hi all
i remember this was a hotly debated topic so maybe i can same someone time and grief with this.
took me about 20 minutes and one call to a friendly zocchi tech.
this to celebrate the (too hot) weather and the fact ive now got a handy little digicam so small and cheap i can take it out to ride, or wrench!
step 1
remove footnuts, 15mm wrench (same as you use for pedals)
step 2
drain oil, put the fork upside down and have a bucket handy to catch the oil, there will be a lot of oil as this one has 200ml per side
step 3
remove lowers, just pull them of and youre done
dont loose the two black plastic spacers that might fall off or get left inside the lowers!
step 4
remove the cartridges, easy, you dont need to remove the adjusters just get the correct wrench (ill admit i used a crescent), then pull them off.
this is how it should look like, take note of the small spacers to the left of the top of the carts on the picture
step 5
now were getting into business.
you have to remove the top cap from the cartridge assembly.
use a small 8mm wrench or a needle nose plier with some rubber around it, and untighten the red locknut from the top cap, then unscrew the top cap, some oil probably will come out.
remove the red locknut (or whatever its called)
remove the silver piece with o-ring
fit the black spacer that previously lived on the bottom of the cartridge, onto the silver piece you just removed, it should "snap" into place.
fit the silver piece back into place as it was before, the black spacer should now be in contact with the spring
[img=http://img488.imageshack.us/img488/1575/66150to1700047hd.th.jpg]
step 5
reassembly of cartridge, put the red piece back in and screw it in as far as it will go
the very top end of the cartridge is the adjuster needle, unscrew it until you can remove it and leave it there
screw the top cap in until it bottoms out on the thread
now back the red nut until it contacts the top cap, and tighten it a little careful here, these are all alloy parts and too much force WILL damage them
in the picture, the cart to the left is at 170, the one on the right is at 150,note the black spacer
step 6
do the other cartridge
step 8
install the cartridges back in the stanchions, just snug them up, no need to be brutal.
here is how it should look like
step 8
refill with oil, this is best done with the fork upside down, slide the lowers on carefully in order not to damage the oil seals, just dont slide them all the way on so you can fill the oil in from the lower hole that now should be facing up since the fork is upside down
step 9
ride the damn thing
i remember this was a hotly debated topic so maybe i can same someone time and grief with this.
took me about 20 minutes and one call to a friendly zocchi tech.
this to celebrate the (too hot) weather and the fact ive now got a handy little digicam so small and cheap i can take it out to ride, or wrench!
step 1
remove footnuts, 15mm wrench (same as you use for pedals)
step 2
drain oil, put the fork upside down and have a bucket handy to catch the oil, there will be a lot of oil as this one has 200ml per side
step 3
remove lowers, just pull them of and youre done
dont loose the two black plastic spacers that might fall off or get left inside the lowers!
step 4
remove the cartridges, easy, you dont need to remove the adjusters just get the correct wrench (ill admit i used a crescent), then pull them off.
this is how it should look like, take note of the small spacers to the left of the top of the carts on the picture
step 5
now were getting into business.
you have to remove the top cap from the cartridge assembly.
use a small 8mm wrench or a needle nose plier with some rubber around it, and untighten the red locknut from the top cap, then unscrew the top cap, some oil probably will come out.
remove the red locknut (or whatever its called)
remove the silver piece with o-ring
fit the black spacer that previously lived on the bottom of the cartridge, onto the silver piece you just removed, it should "snap" into place.
fit the silver piece back into place as it was before, the black spacer should now be in contact with the spring
[img=http://img488.imageshack.us/img488/1575/66150to1700047hd.th.jpg]
step 5
reassembly of cartridge, put the red piece back in and screw it in as far as it will go
the very top end of the cartridge is the adjuster needle, unscrew it until you can remove it and leave it there
screw the top cap in until it bottoms out on the thread
now back the red nut until it contacts the top cap, and tighten it a little careful here, these are all alloy parts and too much force WILL damage them
in the picture, the cart to the left is at 170, the one on the right is at 150,note the black spacer
step 6
do the other cartridge
step 8
install the cartridges back in the stanchions, just snug them up, no need to be brutal.
here is how it should look like
step 8
refill with oil, this is best done with the fork upside down, slide the lowers on carefully in order not to damage the oil seals, just dont slide them all the way on so you can fill the oil in from the lower hole that now should be facing up since the fork is upside down
step 9
ride the damn thing
anyone wanna fill me in?