1999 Marzocchi Z1 Bomber Alloy/BAM servicing

Glossary of Fork terminology

Suspension Fork Servicing

• TroubleShooting
• General rules
• Parts List
• Leg removal
• Spring change
• Fork oil change
• Hydraulic cartridge change
• Pilot bushing and seal assembly change

 

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Glossary of Fork terminology

Arch: Inverted horseshoe made of forged and CNC machined BAM aluminum alloy used to brace the sliders.

BAM: Bomber aerospace material. ie aluminum alloy.

Crown:Forged and CNC machined T6-6082 aluminum alloy component that the fork legs attach to.

Fork oil/Shock oil: Specially formulated oil which eliminates foaming and viscosity breakdown while providing stiction free lubrication.

Seals: Rubber mechanical barrier against dust and moisture while providing freedom of stanchion travel.

Sliders:Cast and CNC machined aluminum alloy with disk brake mounts (ie. lower fork leg).

Slider bushings: Full length guide bushing composed of a copper base and impregnated with an anti friction coating.

Stanchions: anodized EASTON aluminum tube with variable butting. Slides inside lower fork leg (sliders).

Steer tube: 1 1/8" diameter EASTON aluminum or CrMo steel tube that slips into headtube of bike frame.

Springs: Prowind (progressive spring rate, standard) or constant spring rate (optional, tuned for different rider weights) spring in fork leg.

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Suspension Fork Servicing

TroubleShooting

Symptom	Possible cause	Service
Excessive oil build up on stanchions	Oil seal is worn Stanchion tube is scored Excessive dirt on oil seal	Replace oil seal Replace oil seal and stanchion tube Clean the oil seal seat
Oil leaking through the bottom slider	O ring on cartridge nut is damaged	Replace O ring
Fork has not been used for some time and is locked out	Oil seals and dust seals stuck to stanchion tube	Raise dust seal and lubricate stanchion tube, dust seal and oil seal with silicon grease
Fork rebounds too fast even though the adjuster is on the max. damping position	Hydraulic cartridge is defective	Replace hydraulic cartridge
Excessive play in stanchions	Pilot bushings are worn	Replace pilot bushings

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General rules

• Use new seals during reassembly.
• If two screws are close together, tight each screw a few turns alternately to bring the part to uniform torque.
• Clean all metal parts before reassembly.
• Lubricate all parts in contact with silicone spray.
• Always silicon grease the seal before reassembly.
• Use metric wrenchs only.

Thread diameter	Nm	ft lb
M4	4	2.9
M5	9	6.6
M6	11	7.5

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Parts List

 

1 Safety ring 2 Preload knob 3 Allen bolt 4 Stop ring 5 Cap 6 O ring 7 Preload adjuster 8 Lower washer 9 Spring 10 O ring 11 Hydraulic cartridge 12 Rebound spring 13 Stanchion tube 14 Dust seal 15 Stop ring 16 Oil seal 17 Upper washer 18 Pilot bushing 19 R.H. slider 20 L.H.slider 21 O ring 22 Foot nut 23 Cantilever boss 24 Arch 25 Screw 26 Crown with steer tube 27 Screw 28 R.H sticker 29 L.H. sticker 30 Sticker

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Fork oil change

Hydraulic cartridge change

Pilot bushing and seal assembly change

 

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