Marzocchi Fork Maintenance De-Mystefied?

Discussion in 'Trials' started by motobene, Oct 22, 2014.

  1. mayoisnasty

    mayoisnasty trials wannabe

    Joined:
    Feb 19, 2020
    Oddometer:
    42
    Location:
    OK
    Apologies for the resurrection. :pope

    A few questions for the experts here. I don't know why I have had so much trouble. I've done this job before, albeit on old dirt bikes and street bikes many years ago. Been off bikes for quite some time. Anyway, I began to replace seals and fluid on the left side (thought it would be a cinch) and found something unexpected right off. When I was separating the two halves to remove the seal, the lower bushing stayed in place leaving the top bushing, washer and seal in place. Is this a problem? I went ahead and reassembled as I figure parts for these are non-existant.

    I filled the fork back up with oil with a 6" air gap as motobene described and reassembled it. I worked out all the air (I thought), but when I have the fork in my hand and invert it I can hear a gurgling sound from the oil running to the other end. Also if I bump the fork against the heel of my palm lightly, the spring clanks around inside. I disassembled, drained and filled the fork up again with the same result. What am I missing? If I'm struggling this much with the left fork, I am reluctant to tackle the right side.:baldy

    edit: yes, the spacer is in there :lol3
    #81
  2. mayoisnasty

    mayoisnasty trials wannabe

    Joined:
    Feb 19, 2020
    Oddometer:
    42
    Location:
    OK
    I am used to there being holes here to work out trapped air.
    20200524_155407.jpg
    #82
  3. lineaway

    lineaway Long timer

    Joined:
    Oct 1, 2011
    Oddometer:
    11,341
    Location:
    nm
    You have not mentioned what you are working on other than it`s a fork.
    #83
  4. mayoisnasty

    mayoisnasty trials wannabe

    Joined:
    Feb 19, 2020
    Oddometer:
    42
    Location:
    OK
    It started out as a simple seal kit. Now I am trying to get oil back in it to a correct level, air removed and have the fork feel like it should. I have triple checked myself three times. At this point I am just going to take them both to a suspension shop.

    Edit- marzocchi 40 mm. Left fork leg. Open cartridge. Seems all the past talk (including this thread) I can find is about the right side closed cartridge fork.
    #84