Compression valve(nut) on the bottom of a marzocchi 45?

[wence]

The bike is an 07 Ec300 with zoke 45s .
I was just wondering if anyone had a spare compression adjuster valve.
This is the 21mm nut which houses the compression adjuster clicker.
I have managed to strip the nut and need a new one.
It is the right side fork leg.
Can anyone help me out????? please?
Cheers Mark

 

[GMP]

How bad? You can try a 13/16" six point spark plug socket, its a tight fit on a 21mm nut. Grind the lead in taper off the end for more contact area(a trick Les taught me). Use a pneumatic impact tool.

 

[wence]

It is pretty rounded now Glenn.
I was using a rattle gun to undo it and it was obviously locked in good.I thought I had got it undone until I realised it was actually spinning and rounding the nut instead.
I was hoping I could buy one off of someone as I want to fix it before I move it on.
Cheers Mark

 

[wence]

Anyone????

 

[Idahocharley]

Can't help with the compression adjustment nut piece other than offer advice for the future.

Most sockets have a beveled "lead-in edge". To maximize the engagement of socket to soft aluminium nut grind the "lead-in face" off the correct size socket. You will then have full engagement of the socket to the available alumium nut surface which minimizes the chances of rounding the nut. This is a tip applicable to KYB, Zokes, WP and other forks also.

 

[wence]

Thank Idaho,
Hopefully this will help others also.
Cheers Mark

 

[STM Suspension]

I'll check with relevant sources on Monday- Feel free to give me a call if I don't get to posting.

 

[wence]

Thanks Dave, wiil do.
Mark

 

[STM Suspension]

In the process of checking... Marzocchi USA is checking with Italy- and I'm checking with the last people they sold some to- although it was 18 months ago.

 

[wence]

Much appreciated Dave
Thanks again ,
Mark

 

[swazi_matt]

To make sure that I do not end up in a similar predicament could someone let me know what is the secret to removing the comp valve nut from the rest if the fork
I have removed the fork caps and managed to loosen the bottom fork nut but it appears to just be turning and not actually unscrewing what am I missing?
Thx

 

[STM Suspension]

Ok. Marzocchi USA still hasn't heard anything from Italy. Imagine that.

I spoke with the guy here that they sent some to a while ago- they're gone.

So we'll see what Italy has to say about getting some. Sorry.

As to taking the compression holder out of the bottom... Without a cart tool to hold the top, you usually have to either pull on the cart shaft with one hand and hit the compression holder with the impact or, sometimes, you can put the spring back in, put the cap back on, turn it upside down, compress the spring and then turn the nut.

Your mileage may vary.

I'm going to make a tool to hold the cart from the top so we can stop using the impact on the aluminum.

 

[bchatt]

To make sure that I do not end up in a similar predicament could someone let me know what is the secret to removing the comp valve nut from the rest if the fork
I have removed the fork caps and managed to loosen the bottom fork nut but it appears to just be turning and not actually unscrewing what am I missing?
Thx

The entire cartridge will be spinning because there is nothing to hold it. Without using a rattle gun, it's best to unscrew the base valve while the fork is still fully assembled, and under some compression. i.e while the bike is still tied down to the trailer is a good time, if you think of it at that stage. Alternately, flip the fork upside down, put a rag on the floor, compress the fork and jamb the axle sticky outy thing under your work bench, such that you can still get a socket onto the BV. Give it "a smart tap with a hammer". The compression of the spring will prevent the inner cart. from spinning.
Once you've had it apart it should be easier next time - after all, there is an O ring in there - it doesn't need to be done up super tight.!

 

[GMP]

Dress a socket as described, and better yet, start with a spark plug socket that is a VERY tight fit on the hex, and a thin enough wall to fit in the foot recess. After the first disassembly, grease the threads and install with a short burst from a 3/8" impact gun. Less torque with those as not to get into trouble. Next time it should come off with the 3/8" gun. I've done several sets of Zokes many times for years like this with no issues.

 

[swazi_matt]

thanks guys, managed to complress the forks down using some rope and then with a socket and a light tap from a hammer (on the end of the ratchet to imitate a rattle gun) managed to remove the compression valve and pull the cartridges out

 

[swazi_matt]

in case someone else is having issues getting the base nut out and does not have access to machinists, here is a simple tool i made with 40mm pvc pipe, a hacksaw and some sandpaper to hold the Sachs cartridge

Anyone that wants the cutting template just let me know and i will send it as a pdf

 

[wence]

Just to let everyone know.
I ended up belting a slightly smaller socket on the rounded hex nut.I had to remove the excess alloy a few times before the socket went all the way on though.
managed to get it on and fit snug then rattled it off.
Cheers Mark