Marzocchi Fork Rebuild

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NickyT · #1 Post by **NickyT** » Sun Apr 14, 2013 2:35 pm

In case anyone here has a later bike with the Marzocchis forks and is finding them a bit soft, as I did, I've just rebuilt mine. Even with everything wound to maximum, they would dive too much on the brakes and were using almost all their travel. Not ideal, especially as I plan to use it on track.

I took the forks out, and had them dismantled and fully cleaned inside (they were a bit gunged up). Upon rebuild, they were treated to heavier oil (10 instead of 7.5) with a reduced air gap (100mm instead of 110mm).

When I re-fitted them, I set them with 3 rings above the top yoke (there had been 5) and backed the preload, rebound and compression off a little.

I've done about 150 miles on it since, including scrubbing in a new pair of Dunlop Sportsmarts, which feel great. So far, so good, with a firmer feel, less dive, less fork travel used and no headshakes. The final test will be to see how the suspension causes the tyres to mark up on track. It has an Ohlins rear, so all good there, as you'd expect.

#2 Post by **mangocrazy** » Sun Apr 14, 2013 5:13 pm

THat's interesting - a lot of folks have stripped the Showas down, but very few Marzocchis. They have a reputation as difficult to work on - did you find that? Something about the cartridges being completely sealed, I seem to remember. It's also a change to hear about Falco forks that are on the soft side. My opinion of OE Falco Showas is that they're definitely at the firm end of the spectrum.

And +1 for Sportsmarts - totally excellent tyres.

D-Rider · #3 Post by **D-Rider** » Sun Apr 14, 2013 10:18 pm

I think the "Hard to work on" is a bit too much of a generalisation.
They are hard to re-valve due to their cartridge construction but shouldn't be any harder than any others to service

#4 Post by **mangocrazy** » Mon Apr 15, 2013 8:38 pm

Yes - probably different rather than difficult... If they can avoid the need for a spring preload compressor tool, like the Showas need, then they may even be easier to strip down (as long as you don't want to get inside the cartridges).

Were your OE forks Marzocchis, Andy? I know you have Ohlins fitted now.

Aladinsaneuk · #5 Post by **Aladinsaneuk** » Mon Apr 15, 2013 9:33 pm

marzocchi's were fitted as standard to the rust brown falco's iirc

D-Rider · #6 Post by **D-Rider** » Mon Apr 15, 2013 10:02 pm

mangocrazy wrote:Yes - probably different rather than difficult... If they can avoid the need for a spring preload compressor tool, like the Showas need, then they may even be easier to strip down (as long as you don't want to get inside the cartridges).

Were your OE forks Marzocchis, Andy? I know you have Ohlins fitted now.

Yes mine came with Marzocchis - and pretty good they were too - not a million miles behind the Ohlins.

NickyT · #7 Post by **NickyT** » Tue Apr 16, 2013 10:25 am

Yes, mine is Jewish Racing Bronze.

I need to back off the damping a little, as last night on a fast ride on bumpy roads it was lifting the front over bumps in places where I wouldn't expect it to (not when fully hard on the power).

It's nice to have good enough quality OEM forks that this kind of stuff can be adjusted out.

I didn't work on them myself, as I have a local tame mechanic that I use who charges me so little (£40 labour to strip, clean and refill loose forks, plus fit a pair of tyres to loose wheels) that there's literally no point in doing it myself.

NB Certain parts for the Marzocchis are no longer available. Beneath the upper preload mechanism there's a left-handed threaded nut with a hold drilled in one edge for a grubscrew. That nut/grubscrew are no longer available and one of mine had a didgy thread. My mechanic was luckily able to cut a new thread into it (within that £40 charge, too).