This process is only for the 66 and 888 rc2x models. both use the same damping and structure. on difference is the spring size and travel.
If you are getting crunching from your fork and has not been that way for a while then this is for you.
The bike shop will not fix it since they do not know how. all they will say is to get a new cartridge.
Marzocchi WILL NOT SEND YOU THE PART NEEDED. They want you to send the fork in. THE PART COST $180.
Step 1
These are the tools you will need.
1. cassette tool(you can buy one without the long thing to stick through the Qucik release hole).
2. a big File. used to shave down the spring holders.
3. a wrench that can fit between the spring coils.
Step 2
this is my 66rc2x. it is being hanged so i can work on it. you must have something to hold your bike.
Step3
take off the caps and screws
Step4
Make sure it looks like this also Take The Air Out Of The Fork.
Step5
use a big socket to hold the cassette tool because you will need some leverage to open the fork.
Step6
The top cap should look like this.
Step7
now carfully push the lower crown up a bit. But not to much that oil comes out.
Step8
now use that thin wrench to hold the red nut so you can twist the can off. Twist the cap counterclockwise. or the way most things losen.
Step9
Now it should come off like this. And the rod should not sink down.
Step10
Now pull the spring half out or almost out since oil will be dripping.
Step11
Clean the spring off so oil wont get every where.
Step12
To absolutly make sure that its the springs and spring holder that are making noise. push the spring top and bottom of the white spring holder together. if you feel vibration and hear noise then that the problem. The spring holder has worn out or was not tight when made. if may not sound like its the problem since its so quite but when it in the fork and mostly hollow it echos and makes 5 times the noise when its in the fork.
Step13
Take a screw driver and stick it through the hole of the spring holder. and pull the spring off of it.
Step14
Clean off the spring holder so no oil is on it. this makes it easier to shave it down.
Step15
now shave it down evenly. it will take a bit of shaving to get what you want. but test it by putting it back on the spring and push them together. the final result should be that it is loose on the spring holder.
Step16
when you think its done, put it back on the spring holder and do the other one. its the same thing on both sides except the black spacer that has nothing to do with this process.
Step17
Make sure the rod is up so you can srew the cap on when you get the srping in.
Step18
the way it shows in the photo is not how you should try to get the cap back on. you need to compress the spring so the cap can go on and touch the threads of the rod.
Step19
Do Not Tighten very hard. just enough so it wont get loose
If you are getting crunching from your fork and has not been that way for a while then this is for you.
The bike shop will not fix it since they do not know how. all they will say is to get a new cartridge.
Marzocchi WILL NOT SEND YOU THE PART NEEDED. They want you to send the fork in. THE PART COST $180.
Step 1
These are the tools you will need.
1. cassette tool(you can buy one without the long thing to stick through the Qucik release hole).
2. a big File. used to shave down the spring holders.
3. a wrench that can fit between the spring coils.
Step 2
this is my 66rc2x. it is being hanged so i can work on it. you must have something to hold your bike.
Step3
take off the caps and screws
Step4
Make sure it looks like this also Take The Air Out Of The Fork.
Step5
use a big socket to hold the cassette tool because you will need some leverage to open the fork.
Step6
The top cap should look like this.
Step7
now carfully push the lower crown up a bit. But not to much that oil comes out.
Step8
now use that thin wrench to hold the red nut so you can twist the can off. Twist the cap counterclockwise. or the way most things losen.
Step9
Now it should come off like this. And the rod should not sink down.
Step10
Now pull the spring half out or almost out since oil will be dripping.
Step11
Clean the spring off so oil wont get every where.
Step12
To absolutly make sure that its the springs and spring holder that are making noise. push the spring top and bottom of the white spring holder together. if you feel vibration and hear noise then that the problem. The spring holder has worn out or was not tight when made. if may not sound like its the problem since its so quite but when it in the fork and mostly hollow it echos and makes 5 times the noise when its in the fork.
Step13
Take a screw driver and stick it through the hole of the spring holder. and pull the spring off of it.
Step14
Clean off the spring holder so no oil is on it. this makes it easier to shave it down.
Step15
now shave it down evenly. it will take a bit of shaving to get what you want. but test it by putting it back on the spring and push them together. the final result should be that it is loose on the spring holder.
Step16
when you think its done, put it back on the spring holder and do the other one. its the same thing on both sides except the black spacer that has nothing to do with this process.
Step17
Make sure the rod is up so you can srew the cap on when you get the srping in.
Step18
the way it shows in the photo is not how you should try to get the cap back on. you need to compress the spring so the cap can go on and touch the threads of the rod.
Step19