marzocchi Super Z 38mm Fork Pinkbike User Guide
- June 1, 2024
- marzocchi
Table of Contents
- OWNER’S GUIDE
- Documents / Resources
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
OWNER’S GUIDE
CONGRATULATIONS!
Thank you for choosing a Marzocchi suspension product for your bicycle. Marzocchi suspension products are designed and tested by the finest professionals in the industry, in Santa Cruz County, California, USA.
Follow the guidelines and instructions provided in this owner’s guide, so that you are able to properly set up, use, and maintain your new Marzocchi product.
More information and videos are available at www.Marzocchi.com, or call Marzocchi US at 1.800.369.7469, or contact an Authorized International Marzocchi Service Center at www.Marzocchi.com. If access to the Internet is not available to you, contact Marzocchi to order a paper copy of the online Marzocchi owner’s manual for your product, free of charge.
WARNING AND SAFETY INFORMATION
Marzocchi products should be installed by a professional bicycle service technician, in accordance with Marzocchi installation specifications. Improperly installed forks can fail, causing the rider to lose control resulting in SEVERE INJURY OR DEATH.
Modification or alteration of a Marzocchi product can cause product failure resulting in SEVERE INJURY OR DEATH. Never modify or alter ANY part of a Marzocchi product (including coil springs, lower leg cross brace, crown, steerer, upper tubes, lower leg, air can, seat post, air volume spacers, internals, axle slit shims, axle adapters, or any other parts).
Marzocchi bicycle suspension products may also be used on Class 1 (USA Designation) and L1e-A (EU designation) electric bicycles.
Marzocchi E-BIKE+ suspension products may be used on Class 3 (USA designation) and L1e-B (EU designation) electric bicycles.
DO NOT use any Marzocchi bicycle suspension products on any pedal-assisted motorized cycle or motorized vehicle that exceeds a max assisted speed of 32 km/h (20 mph) or a max system weight of 140 Kg (308 lb).
DO NOT use any Marzocchi E-BIKE+ suspension products on any pedal-assisted motorized cycle or motorized vehicle that exceeds a max assisted speed of 45 km/h (28 mph) or a max system weight of 169 Kg (372 lb). DO NOT use any Marzocchi bicycle suspension product on any throttle-equipped motorized vehicle.
Misuse of Marzocchi suspension products may cause the suspension to fail, resulting in property damage or SERIOUS INJURY OR DEATH, and void the warranty.
DO NOT use Marzocchi bicycle suspension products on any vehicle carrying more than one operator or rider, such as a tandem bicycle or heavy utility bicycle.
Do not remove or replace the steerer tube. This could result in the loss of control of the bicycle and SEVERE INJURY OR DEATH.
Never attempt to remove or replace the steerer or upper tubes independently from the crown. Modifying the integrated crown, steerer, or upper tubes can cause an assembly failure, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
Do not cut the steerer more than three (3) mm below the uppermost installed part. If the steerer length is mistakenly cut too short, it MUST BE REPLACED! Using a fork with clamped steerer engagement that is too short can lead to sudden fork failure, which can cause loss of control of the bicycle resulting in SEVERE INJURY OR DEATH.
If the steerer tube has any nicks or gouges that can be felt with your fingernail, the crown/steerer tube assembly must be replaced. A nick or gouge can cause the steerer tube to fail, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
Never attempt to cut threads into the threadless steerers of Marzocchi forks. Cutting threads into a threadless steerer can cause the steerer tube to fail, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
Never use more than 30 mm of height of steerer stem spacers under the steerer stem, as this condition can cause the steerer tube to fail, causing a loss of control resulting in SEVERE INJURY OR DEATH.
Never allow things such as cable or cable housing to come in contact with the steer tube of a fork. If your bike has internal cable and cable housing routing, please consult your bicycle manufactures owner’s guide for safety instructions. Cable and/or cable housing that comes in contact with a steer tube can cause the steerer tube to fail, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
Cable housing contacting the fork crown will cause abrasion damage to the crown over time. If contact is unavoidable, use vinyl tape or similar protection to cover the point of contact. The Marzocchi warranty does not cover abrasion damage to the Marzocchi fork crown.
Improper service, or use of non-Marzocchi replacement parts with Marzocchi forks may cause the product to malfunction, resulting in SEVERE INJURY OR DEATH.
As dirt and debris can accumulate between the fork axle openings, always check and clean these areas before installing the wheel. Improper hub and axle installation can result in SEVERE INJURY OR DEATH.
Never use a power washer to clean your Marzocchi product.
If your fork loses oil, tops or bottoms out excessively, or makes unusual noises, do not ride the fork and immediately contact Marzocchi or an Authorized Marzocchi Service Center for an inspection or repair service.
Follow your brake manufacturer’s installation instructions for proper installation and adjustment of the brake system. Failure to properly install and adjust your brakes can lead to a loss of control of the bicycle, which can result in SEVERE INJURY OR DEATH.
Your fork may fail under conditions that cause bending and/or breaking to any part of the fork. Any condition that causes a loss of air and/or oil, such as a collision or extended periods of non-use, may also cause your fork to fail. A damaged and/or leaking fork can fail, resulting in a crash and SEVERE INJURY OR DEATH. If you suspect your fork has been damaged, stop riding immediately and contact Marzocchi for inspection and repair.
A fork-mounted carrier may cause damage to the fork legs and/or dropouts, especially in cases where the fork is side-loaded and/or when the rear wheel is not secured in the carrier. Damaged fork legs and/or dropouts can fail, resulting in a crash and SEVERE INJURY OR DEATH. If you suspect your fork has been damaged, contact Marzocchi for inspection and repair.
FORK INSTALLATION
1. Remove the existing fork from the bicycle. Remove the crown race from the old fork. Measure the steerer tube length of the old fork and transfer this measurement to your new Marzocchi fork’s steerer tube. If you don’t have an existing fork, measure the headset stack height (headset parts and frame head tube) and refer to your stem manufacturer’s instructions to be sure there will be enough clamping surface for the stem.
2. Cut the steerer tube to the proper length. Mark the steerer tube and cut it to the proper length.
WARNING
Prior to any cutting, consult your headset and stem manufacturer’s instructions to ensure that you have enough steerer tube length for clamping the steerer and stem. Improper installation can lead to a separation of the stem from the steerer, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
3. Install the headset. Always use a new threadless headset and follow the headset manufacturer’s instructions.
4. Install a 39.8 mm crown race for 1 1/2 in. steerer tubes. Use a crown race setter to install the crown race firmly against the top of the crown.
5. Use a star-fangled nut installation tool to install the star nut 4-10 mm below the top of the steer tube.
6. Install the fork onto the bicycle. Install the headset bearing parts and stem in accordance with the headset manufacturer’s instructions, and adjust the headset preload accordingly until you feel no excessive play or bearing drag. Tighten the stem clamping bolts to the stem manufacturer’s torque specifications.
7. Install the brakes according to the brake manufacturer’s instructions. Maximum rotor size for Super Z is 230 mm.
WARNING
The disc brake caliper mounting bolts must have 10-12 mm of thread engagement with the fork. Use a torque wrench to tighten the caliper mounting bolts to the disc brake manufacturer’s specification, but do not exceed 10.2 N·m (90 in-lb). Improper installation can lead to brake failure, resulting in a loss of control of the bicycle and SEVERE INJURY OR DEATH.
8. Route the front disc brake hose or cable housing to the inside of the lower leg, and through the supplied disc brake housing guide. Use a torque wrench to tighten the disc brake hose guide screw to 0.9 N·m (8 in-lb).
- 10-12 mm thread engagement
15 MM QUICK RELEASE INSTALLATION
- Install the front wheel into the fork dropouts. Slide the axle through the drive side dropout and hub.
- Open the axle lever.
- Turn the axle clockwise 5-6 complete turns.
- Close the lever. The lever must have enough tension to leave an imprint on your hand
- The closed lever must be between 1-20 mm in front of the fork leg. If the lever does not have enough tension, or has too much tension when closed at the recommended position (1-20 mm in front of the fork leg), refer to the next section for adjustment instructions.
WARNING
Use hand pressure only. Never use any tool to tighten the quick release lever. Over-tightening the levers can damage the axle or fork dropouts, leading to a sudden failure with one or more of these components, resulting in SEVERE INJURY OR DEATH. Conversely, failure to secure the axle properly, including insufficient tension upon closing, can cause the wheel to become detached from the bicycle, resulting in SEVERE INJURY OR DEATH.
LEVER POSITION ADJUSTMENT
- Note which direction the axle lever needs to turn to close with sufficient tension in the proper orientation (1-20 mm in front of the fork leg).
- Open the axle lever and unthread the axle from the fork.
- Use a 4 mm hex wrench in the end of the axle to adjust the lever position in the direction noted in Step 1. With the 4 mm adjuster set properly, you should start to feel tension in the axle when the QR lever is 90 degrees before full closure in the vertical position.
- Repeat the axle installation instructions to verify proper installation and adjustment.
KABOLT INSTALLATION
- Install the front wheel into the fork dropouts. Slide the Kabolt axle through the drive side dropout and hub.
- Use a 6 mm hex wrench to torque the Kabolt axle clockwise to the torque specification etched on the head of the Kabolt.
TIRE CLEARANCE TEST
1. Release all air pressure from the fork by depressing the Schrader valve.
WARNING
Marzocchi forks may contain high air pressures. Release ALL air pressure from the main air chamber before disassembly. Failure to do so may result in parts or fluids ejecting from the fork, which can cause SEVERE INJURY OR DEATH.
2. Compress the fork completely.
3. Measure the distance from the edges of the inflated tire to the crown, fork brace, and steerer. There must be AT LEAST 8.5 mm of clearance around the entire tire.
WARNING
Failure to leave at least 8.5 mm of clearance between the edges of the inflated tire and the crown, fork brace, and steerer may cause the tire to jam against the crown when the fork is fully compressed, which can result in SEVERE INJURY OR DEATH.
4. Add air pressure to your desired setting using a high-pressure pump. Set the sag according to instructions online at www.Marzocchi.com.
5. You must repeat this test EVERY time you change tires or rims.
WARNING
Do not exceed maximum air pressure: Super Z maximum air pressure is 120 psi.
Minimum air pressure is: 40 psi.
Pressure measured at an ambient temperature of 70-75˚F. Normal operating temperature range for Marzocchi products is 20-140˚F.
AIR SPRING VOLUME SPACERS
Changing volume spacers in Marzocchi Super Z forks is an easy internal adjustment that allows you to change the amount of mid stroke and bottom out resistance. If you have set your sag correctly and are using full travel (bottoming out) too easily, then you could install one or more spacers to increase bottom out resistance. If you are not using full travel, then you could remove one or more spacers to decrease bottom out resistance.
1. Remove the air cap.
2. Release all air pressure from the fork by depressing the Schrader valve.
WARNING
Marzocchi forks may contain high air pressures. Release ALL air pressure from the main air chamber before disassembly. Failure to do so may result in parts or fluids ejecting from the fork, which can cause SEVERE INJURY OR DEATH.
3. Carefully unthread the topcap from the fork with a 6-point chamfer-less 32 mm socket.
4. Pull up to remove the topcap assembly from the fork crown.
5. Slide the air volume spacer or spacers horizontally to install or remove them from the topcap.
WARNING
Do not exceed the maximum number of volume spacers for your fork. This can damage your fork. Find volume spacer information online at www.Marzocchi.com.
6. Reinstall the topcap assembly into the fork crown and tighten to 24.8 N·m (220 in-lb) with a 6-point chamfer-less 32 mm socket.
7. Add air pressure to your desired setting using a high-pressure pump. Set the sag according to instructions online at www.Marzocchi.com.
SAG SETTING
To achieve the best performance from your Marzocchi suspension, adjust the air pressure to attain your proper sag setting. Sag is the amount your suspension compresses under your weight and riding gear. Sag range should be set to 15-20% of total fork travel.
Make sure to set sag with the compression lever in the OPEN mode.
Watch the sag setup video at ridefox.com/sagsetup
Suggested Sag Measurements
Travel| 15% sag (Firm)|
20% sag (Plush)
150 mm (5.9 in)
| 22 mm (.9 in)| 30 mm (1.2 in)
160 mm (6.3 in)| 24 mm (1.0 in)|
32 mm (1.3 in)
170 mm (6.7 in)
| 26 mm (1.0 in)| 34 mm (1.3 in)
180 mm (7 in)| 27 mm (1.0 in)|
36 mm (1.4 in)
190 mm (7.7 in)
| 28.5 mm (1.1 in)|
38 mm (1.6 in)
Do not exceed maximum air pressure: Super Z maximum air pressure is 120 psi.
- TOTAL FORK TRAVEL
- O-RING
- SAG RANGE
- DUCT WIPER
Suggested Starting Points for Setting Sag
Rider Weight
(lbs)| Rider Weight
(kgs)| Super Z
Pressure|
Super Z
Rebound Setting
120-130
| 54-59| 54 psi (3.7 bar)| 13
130-140| 59-64| 58 psi (4.0 bar)|
12
140-150
| 64-68| 62 psi (4.3 bar)| 11
150-160| 68-73| 67 psi (4.6 bar)|
10
160-170
| 73-77| 71 psi (4.9 bar| 9
170-180| 77-82| 75 psi (5.2 bar|
8
180-190
| 82-86| 79 psi (5.4 bar)| 7
190-200| 86-91| 83 psi (5.7 bar)|
6
200-210
| 91-95| 87 psi (6.0 bar)| 5
210-220| 95-100| 92 psi (6.3 bar)|
4
220-230
| 100-104| 96 psi (6.6 bar)| 3
230-240| 104-109| 100 psi (6.9 bar)|
2
240-250
| 109-113| 104 psi (7.2 bar)|
1
COMPRESSION ADJUSTMENT
GRIP X COMPRESSION ADJUST
Use this diagram as a starting point for your compression adjusters. Turn your compression adjusters to the closed position (full clockwise) until they stop. Then back them out (counterclockwise) to the number of clicks shown below.
High-speed compression adjustment is useful to control fork performance during bigger hits, landings, and square-edged bumps.
Low-speed compression adjustment is useful to control fork performance during rider weight shifts, G-outs, and other slow inputs.
-
OPEN
15 CLICKS -
CLOSED
(FULL CLOCKWISE) -
OPEN
16 CLICKS -
LEAST AMOUNT OF COMPRESSION DAMPING; FORK COMPRESSION LIGHTEST
-
MOST AMOUNT OF COMPRESSION DAMPING; FORK COMPRESSION FIRMEST
REBOUND ADJUSTMENT
Rebound controls the rate of speed at which the fork extends after compressing. The rebound adjustment is dependent on the air pressure setting. For example, higher air pressures require slower rebound settings. Use your air pressure to find your rebound setting. The rebound adjuster is located underneath the damper-side fork leg.
a) LEAST AMOUNT OF REBOUND DAMPING, FORK REBOUNDS FASTEST
b) MOST AMOUNT OF REBOUND DAMPING, FORK REBOUNDS SLOWEST
GRIP X REBOUND
Turn your
rebound knob to the closed position, clockwise until it stops.
Then turn it counter-clockwise to the number of clicks shown in the table on
page 9.
ADDITIONAL TUNING OPTIONS
CLIP-ON VOLUME SPACERS
Changing volume spacers in the Super Z fork is an easy internal adjustment that allows you to change the amount of mid stroke and bottom out resistance.
If you have set your sag correctly and are using full travel (bottoming out) too easily, then you could install one or more spacers to increase bottom out resistance.
If you have set your sag correctly and are not using full travel, then you could remove the spacer to decrease bottom out resistance.
Installation procedure and tuning options are available online at: ridefox.com/ownersmanuals
Super Z Volume Spacer Configurations
Travel| Volume Spacers Factory Installed|
*Max Volume Spacers
190 mm
| 0| 4
180 mm| 1|
5
170 mm
| 2| 6
160 mm| 3|
7
150 mm
| 4|
8
SERVICE
Properly cleaning your Marzocchi product between rides, in addition to maintenance service scheduled at regular intervals, will help to reduce repair costs and extend product life.
For further service procedures information, visit www.Marzocchi.com, or contact Marzocchi US for complete maintenance service (1.800.369.7469).
Minimum Recommended Service Items
| Before every ride| After every ride| Regularly|
**Every 125 hours or yearly, whichever comes first***
---|---|---|---|---
Inspect the entire exterior of your fork. The fork should not be used if any
of the exterior parts appear to be damaged. Contact your local dealer or
Marzocchi for repair.|
X
| | |
Check that quick-release levers and axles are properly adjusted and
tightened.|
X
| | |
Check your headset adjustment. If loose, adjust it accordingly to your bicycle
manufacturer’s recommendations.|
X
| | |
Check that all brake cables or hoses are properly fastened. Test the proper
operation of your front and rear brakes on level ground.|
X
| | |
Clean exterior with mild soap and water only, then wipe dry with a soft towel.
Do not use a high-pressure washer or spray water directly at the seal.| |
X
| |
Check sag and damper settings. Inspect the controls for visual damage and
function.| | |
X
|
Full service (full internal/external inspection, damper rebuild, air spring
rebuild, bath oil and wiper replacement).| | | |
X
*For those who ride lift-accessed DH, Park, or Extreme Freeride or in extremely wet/muddy or dry/dusty enviroN•mental conditions where trail debris is sprayed onto the fork while on the trail, Marzocchi encourages riders to perform maintenance earlier than recommended above as needed. If you hear, see, or feel something unusual, stop riding immediately and contact a Marzocchi Authorized Service Center for proper servicing.
Marzocchi makes the following LIMITED WARRANTY with respect to its suspension products:
MARZOCCHI LIMITED WARRANTY
LIMITED ONE (1) YEAR WARRANTY ON SUSPENSION PRODUCTS
Subject to the limitations, terms and conditions hereof, Marzocchi warrants, to the original retail owner (consumer) of each new Marzocchi suspension product, that the Marzocchi suspension product, when new, is free from defects in materials and workmanship. This limited warranty expires one (1) year from the date of the original Marzocchi suspension product retail purchase from an authorized Marzocchi dealer or from a Marzocchi authorized Original Equipment Manufacturer where Marzocchi suspension is included as original equipment on a purchased vehicle.
TERMS OF WARRANTY
This limited warranty is conditioned on the Marzocchi suspension product being operated under normal conditions and properly maintained as specified by Marzocchi. This limited warranty is only applicable to Marzocchi suspension purchased new from an authorized Marzocchi source and is made only to the original retail owner (consumer) of the new Marzocchi suspension product and is not transferable to subsequent owners.
Should it be determined, by Marzocchi in its sole and final discretion, that a Marzocchi suspension product is covered by this limited warranty, it will be repaired or replaced, by a comparable model, at Marzocchi’s sole option, which will be conclusive and binding. THIS IS THE EXCLUSIVE REMEDY UNDER THIS LIMITED WARRANTY. ANY AND ALL OTHER REMEDIES AND DAMAGES THAT MAY OTHERWISE BE APPLICABLE UNDER THIS LIMITED WARRANTY ARE EXCLUDED, INCLUDING, BUT NOT LIMITED TO, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR PUNITIVE DAMAGES.
This limited warranty does not apply to normal wear and tear, malfunctions or failures that result from abuse, neglect, improper assembly, alteration or modification, improper or unauthorized repair or maintenance, crash, accident or collision, or other abnormal, excessive or improper use.
This limited warranty gives the consumer specific legal rights. The consumer may also have other legal rights under the applicable national laws which are not affected by this limited warranty. If it is determined by a court of competent jurisdiction that a certain provision of this limited warranty does not apply, such determination shall not affect any other provision of this limited warranty and all other provisions shall remain in effect.
THIS IS THE ONLY WARRANTY MADE BY MARZOCCHI ON ITS SUSPENSION PRODUCTS AND COMPONENTS, AND THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION HEREIN. ANY WARRANTIES THAT MAY OTHERWISE BE IMPLIED BY LAW INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED.
This limited warranty shall be governed exclusively by the laws of the State of California.
For questions regarding this warranty or Marzocchi products please contact the US Customer Service Department at Marzocchi by calling 1-800-369-7469, or visiting www.Marzocchi.com.
When making a claim under this Limited Warranty you will be required to provide to an authorized Marzocchi Service Center:
- The Product (or the affected part) and
- A copy of the original proof of purchase, which clearly indicates the name and address of the seller, the date and place of purchase, the product part number and if utilized, a serial number. If Marzocchi products are sold as part of a complete bicycle, the bicycle brand, model, model year, and serial number should be included.
Marzocchi is a FOX Factory, Inc owned brand.
This page is intentionally left blank.
©MARZOCCHI. 2024 // 1.800.369.7469
915 Disc Drive, Scotts Valley, CA 95066 USA
605-00-310 REV B
Documents / Resources
|
marzocchi Super Z 38mm Fork
Pinkbike
[pdf] User Guide
Super Z 38mm Fork Pinkbike, Super Z, 38mm Fork Pinkbike, Fork Pinkbike
---|---
References
- Marzocchi | Bombproof Mountain Bike Suspension
- FOX - RIDEFOX
- Sag Setup 101 | FOX
- Marzocchi | Bombproof Mountain Bike Suspension
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