUST SEAL FIG. 6

PUMPING ELEMENT INNER O-RING

FIG. 12

STOP RING. 7

OIL SEAL FIG. 8

VALVE ASSEMBLY CHANGE

UPPER WASHER FIG. 9

STOP RING FIG. 13

FORK LEG OIL CHANGE

SPRING FIG. 2

BOTTOM ADJUSTER FIG. 3

CHANGING PUMPING
ELEMENT SEALS

STANCHION TUBE CAP FIG. 1

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

SPRING CHANGE

Z1
Drop-Off

PILOT BUSHING FIG. 10

VALVE ASSEMBLY FIG. 13

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 (12) from each fork leg.
Drain all oil from the fork legs.
WARNING: Remember to always
recycle any used oil.

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE
FIG. 3
Turn fork legs upside down and press
adjuster retainer (32-33) with a small
screwdriver to release it. Remove adjuster
assembly (32-33) from the slider.

To change the fork leg oil follow the

procedure as described in section
REASSEMBLY from Fig. 26 to Fig. 28.

Z1
Drop-Off

11
12

4
5
32-33

FIG. 4
Remove foot nuts (30) with a socket
wrench.

FIG. 5
Withdraw the crown and stanchions assembly (1) from the sliders.

FIG. 6
Remove the dust seal (19) from the top of
the sliders using a small screwdriver.

Z1
Drop-Off

19
1

30

FIG. 7
Remove the stop ring (20) from the sliders
by placing the screwdriver bit in one of
the three openings on the stop ring.

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 stop

ring, make sure not to damage its seat.

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.

Z1
Drop-Off

20
21

A
22

FIG. 10
Fit the bit of a small screwdriver into upper
edge slot of the pilot bushing (23) and lift
gently. 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 (26) from the pumping rod (14)
end.
Withdraw the pumping element (14) and
the rebound spring (15) from the stanchion
tube top. Replace the seal ring (13) if
damaged or worn out.

FIG. 12
Remove the stop ring (29) from pumping
element bottom (14) with a small flat
screwdriver.
Mark stop ring seat into inner rod for
proper fitting.
Use the same screwdriver to remove the
ring (A) and screw inner rod until adjuster
threaded end is disengaged from pumping element.
Remove inner rod and replace O-ring
(31) if damaged.

Z1
Drop-Off

13

29
14

15
14
23

31

26

18

VALVE ASSEMBLY CHANGE

FIG. 13
To check that the valve assembly is operating 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 same sequence
as in the figure.

Z1
Drop-Off

17

16

REASSEMBLY
CAUTION: before reassembling, all
metal components should be washed
carefully with inflammable, preferably biodegradable, solvent and dried with
compressed air.

Z1
Drop-Off

FIG. 15
Fit the upper washer (22) into the slider so
that it touches the pilot bushing.

FIG. 16
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 above seal press.

PILOT BUSHING AND SEAL

ASSEMBLY
FIG. 14
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.

22
23

B
21

FIG. 17
Insert the stop ring (20) into the slider
making sure it is properly seated into
place.
Use buffer (B) to properly seat the ring
into the slider.

FIG. 18
Lubricate the dust seals (19) and fit them
into the stanchions from the spring end.

PUMPING ROD ASSEMBLY

FIG. 19
Lubricate the O-ring (31) 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 (29), marked during
disassembly.
Fit stop ring (29) into inner rod seat and
ring (A) into pumping element seat.

Z1
Drop-Off

31
20

19
A
29

14

VALVE AND PUMPING ROD

ASSEMBLY
FIG. 20
After having overhauled or replaced the
valve unit and after having cleaned the
inside of the tube, reassemble. Assemble
valve components (16), in correct sequence.
Then fit pumping rod (14) with seal ring
(13) and rebound spring (15) into the
valve assembly (16).

FIG. 21
Lubricate O-rings(25-26) and reassemble the foot buffer (18) onto the end part
of pumping rod (14).

FIG. 22
Fit this assembly into the stanchion tube
and properly seat the valve assembly
(16).
Insert the stop ring (17).

Z1
Drop-Off

26

13
14

25
16

15
16

18

14

17

CROWN AND STANCHIONS

ASSEMBLY
FIG. 23
Fit the crown and stanchions assembly
(1) - with the dust seals in place - gently
into the sliders seals.

Z1
Drop-Off

IMPORTANT: to avoid any damages to

sealing surfaces, keep the stanchions duly
lubricated and squared into the sliders.
Press the crown and stanchions assembly
fully down and check that threaded ends
of pumping elements (14) are coming out
through the bottom of the sliders.
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
assembly without any side play. In the event
it is too hard or too soft, repeat the previous
steps described above and check components to ensure they are not damaged.
Seat the dust seals (19) on top of the
sliders.

FIG. 24
Screw the foot nut (30) on the pumping
rod thread (14).
Tighten to 12 Nm.
Check to verify that the stanchions slide
properly through the stroke by pumping
them up and down several times.

12

FIG. 25
Fit the retainer (D) into the slider (E) to
reassemly the adjuster unit (32-33).

Nm

19

19

30
32 - 33

HOW TO FILL WITH OIL

FIG. 26
Pour oil little by little when the stanchions
are fully down and then pump with the
crown so as to have a better filling.
Check that the oil level is 65 mm from the
top of the stanchion tube, in both legs.

SPRING AND CAP

FIG. 27
Fit the springs (12) into each stanchion
tube.

FIG. 28
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 12 Nm.

Z1
Drop-Off

12

12

65

4
5

Nm

SPECIFIC MARZOCCHI TOOLS

Ref.
A
B

Z1
Drop-Off

Item.
R 5089 AB

Description and use

Slider protector: to remove the oil seal from the slider

R 5090

Oil seal press: to press oil seal into the slider

B
A