Disturbing find.....!

[bukwheat]

I have an '06 250 ec and I decided it was time to change the fork oil for the first time. Its got probably 60 hrs on it and the right hand fork seal was leaking just a tad bit so I ordered some Synergy Seals.

Took the forks over to a buddies house last nite to do the work as he has all the right tools.

On disassembly of the left fork, everything went fine. The oil was not too bad but it was time to change it. On reassembly, I will be using Repsol 5w fluid, but it will be next week before the assembly can get under way.....

The right fork leg, on disassembly was the disturbing part. When we got the
lower fork tube out of the outer tube, we found the large flat washer that sits under the bushings on the lower tube was missing. We were very careful of disassembly to keep all parts separated from one fork leg to the other. Apparently it was left out at the factory. I noticed when I took the forks out of the triple clamps, I compressed each one by hand and noticed a slight bit of "free play" in the right one that the left didn't have. Probably why the fork seal was leaking too.

I am going to call GoFasters this morning and see if they have one and get it
headed this way. So thats why it'll be until next week (hopefully!) when I get
them finished.

Just thought y'all would find this interesting....

 

[iancp5]

Doesn't surprise me.
I think if GG ever sort their quality systems they'll scare a few big manufacturers. The designs are good. The build is hit and miss. Better each year but had they sorted it to begin with they'd double or triple the size now.

 

[GMP]

The thing though is that the fork was probably assembled in Italy, unless someone else knows different for sure.

 

[eff]

This is inside the forks. I can't imaging GasGas opens up the forks when assembling the bikes. I think that suggests a QA issue at Marzocchi.

 

[bukwheat]

Yeah, I chalk this one up to Marzzochi's assembly line.

I called GoFasters this morning, talked to Jeff, it was about 830am cst and I was surprised to get an answer that early. He said it was -13F there with a foot of new snow and he was already at work! Thats some dedication right there! I told him I wouldn't have got out of bed if it was that cold here!
Anyway, they had the part I needed and I should have it early next week.

GoFasters pulls through again! Great to do business with!

 

[iancp5]

True probably Marzzochi.
But I still think GasGas need to improve. Love the bikes for the way they ride but they are no where near KTM for quality or robustness. I just think it's a shame when the design itself yields a bike that rides so nice.

 

[coolum74]

Sorry to go off track but.. I too found the inner bearing/thrust washer missing from the sprocket side of the rear wheel last week. I know it sounds hard to believe but I just couldn't understand it. I must have bought a friday built bike. I was a bit dissapointed

Adam

 

[gasser]

I don't agree on the robustness remark. I replaced more broken parts the 3 years I rode KTM than I have the last 7 riding GG. Having said that I think both brands are getting more fragile as a result of their quest for ever lighter weight.

 

[stay_upright]

At the minute my 05 300 is a lot more robust than either my 99 200 ktm, a friends 99 ktm or another friends 07 200 ktm. They have quite a few issues - all of them have clutch slave cylinder issues, some clutch master cylinders and a surprising amount of faults on the 07 ktm that seemed like poor design or quality.

 

[stay_upright]

Bukwheat - I would rebuild with standard 7.5wt oil as whatever issue you are trying to fix will be changed when you build the forks correctly. Quite a few people think these forks could do with more rebound damping and 5wt will only reduce this from stock.

Was it the compression check plate washer (spring loaded) that was missing?

 

[iancp5]

At the minute my 05 300 is a lot more robust than either my 99 200 ktm, a friends 99 ktm or another friends 07 200 ktm. They have quite a few issues - all of them have clutch slave cylinder issues, some clutch master cylinders and a surprising amount of faults on the 07 ktm that seemed like poor design or quality.

Maybe I was lucky but I had an 04 KTM 450 and I reckon it needed a 1/3 of the work my Gasser did. Everything held together and the only maintenance it seemed to need apart from oil was valve clearances about once a year. But ... I preferred the Gasser somehow. Can't be sure why.

 

[bukwheat]

Bukwheat - I would rebuild with standard 7.5wt oil as whatever issue you are trying to fix will be changed when you build the forks correctly. Quite a few people think these forks could do with more rebound damping and 5wt will only reduce this from stock.

Was it the compression check plate washer (spring loaded) that was missing?

I'm a fairly light rider (160lbs) and I was looking for a more supple setting than
what I had prior to oil change. It maybe that I do have too much rebound and that maybe some of the problem. After I get them rebuilt (still waiting on
parts to arrive) I will see how it feels and may go for the 7.5 wt. you suggest.
Thanks for the info.

 

[stay_upright]

I use a compression shim stack that is nice and supple - can find/post it if you want of maybe you want to rebuild first and take it from there?i only used shims already present in the stack so no need to buy some.

 

[bukwheat]

Yeah, I will try it out for a couple of weeks and then I might hit you up for the info on the shim stack. Thanks for the offer!

 

[bukwheat]

Just wanted to update you gents on the additional findings in the fork rebuild job.

Upon reassembly of the fork that was missing the large washer/ring, the pilot bushing was spread apart about 3/8 of an inch. I tried collapsing the bushing in a vice and that helped a small bit. But I ended up safety wiring it closed and as it seated, the safety wire slid off real slick like....excellent.

Obviously the pilot bushing was never seated in this fork from the factory and they (Marzocchi) just left the large washer out....

Anyway, they're back together and will see how they work this weekend at the Fun Run at Perry Mtn.

 

[GMP]

You shouldn't have to go to such extremes to seat that bushing, I hope it wasn't damaged. I have a seal/bushing driver I got for around $40 that makes life so much eaiser. It works with both the Zoke 45s as well as WP 43s so all the bikes I work on are covered. Before that I used home made PVC drivers. The bushing should go in easy if you heat the tube with a propane torch just enough to be uncomfortable to touch, no more. The seal is usually more of a hassle to get seated completely from my experience, a tight fit on the three pair of Zokes I've done.

Spectro 125/150 fork fluid or if you have a Honda shop nearby 50/50 mix of SS7 and SS8 (5w and 10w) fork fluid.