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2008 Marzocchi 55 TST2 Rebuild Oil Level Problem

J

_James_

Chimp
Sep 14, 2003
46
0
oakland
So, I'm rebuilding my 2008 55 TST2 this morning, well really just doing an oil change.

Glad I did, because what came out was diiiiiiirty. I should probably do this a bit more often. But, after I drained all the oil I started to run into problems.

First off, the oil levels in each leg were not what I expected (no surprise coming from Marzo). The left leg has about 75-100cc in it, the right leg 100cc or so.

Online, the Marzocchi website calls for 50cc in the right leg and 200cc in the left leg. ( 50/200 from the table ).

(1) Why would I pull more oil out of the right leg than they suggest having in there?
(2) When I put the 50cc in the right leg and 200cc in the left leg, the fork is essentially locked out. wtf? The only thing I can imagine is that the Marzocchi website is wrong, but that seems a bit far fetched to me. Any ideas?

Thanks for the help RM!
 
BrooklynMachine

BrooklynMachine

Monkey
Sep 1, 2007
320
0
16 powers st BKLN NY
The non-damper oil is just for lubrication, though it's strange that they put too much oil in the wrong side. Usually we've found oil low in both legs.
Also, drrrrrrty oil is pretty common for the damper side of marzo forks, especially in the initial break in.
We've turned golden spectro chunky gray in 2 weekends, though there wasn't a noticeable effect in damping (busted seal).
 
J

_James_

Chimp
Sep 14, 2003
46
0
oakland
Good to know about the non-damper side. Any ideas about the wrong oil level for the other leg then? I don't want to have too much or too little (within reason).
 
Racebike

Racebike

Monkey
Jul 28, 2008
463
4
Sweden
The oil levels in Mz. forks have always been dodgy from the factory.

Make sure you have emptied the whole fork before pouring mor oil in, if you simply put the fork up side down it doesn't always empty completely. You may need to cycle the fork (move the outers up an down) or take the outers off to ensure it's really empty.

Pour in the correct amount and compress the fork without the topcaps on, the oil should not be able to reach the topcap threads in the left leg, I imagine that's where the problem is.

If you are still not getting full travel, the problem could be inside your TST2 cartridge. This is easy to change the oil in as well, and the TST2 has had a lot of issues.
 
Racebike

Racebike

Monkey
Jul 28, 2008
463
4
Sweden
Topping out?

That's quite odd having that particular damping system in mind. What settings you running it with?
 
J

_James_

Chimp
Sep 14, 2003
46
0
oakland
well, it is taken apart right now. but i got the proper oil levels from Marzo support. I think my fork might have been missing some parts from the factory: the bottom seal cap assembly for the TST2 system. So, I am trying to work it out with them.
 
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