How to fix rebound cartridge on Marzocchi forks

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Flying FOX

Flying FOX

8 жыл бұрын

Most of the problem people have when drilling the cartridge is not knowing about the piston at the bottom of the cylinder. If the piston moves above the bottom hole, oil can’t get to the rebound valve so your rebound won’t work. Also as the shock is compressed the oil will have to pass through the hole you drilled and a hydro lock will occur on the bottom of the travel.
Extend the cylinder and drill any where below 13mm from the bottom of the cylinder, (I recommend 8mm because the piston is 13.12mm long.).. That will let all the nitrogen out. Push the cylinder down and drill through the piston, using the same hole. (Use a long clamp to hold the cylinder down.) Then you need to tap and put in a set screw, bolt and nut with lock tight or use a roll pin to stop the piston from moving up and down. If you use a roll pin or bolt drill all the way through. Decide what you are going to block the piston with and drill the hole size appropriately.
Next drill a 1/16inch (1.5 mm) or smaller hole 30 mm from the weld on the bottom of the Cartridge. Make sure you extend the cartridge to its maximum length. This way you won’t damage the rebound seal.
Also drill a hole 12mm from the top of the cartridge (no more that 12.5mm no less than 11.5mm) with a 1/16 inch bit, smaller size is better this is to let the air out.
Avoid drilling to deep so you don't nick the shaft, 2.5mm deep will put you in the seal groove but do not drill deeper than 4.75mm you will hit the shaft. If you do it right you should be able to see the seal or the bottom of the seal groove, this allows air to escape from the top of the cylinder.
Now reinstall it, compress the fork all the way then fill the fork with oil till it covers the top of the Cart. Move the shaft of the cartridge up and down to suck in the oil,
fill as needed (170cc in my case) and your read to go. Finish putting you fork back together.
P.S. up the oil weight to compensate for the extra flow, try 10 weight.

Пікірлер: 149
@64maxpower
@64maxpower 6 жыл бұрын
Thanks for putting this up. I need to watch it again few more times before I attempt fixing my cartridge
@steveleroux9136
@steveleroux9136 4 жыл бұрын
Holy SMOKES!!! I followed your video and instructions slowly and carefully and it worked GREAT on my 2008 Marzocchi DJ3 forks. Thank you the video. Your measurements were precise and accurate. 👍🏼👍🏼
@ReindeerBork
@ReindeerBork 4 жыл бұрын
Thanks!!! Just fixed my friends 55R and it’s working beautifully rebound fully functional and smooth once again.
@alopor1
@alopor1 3 жыл бұрын
Thank you so much for this video. It worked perfectly in my Marz 55R. I added more oil (10w) to my fork. The rebound works amazingly. I added an electric tape to the drill leaving 3mm exposed to be safe on the upper hole. Thank you so much.
@jostafew
@jostafew 7 жыл бұрын
Thanks very much for the video! Completely fixed the 55R that came on my '08 Norco Six. Working great now with no need to up the oil weight for me, still have lots of rebound adjustment range with the stock 7.5wt oil. One comment that I think should be made is not to cycle the damper past the 30mm bottom hole as the burr on the inside of the tube will tear up the plunger seal. Took me a couple strokes with resistance around that point, and then a visual confirmation that the seal was just travelling past the 30mm hole. Pretty confident that in normal operation it won't reach that far, but on the bench damage could be done that way. Thanks again
@kaseyburlingham2861
@kaseyburlingham2861 3 жыл бұрын
Going to try this next week, so happy to find a video!
@CalinAlexander
@CalinAlexander 4 жыл бұрын
Right on brother - worked perfectly. Good measurements for the drilling. I added more fluid than you, also used 7.5 not 10 wt. If you feel the shock isn't stiff enough just add more until you like the feel and it doesn't bottom out too easily! Cheers. P.S. You DO NOT need to remove your forks form the bike, nor the stem... just pull the cartridge out of the left tube by loosening the bottom nut. Highly recommend safety glasses, the Nitrogen came out clean and low pressure but the oil squirted 1 meter in the air when I drilled the second hole. My Marzocchi 55 r on my 2008 Norco Sasquatch are now back to factory perfection.
@robedge7670
@robedge7670 3 жыл бұрын
Rebuilt the forks again a second time as big failure of both damper mod and no oil left in the left leg. Received the new seals and put them back together. Massive difference! I put 170ml in the left leg, 160 in the right leg and 50 psi . My weight on the bike is roughly 95kg with all my gear. Delighted so far! Hopefully they’ll keep this way. Used 120 of the 160mm travel so far. Just taking things easy on this run. No big jumps, but will do next time.
@kaseyburlingham2861
@kaseyburlingham2861 3 жыл бұрын
Modification worked, can't wait to test it on on a trail!
@leichengift
@leichengift Жыл бұрын
Z1 sport 2008 with this tutorial = new performance:) thx!!!!!!
@kellysimpson3509
@kellysimpson3509 7 жыл бұрын
Just did the suggested change to my Bomber 55 as I was having problems with the full stroke of the shock. After doing the fix I now have a full stroke and like the results. The only issue the rebound seems to rebound harder causing a shock to extend out harder making a full extension noise. I turned the rebound all the way back and still have the kick out full extension noise. I only have this problem with doing a wheelie or hitting a jump. I figured I try it as I was looking at a new cartridge anyway. Im over all impressed other then the problem and will keep riding it this way. It does suck up the bumps better. Thank you for the fix.
@flying.fox987
@flying.fox987 7 жыл бұрын
What do you mean "the rebound seems to rebound harder"? You mean faster? Did you put enough oil on leg with rebound?
@aliwatsonlilley2894
@aliwatsonlilley2894 6 жыл бұрын
Yeh mate I have the exact same problem I’m no sure what it is but it might need more oil
@grayman505
@grayman505 3 ай бұрын
I'm going to try this with my DJ1 and see how it goes
@darotizacija
@darotizacija 10 ай бұрын
it works man but the 2 holes i drill it with 4mm drill a bit bigger and it works fine the rebound is fast in the bottom but on top out its slow sooo DONE!!
@trentschnell7225
@trentschnell7225 4 жыл бұрын
Thanks for this lmao every forum post has expired links and photos
@n8_vel868
@n8_vel868 Жыл бұрын
I have a damper cartridge similar to that but it's sealed and non serviceable like that and it's not going down into it's full travel anymore. I don't know if oil from my lowers leaked into the damper and caused it to be overfilled because it gets locked out 50% up it's travel. I don't have a rebound adjust and the compression isn't locking the damper when I have it off
@luchofly
@luchofly 4 жыл бұрын
What air pressure do you put on the rebound side?
@yuppie3689
@yuppie3689 6 жыл бұрын
Hello, great tutorial, i got a sr xcr fork its had a same damper catridge like marzocchi but with remote lockout on top of it, the damper now leaking cannot use the lockout mode. The question is can i do the same thing like in your video to repair the lockout mode with open bath system? Hope you will help thanks in advance
@flying.fox987
@flying.fox987 6 жыл бұрын
Sorry for late answer, Im not sureyou can do the same thing... In this video Im using rebound catrige, Im not sure if your lock out catrige work the same like mine rebound... So sorry, but I cant tell you what to do...
@robedge7670
@robedge7670 3 жыл бұрын
how did you open up the damper?
@MadGQ
@MadGQ 8 ай бұрын
Hi there, I have a Kona dh bike with the Marzocchi 888 rcv 2008, the fork functions fairly fine however the rebound knob is stuck and unable to move, is it becoz of lack of oil or something, i haven’t serviced the fork or anything yet, please let me know..
@dillonpaulsen3294
@dillonpaulsen3294 2 жыл бұрын
Haw can I safely drain the nitrogen from my shock so I can do what you do in video
@samirakhmedov4083
@samirakhmedov4083 4 жыл бұрын
Hi, Thanks for a great video! The first hole at 8mm from bottom, is it still only 1,5 mm and you can fit the wire? How large is the wire? Also about the top hole, how do you know when you've drilled it to only 2.5 mm? Thanks!
@toganlompkins8886
@toganlompkins8886 Жыл бұрын
Measure it on the drill bit and use tape to mark it. When you hit the tape, it will be far enough.
@faghgoog7412
@faghgoog7412 5 жыл бұрын
Thank you very much for this video. I made the modification on a 2008 DJ2, but I can't tighten the bottom nut when I put the fork back up: the cartridge rotates on itself when I tighten. Do you have a solution? Regards.
@flying.fox987
@flying.fox987 5 жыл бұрын
hmm, hard to give some advice about that :/
@neildavies821
@neildavies821 3 жыл бұрын
I've just Carried this out on my BOMBER DJ2'S. When you pour the oil in at the end does it need to cover the top hole or should the hole stay above the oil level?
@flying.fox987
@flying.fox987 3 жыл бұрын
Sorry, to long time ago... I cant rememebr... You can try above first...
@Dirtstroyer
@Dirtstroyer 4 жыл бұрын
Hi...I have Suntour AXON fork which lockout doesn't work from 2010 and also reboud....do you think this will work also wit my fork?
@flying.fox987
@flying.fox987 4 жыл бұрын
Not sure if its the same catrige, but it could be....
@krisztianmolnar24
@krisztianmolnar24 6 жыл бұрын
How much oli you pour in catridge? And what dense 5w,15w,7.5w?
@flying.fox987
@flying.fox987 6 жыл бұрын
170cc, 10w...
@darryljcarrington
@darryljcarrington 6 жыл бұрын
Hey man would this work on a dj3 fork I think the chamber is the other way around. The internal piston is at the bottom and the chamber at the top. Many thanks great vid
@flying.fox987
@flying.fox987 6 жыл бұрын
What year is your dj3? But yes, I think it should work on it also.....
@smart9582
@smart9582 5 жыл бұрын
The piston is upside down in the newer DJ3's. Would this method work with the upside down piston? Well I don't think so. :S
@Sendit-xr3jz
@Sendit-xr3jz 7 жыл бұрын
So I have a kona five o I have looked for so many methods to fixing my problem with my forks and no matter how hard I try or what I do my forks are still the same So the problem is my forks are way to stiff I have the marzocchi bomber 55 forks it says rebound on one side and air preload on the other. I have tried playing with the rebound dial and it didn't help I tried putting air in taking it out still didn't help I'm probably only using 1 inch of my fork it's that bad so I took them apart and it seems like my cartridge is way to stiff what do it do to fix my forks?
@flying.fox987
@flying.fox987 7 жыл бұрын
Or the spring is to hard for you in preload leg (but I dont think so), and it depends on how much do you weigh...
@GuitarGreekPlayer
@GuitarGreekPlayer 4 жыл бұрын
did the rebound ajustemt work after that or returns like crazy?
@flying.fox987
@flying.fox987 4 жыл бұрын
Adjustmen work after that....
@sbek1386
@sbek1386 4 жыл бұрын
www.marzocchi.com/System/19144/MY2010%20-%2022%20RLO%20RC%20-%20120_R00-06.pdf I have this fork. My problem is the oil comes out of the cartridge and goes on that "piston" then it deposits on the lower legs wall. After doing all of this I see the oil on my stanchion. What should I do? Do I need to refill the damper unit or even change it?
@Leinadeq
@Leinadeq 2 ай бұрын
can i do that in marzocchi 66 rc3 evo ti ?
@ethanharding3573
@ethanharding3573 7 жыл бұрын
do you still have the forks, and are they still working fine?
@flying.fox987
@flying.fox987 7 жыл бұрын
yes, still have it, and still works fine...
@davemunk
@davemunk 4 жыл бұрын
Hi - great video. I have an issue with the rebound not working properly on my 55r's. The rebound is very fast and turning the adjust knob does nothing. Do you know if this mod fixes this? Or does it fix the locked Travel issue only? Many thanks in advance! Dave
@flying.fox987
@flying.fox987 4 жыл бұрын
This will make your rebound work 👍
@davemunk
@davemunk 4 жыл бұрын
@@flying.fox987 amazing - thanks for the reply. I shall give it a try!
@grr1972
@grr1972 4 жыл бұрын
@@davemunk results?
@mikoajkoodziej702
@mikoajkoodziej702 6 жыл бұрын
What model of fork you change there?
@flying.fox987
@flying.fox987 6 жыл бұрын
bomber 55R..
@sh1wsp0wntday94
@sh1wsp0wntday94 5 жыл бұрын
My fork strokes 90mm out of 160mm, but the rebound works fine. The rebound is the same, on the sticker is written SR Suntour. I think the cartridge is overflown so i will make it open bath. Is it going to work ? Thank you. 🤔
@flying.fox987
@flying.fox987 5 жыл бұрын
It should work...
@sh1wsp0wntday94
@sh1wsp0wntday94 5 жыл бұрын
@@flying.fox987 thanks for the fast response, bro
@dcoll988
@dcoll988 4 жыл бұрын
Was the fork you repaired the adjustable travel ata version? I want to make sure it will work the same before I go drilling into anything
@flying.fox987
@flying.fox987 4 жыл бұрын
mine was not adjustable travel....
@dcoll988
@dcoll988 4 жыл бұрын
@@flying.fox987 Do you think i would be save to do the same with the adjustable version? I'm assuming the cartridges would be the same I have the 55 AMA looks nearly identical to the R. its completely locked out at the moment not sure what else to try.
@flying.fox987
@flying.fox987 4 жыл бұрын
@@dcoll988 i really dont know that, sorry
@gabrielluiz1549
@gabrielluiz1549 3 жыл бұрын
2k21 update!! Rebound Works 100% with this tutorial. I used 7.5wt oil, 220cc, rebound adjust Works with perfect flow in my case! Thanks for the great vídeo. Im for Brasil, Sorry for the poor english
@flying.fox987
@flying.fox987 3 жыл бұрын
Glad that I help you.
@kaseyburlingham2861
@kaseyburlingham2861 3 жыл бұрын
Anyone know where I can get a firm spring for 55r bomber fork?
@flying.fox987
@flying.fox987 3 жыл бұрын
Sorry, I dont know...
@HobbySkills
@HobbySkills 7 жыл бұрын
hello!I have 44 rlo. The cartridge is upside down. Its same catridge? How to drill it? help please!
@flying.fox987
@flying.fox987 7 жыл бұрын
I didnt see upside down catridge, sorry... Try ask on some forum... Really sorry that i cant help...
@tomassuvada2084
@tomassuvada2084 5 жыл бұрын
I have same issue, in cartridge there is no oil so cartridge doesn't work
@rodrihand
@rodrihand 4 жыл бұрын
Hi mate! Is this tutorial valid for an 2008 55 tst2?
@flying.fox987
@flying.fox987 4 жыл бұрын
Im not sure, sorry.
@64maxpower
@64maxpower 6 жыл бұрын
I'm assuming you wired the Piston to hold it instead of a set screw. Or am I confusing something? I know this is simple but parts are still a little vauge for me
@flying.fox987
@flying.fox987 6 жыл бұрын
yep, I use wire instead bolts....
@davecowell5183
@davecowell5183 4 жыл бұрын
Does the wire last or does it need replacing every time you service the forks?
@G4Disco
@G4Disco 3 жыл бұрын
Was your rebound knob stiff or unable to move before you converted it?
@flying.fox987
@flying.fox987 3 жыл бұрын
Knob was fine...
@MadGQ
@MadGQ 8 ай бұрын
Mine is also stiff and unable to move, what do I do? Did you find a solution? I have a marz 888 rcv..
@tomaperkovic
@tomaperkovic 3 жыл бұрын
sorry is it fixing the pumping problem to sound like something is hitting
@flying.fox987
@flying.fox987 3 жыл бұрын
I dont think so...
@ivanroncevic4797
@ivanroncevic4797 3 жыл бұрын
Does this eork on a marzocchi 66 from idk year but its taperd and it has air preload i think its a 2010
@ivanroncevic4797
@ivanroncevic4797 3 жыл бұрын
Also its a marsoccho 66 rcv
@flying.fox987
@flying.fox987 3 жыл бұрын
@@ivanroncevic4797 sorry, I dont know that...
@liuwenjie9105
@liuwenjie9105 7 жыл бұрын
I did the same job when I worked for KYB lol drill da cylinder with multiple diameters !XD
@desmondallen9374
@desmondallen9374 6 жыл бұрын
does it work cause my forks are almost seized but move fine with out the cartridge could this work for me
@papo_freerider6856
@papo_freerider6856 3 жыл бұрын
Hi, I've done the job, but will the rebound adjustment still work or won't it work anymore?
@flying.fox987
@flying.fox987 3 жыл бұрын
Adjusment should work...
@papo_freerider6856
@papo_freerider6856 3 жыл бұрын
Thank’s
@papo_freerider6856
@papo_freerider6856 3 жыл бұрын
Ok it still works Thanks 😊
@WujoCaZa
@WujoCaZa 3 жыл бұрын
Works on sun tour lock on cartridge as well
@darkter8071
@darkter8071 Жыл бұрын
On what suntour fork you did that. You drilled holes same way as in the video?
@WujoCaZa
@WujoCaZa Жыл бұрын
@@darkter8071 oh dude, I don’t quite remember. I think some xcr one. Yes I do everything as is on the video. But also I had to weld some upper bolt because it was drilled for some reason, and oil was pumping out from fork.
@darkter8071
@darkter8071 Жыл бұрын
@@WujoCaZa Thanks bro
@joaofranca9334
@joaofranca9334 7 жыл бұрын
hello mate i have a 888 rc2x and the rebound doesn't work at all, because it works fine before i make 1/4 of the travel, after that it returns slowly in all of the travel, if i do that mod on mine does it will solve the problem? best regards
@flying.fox987
@flying.fox987 7 жыл бұрын
Hmm, Im not sure, I am not familiar with 888 rc2x... Try to contact marzocchi.
@joaofranca9334
@joaofranca9334 7 жыл бұрын
Fox Lehkec thank you anyway :)
@flying.fox987
@flying.fox987 7 жыл бұрын
np... Anyway, I think that rebound should work if you do the same on your fork... But I cant promise it will...
@joaofranca9334
@joaofranca9334 7 жыл бұрын
Fox Lehkec ok i will contact Marzocchi and try that mod then i say something thanks again mate +1 subscriber
@flying.fox987
@flying.fox987 7 жыл бұрын
Thank you!
@user-ko9gz5nf9l
@user-ko9gz5nf9l 6 жыл бұрын
Do not have to wash the scraps?
@flying.fox987
@flying.fox987 6 жыл бұрын
no need....
@fl0wmate563
@fl0wmate563 5 жыл бұрын
Hello, why do u put wire trough the holes ?
@flying.fox987
@flying.fox987 5 жыл бұрын
To fix the piston in.... So it cant go up and down anymore and cant close the holes for oil...
@fl0wmate563
@fl0wmate563 5 жыл бұрын
@@flying.fox987 i dont understand
@flying.fox987
@flying.fox987 5 жыл бұрын
Read description, please.
@ThomasOberthanner
@ThomasOberthanner 6 жыл бұрын
is this tutorial also valid for a 2014 55 MICRO SWITCH TA (120-160mm travel)? current max travel is roughly 60mm...
@flying.fox987
@flying.fox987 6 жыл бұрын
I think no....
@Gustavo-ov8et
@Gustavo-ov8et 4 жыл бұрын
Works on my rst storm!
@ricardocastillo4711
@ricardocastillo4711 3 жыл бұрын
I have a Marzocchi Bomber 55 2008 140mm travel drilled no travel only working with air. Is it possible to put it back to travel and working as new??
@flying.fox987
@flying.fox987 3 жыл бұрын
Im not sure...
@ricardocastillo4711
@ricardocastillo4711 3 жыл бұрын
@@flying.fox987 hi just one question when you drilled the cartridge the nitrogen and the oil inside goes out?
@flying.fox987
@flying.fox987 3 жыл бұрын
@@ricardocastillo4711 yes...
@ricardocastillo4711
@ricardocastillo4711 3 жыл бұрын
Hi I did all the work exactly to the video. But when I TESTED the fork got hydroluck
@ricardocastillo4711
@ricardocastillo4711 3 жыл бұрын
Is it still functional by doing some thing else??
@SK-mc7uw
@SK-mc7uw 7 жыл бұрын
So this process is what I would do to my 2010 bomber 55 RV, alongside replacing the oil, yeah? I believe my forks have the hydro locking problem .
@flying.fox987
@flying.fox987 7 жыл бұрын
I dont think that you have same rebound cartridge.... www.mountainbikes.net/mtbikes/spl/marzocchisk55rv2010_b.png
@SK-mc7uw
@SK-mc7uw 7 жыл бұрын
Fox Lehkec greatttttt....
@robedge7670
@robedge7670 3 жыл бұрын
sorry, bit of a stupid question I put up the other day, please ignore! Can I ask what the wire is for? I take it the piston is not attached to the shaft?? My forks are a 2008 Marzocchi Bomber Z1 Sport from a Big Hit 1. No travel passed 55mm the last 2 weeks and the damper is the issue. Will this work on my forks too? Many thanks
@flying.fox987
@flying.fox987 3 жыл бұрын
Wire is to fix the piston in place, so its not able to travel up and down anymore...
@robedge7670
@robedge7670 3 жыл бұрын
@@flying.fox987 thanks, thought so. Just watched it again. Will give it a go tomorrow and see what happens. 👍
@flying.fox987
@flying.fox987 3 жыл бұрын
@@robedge7670 lot of guys says its works perfect after this makeover...
@robedge7670
@robedge7670 3 жыл бұрын
@@flying.fox987 managed to grab a used set of fox 40’s with 180mm travel on Christmas Eve just in case! But need a wheel for these as the axle is 25mm not 20 as advertised and as per my specialized one.
@flying.fox987
@flying.fox987 3 жыл бұрын
@@robedge7670 didnt know there is 25mm axle on MTB forks 😲
@FernandoRodriguez-sg6uf
@FernandoRodriguez-sg6uf 4 жыл бұрын
I hope it work on my RLO 44
@cthevarge
@cthevarge 3 жыл бұрын
Did it work on your 44 rlo?
@FernandoRodriguez-sg6uf
@FernandoRodriguez-sg6uf 3 жыл бұрын
@@cthevarge Never tried
@cristhiamarango4320
@cristhiamarango4320 5 ай бұрын
Nececito comprar esta pieza
@deddyzhy9203
@deddyzhy9203 3 жыл бұрын
Is there any other way?
@flying.fox987
@flying.fox987 3 жыл бұрын
Not that I would know...
@deddyzhy9203
@deddyzhy9203 3 жыл бұрын
@@flying.fox987 👍How are the characteristics of a problem cartridge? If the fork sounds "dug" (like the sound of metal colliding) when it is lifted, what is the problem and how to fix it?
@eldelabicidecolores
@eldelabicidecolores 3 жыл бұрын
@@deddyzhy9203 That's a top out. Maybe you've got it set up on high rebound, maybe check oil levels... may be cause of multiple things.
@xts-dk2wb
@xts-dk2wb 5 жыл бұрын
imam marzocchi 888 dupla kruna i rebound me jebe kako god nastimam polako se vraca skroz, da libce ova metoda sta pomoci. Hvala unaprijedm
@flying.fox987
@flying.fox987 5 жыл бұрын
Mislim da ne, sumnjam da 888 ima takav catrgie....
@xts-dk2wb
@xts-dk2wb 5 жыл бұрын
Fox Lehkec Probat cu ja sutra izbusit jbt ga
@flying.fox987
@flying.fox987 5 жыл бұрын
haha... al nebi baš preporučio.... ovo na snimci se radi kad je rebound prebrz i uopće ne reagira na podešavanje....
@xts-dk2wb
@xts-dk2wb 5 жыл бұрын
Fox Lehkec meni podesavanje ne radi a ne znam kako da nastimam normalno da radi, jer svaki put kad mi vila ima 7cm hod izvlaci se kao jebeni puz tako da ne stigne ublazit udarce drugih prepreka na stazi .. a puno mi ke dati 300 do 400 eura za drugu
@flying.fox987
@flying.fox987 5 жыл бұрын
jasno.... a niš, probaj rastavit pa vidit kaj je...
@tonynualchanchy1195
@tonynualchanchy1195 5 жыл бұрын
How to remove nitrogen from cartridge
@flying.fox987
@flying.fox987 5 жыл бұрын
With drilling first hole...
@tonynualchanchy1195
@tonynualchanchy1195 5 жыл бұрын
@@flying.fox987 it explode or not because look like high pressure inside i'm afraid when i'm drilling it be danger
@flying.fox987
@flying.fox987 5 жыл бұрын
It does explode, but nothing special or dangerous.
@isaaccuartase3546
@isaaccuartase3546 3 ай бұрын
This mod sucks 😾
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