How to fix rebound cartridge on Marzocchi forks

[@steveleroux9136]

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. 👍🏼👍🏼

[@alopor1]

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.

[@64maxpower]

Thanks for putting this up. I need to watch it again few more times before I attempt fixing my cartridge

[@CalinAlexander]

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.

[@grayman505]

I'm going to try this with my DJ1 and see how it goes

[@kaseyburlingham2861]

Going to try this next week, so happy to find a video!

[@robedge7670]

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.

[@leichengift]

Z1 sport 2008 with this tutorial = new performance:) thx!!!!!!

[@jostafew]

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

[@ReindeerBork]

Thanks!!! Just fixed my friends 55R and it’s working beautifully rebound fully functional and smooth once again.

[@kellysimpson3509]

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]

What do you mean "the rebound seems to rebound harder"? You mean faster? Did you put enough oil on leg with rebound?

[@aliwatsonlilley2894]

Yeh mate I have the exact same problem I’m no sure what it is but it might need more oil

[@kaseyburlingham2861]

Modification worked, can't wait to test it on on a trail!

[@Leinadeq]

can i do that in marzocchi 66 rc3 evo ti ?

[@G4Disco]

Was your rebound knob stiff or unable to move before you converted it?

[@flying.fox987]

Knob was fine...

[@MadGQ]

Mine is also stiff and unable to move, what do I do? Did you find a solution? I have a marz 888 rcv..

[@dillonpaulsen3294]

Haw can I safely drain the nitrogen from my shock so I can do what you do in video

[@WujoCaZa]

Works on sun tour lock on cartridge as well

[@darkter8071]

On what suntour fork you did that. You drilled holes same way as in the video?

[@WujoCaZa]

@@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]

@@WujoCaZa Thanks bro

[@MadGQ]

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..

[@darotizacija]

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!!

[@gabrielluiz1549]

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]

Glad that I help you.

[@n8_vel868]

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

[@trentschnell7225]

Thanks for this lmao every forum post has expired links and photos

[@sh1wsp0wntday94]

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]

It should work...

[@sh1wsp0wntday94]

@@flying.fox987 thanks for the fast response, bro

[@robedge7670]

how did you open up the damper?

[@luchofly]

What air pressure do you put on the rebound side?

[@tomaperkovic]

sorry is it fixing the pumping problem to sound like something is hitting

[@flying.fox987]

I dont think so...

[@neildavies821]

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]

Sorry, to long time ago... I cant rememebr... You can try above first...

[@yuppie3689]

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]

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...

[@ricardocastillo4711]

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]

Im not sure...

[@ricardocastillo4711]

@@flying.fox987 hi just one question when you drilled the cartridge the nitrogen and the oil inside goes out?

[@flying.fox987]

@@ricardocastillo4711 yes...

[@ricardocastillo4711]

Hi I did all the work exactly to the video. But when I TESTED the fork got hydroluck

[@ricardocastillo4711]

Is it still functional by doing some thing else??

[@Dirtstroyer]

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]

Not sure if its the same catrige, but it could be....

[@dcoll988]

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]

mine was not adjustable travel....

[@dcoll988]

@@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]

@@dcoll988 i really dont know that, sorry

[@64maxpower]

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]

yep, I use wire instead bolts....

[@davecowell5183]

Does the wire last or does it need replacing every time you service the forks?

[@FernandoRodriguez-sg6uf]

I hope it work on my RLO 44

[@cthevarge]

Did it work on your 44 rlo?

[@FernandoRodriguez-sg6uf]

@@cthevarge Never tried

[@papo_freerider6856]

Hi, I've done the job, but will the rebound adjustment still work or won't it work anymore?

[@flying.fox987]

Adjusment should work...

[@papo_freerider6856]

Thank’s

[@papo_freerider6856]

Ok it still works Thanks 😊

[@darryljcarrington]

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]

What year is your dj3? But yes, I think it should work on it also.....

[@smart9582]

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

[@ivanroncevic4797]

Does this eork on a marzocchi 66 from idk year but its taperd and it has air preload i think its a 2010

[@ivanroncevic4797]

Also its a marsoccho 66 rcv

[@flying.fox987]

@@ivanroncevic4797 sorry, I dont know that...

[@krisztianmolnar24]

How much oli you pour in catridge? And what dense 5w,15w,7.5w?

[@flying.fox987]

170cc, 10w...

[@GuitarGreekPlayer]

did the rebound ajustemt work after that or returns like crazy?

[@flying.fox987]

Adjustmen work after that....

[@samirakhmedov4083]

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]

Measure it on the drill bit and use tape to mark it. When you hit the tape, it will be far enough.

[@davemunk]

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]

This will make your rebound work 👍

[@davemunk]

@@flying.fox987 amazing - thanks for the reply. I shall give it a try!

[@grr1972]

@@davemunk results?

[@faghgoog7412]

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]

hmm, hard to give some advice about that :/

[@robedge7670]

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]

Wire is to fix the piston in place, so its not able to travel up and down anymore...

[@robedge7670]

@@flying.fox987 thanks, thought so. Just watched it again. Will give it a go tomorrow and see what happens. 👍

[@flying.fox987]

@@robedge7670 lot of guys says its works perfect after this makeover...

[@robedge7670]

@@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]

@@robedge7670 didnt know there is 25mm axle on MTB forks 😲

[@deddyzhy9203]

Is there any other way?

[@flying.fox987]

Not that I would know...

[@deddyzhy9203]

@@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]

@@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.

[@cristhiamarango4320]

Nececito comprar esta pieza

[@fl0wmate563]

Hello, why do u put wire trough the holes ?

[@flying.fox987]

To fix the piston in.... So it cant go up and down anymore and cant close the holes for oil...

[@fl0wmate563]

@@flying.fox987 i dont understand

[@flying.fox987]

Read description, please.

[@rodrihand]

Hi mate! Is this tutorial valid for an 2008 55 tst2?

[@flying.fox987]

Im not sure, sorry.

[@Ярослав-ы8г2ы]

Do not have to wash the scraps?

[@flying.fox987]

no need....

[@kaseyburlingham2861]

Anyone know where I can get a firm spring for 55r bomber fork?

[@flying.fox987]

Sorry, I dont know...

[@Sendit-xr3jz]

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]

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...

[@mikoajkoodziej702]

What model of fork you change there?

[@flying.fox987]

bomber 55R..

[@ethanharding3573]

do you still have the forks, and are they still working fine?

[@flying.fox987]

yes, still have it, and still works fine...

[@HobbySkills]

hello!I have 44 rlo. The cartridge is upside down. Its same catridge? How to drill it? help please!

[@flying.fox987]

I didnt see upside down catridge, sorry... Try ask on some forum... Really sorry that i cant help...

[@tomassuvada2084]

I have same issue, in cartridge there is no oil so cartridge doesn't work

[@joaofranca9334]

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]

Hmm, Im not sure, I am not familiar with 888 rc2x... Try to contact marzocchi.

[@joaofranca9334]

Fox Lehkec thank you anyway :)

[@flying.fox987]

np... Anyway, I think that rebound should work if you do the same on your fork... But I cant promise it will...

[@joaofranca9334]

Fox Lehkec ok i will contact Marzocchi and try that mod then i say something thanks again mate +1 subscriber

[@flying.fox987]

Thank you!

[@sbek1386]

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?

[@SK-mc7uw]

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]

I dont think that you have same rebound cartridge.... www.mountainbikes.net/mtbikes/spl/marzocchisk55rv2010_b.png

[@SK-mc7uw]

Fox Lehkec greatttttt....

[@xts-dk2wb]

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]

Mislim da ne, sumnjam da 888 ima takav catrgie....

[@xts-dk2wb]

Fox Lehkec Probat cu ja sutra izbusit jbt ga

[@flying.fox987]

haha... al nebi baš preporučio.... ovo na snimci se radi kad je rebound prebrz i uopće ne reagira na podešavanje....

[@xts-dk2wb]

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]

jasno.... a niš, probaj rastavit pa vidit kaj je...

[@tonynualchanchy1195]

How to remove nitrogen from cartridge

[@flying.fox987]

With drilling first hole...

[@tonynualchanchy1195]

@@flying.fox987 it explode or not because look like high pressure inside i'm afraid when i'm drilling it be danger

[@flying.fox987]

It does explode, but nothing special or dangerous.

[@ThomasOberthanner]

is this tutorial also valid for a 2014 55 MICRO SWITCH TA (120-160mm travel)? current max travel is roughly 60mm...

[@flying.fox987]

I think no....

[@Gustavo-ov8et]

Works on my rst storm!

[@liuwenjie9105]

I did the same job when I worked for KYB lol drill da cylinder with multiple diameters !XD

[@desmondallen9374]

does it work cause my forks are almost seized but move fine with out the cartridge could this work for me

[@isaaccuartase3546]

This mod sucks 😾