[Joz]

Hello,
i own a Marzocchi Dirt Jumper 1 fork (2007) that seems to have too less oil in it.
The performance - especially rebound - lacks and it makes a "clonky" sound on quick small hits.

So i found out how much oil it would need and got the oil but I am not quite sure where to insert the oil. At the top or the bottom?

We are talking about this fork:

I hope somebody can help me out.
Thanks a lot,

Joz

 

[sanjuro]

You take the top caps off. Probably a 21 or 23mm socket. I would not use a crescent wrench.

 

[Joz]

Thank you very much. I'll check the forks tonight. :>

 

[sanjuro]

I think the DJ1 has air assist. Make sure to let out the air first unless you want a cap shot into your eye.

 

[Joz]

I think the DJ1 has air assist. Make sure to let out the air first unless you want a cap shot into your eye.

Yes it has air assist on both legs. But isn't the air kept in a sealed cartridge so oil and air dont get mixed up?
Thank you,
Joz

 

[sanjuro]

The air goes into the top cap, which you have to remove. I am not sure of the exact schematic, but if you choose to ignore my advice, please have a camera running for posterity.

 

[Joz]

Sorry, no camera will be running. Air has already been removed.
But thank you for the advise. :>

 

[Joz]

All right, after asking Google for the right oil levels for about 20 minutes I decided to take the hard way and taking out oil step by step until full travel was provided again.

I found out that the following volumes work just fine:

Left leg (in riding direction): 130cc
Right leg: 170cc

Using these oil volumes, the distance from the top thread to the oil level is about 24mm on each side.

Now the fork just works as it should.
Joz

 

[sanjuro]

Good job.