2005 66 travel change

Tools
15mm socket
10 & 26mm spanner
Torque wrench

1/ First off all make sure the adjusters are in the middle setting
2/ Unscrew the top cap using a 26mm spanner
3/ Compress the stanchion to expose the top cap assembly
4/ Holding the locknut (51) with a 10mm spanner, undo the top plug & remove
5/ Remove part 52 and remove the spring
6/ Using a 15mm socket, undo both foot nuts
7/ Remove both damper units & drain oil
8a/ if extending to 170mm; remove spacer 61 from damper shaft
8b/ turn part 52 upside down (o-ring on top) and place 61 over the o- ring seat
8c/ if reducing to 150mm; remove part 61 from part 52
8d/ turn part 52 upside down (o-ring underneath)
9/ place the part 61 over the damper shaft
10/ Re-fit damper units
11/ TORQUE foot nuts to 12Nmm
12/ Re-fill using SAE 7.5w oil with 210cc per leg
13/ Re-fit springs
14/ re-fit part 52 and lock nut 51
15/ Tighten lock nut and then top plug on to the damper shaft
16/ Tighten top plug in to the stanchion

Tuning tip: Oiling the foam ring.

For the 2010 season Marzocchi introduced a foam/ felt ring that sits between the oil and dust seal. When originally fitted these were dry, this can lead to a sticky – notchy feeling over small movements. Newer forks have the ring assembled wet, however it is good practice to look after them. *Update: 2013 forks do not have these fitted.

The simple solution is to just cut them out! However by wetting the ring with oil, small pump performance and sensitivity of the fork is greatly improved – in fact this mod was done to my own fork by Marzocchi’s race mechanic and the difference is incredible.

1/ Carefully prise the dust seal up using a small flat bladed screwdriver – be careful not to slip as not to damage the stanchion.

2/ inspect and clean the area underneath the dust seal.

3/ Using a syringe, soak SAE7.5w suspension fork oil (the same as what’s inside) in to the foam ring until it looks completely wet.

4/ Re-seat dust seal

5/ you will get some oily smears on the station the first time you use it, just wipe these off and they will disappear after a very short time.

UPDATE 2013

We have noticed that in the new production of 2013 models there in no foam ring. The tolerance can also be tight, so combined with the NOK dust seal it can create a 'sticky' feeling. Marzocchi recommend using calcium grease under the dust seal to keep things running sweet.

carefully lift the dust seal with a flat bladed screw driver

clean and inspect

We are currently testing Morgan Blue calcium grease

get it up and under the seal, work it in by rotating the seal.