Marzocchi Repair Manual

Discussion in 'The Workshop' started by 92se-r, Sep 1, 2008.

  1. 92se-r

    92se-r Active Member

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    Anyone have these? I need to rebuild my Marzocchi 888.
     
  2. jamesdc

    jamesdc New Member

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    you dont need a repair manual to service an 888, they are really easy
     
  3. 92se-r

    92se-r Active Member

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    post up some instructions. i dont want to hit any gotchas. ive only done air forks.
     
  4. dubjay

    dubjay Having upgraditis is OK

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    I have a bunch of 2006 Marzocchi Manuals. Not sure if it's the same one as you got, but here's what I have.
     

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  5. Bryguy17

    Bryguy17 A little Shaggy

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    would you (or anyone else for that matter) happen to have a manual for an '06 66 SL RC2? I was thinking of sending it to garageworks, but perhaps I'll try my hand at rebuilding it myself.
     
  6. dubjay

    dubjay Having upgraditis is OK

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    Here's one for the 2006 66 SL, not sure if it includes the RC2 though or not.
     

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  7. DirtymikeTDB

    DirtymikeTDB Guest


    66 RC2 is stupid easy to do. no reason at all to send it out. should take less than an hour easy, Mine took abou 20 minutes.
     
  8. Bryguy17

    Bryguy17 A little Shaggy

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    yeah, looking through the manual it doesn't seem too hard to do, just need a new seal kit. should I worry about replacing bushings if the fork isn't knocking or anything? or just wait until they wear out more? Any other special tools I'll need to get?
     
  9. DirtymikeTDB

    DirtymikeTDB Guest

    Yes, there is a special tool, no I wouldnt worry about the bushing, and if there not leacking I wouldnt even worry about teh seals on taht one.


    Special tool required..... Shimano lock ring tool for the top caps
     
  10. Bryguy17

    Bryguy17 A little Shaggy

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    well, it doesn't leak horribly, but I'm pretty sure it's leaking air somewhere. I'll look after a ride and the top of the crown will be covered in oil residue, and the right leg kinda bubbles a little if you move the rebound knob the wrong way :?: fork still functions fine though
     
  11. DirtymikeTDB

    DirtymikeTDB Guest

    Well, in that case I would go ahead and get some seals then. Might as well be safe rather than sorry. May also want to go ahead and get the lower nuts that hold the lowers on, they have a crush seal on them, that your not supposed reuse, but everyone does anyways, usually without trouble.
     
  12. Bryguy17

    Bryguy17 A little Shaggy

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    Any ideas on where to get a rebuild kit for it? Just a kit that has all the oring I'd need to rebuild the fork completely (i.e. doppio cart, any seals on the outside, anything serviceable on the rc2 cart, etc). I looked around and didn't see anything.

    Also should I go ahead and just replace the dust seals? they're fine right now, but I'm not sure how much use they got before I purchased the fork.

    and 92se-r, sorry for slightly derailing your thread (even if you already got an answer) :wave:
     
  13. 92se-r

    92se-r Active Member

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    I actually didn't really get the answer I wanted. Someone has to have 04 service manuals.
     
  14. Bryguy17

    Bryguy17 A little Shaggy

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    oh. hmm... sorry #-o

    might try looking through here, it may be hiding there somewhere http://manualer.happymtb.org/marzocchi/

    don't see any 2004 888 manual, but there is 2005, which may be close enough for your uses :?:
     
  15. 92se-r

    92se-r Active Member

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    It's crazy. I don't understand how I can't find a manual at all even with google. Every other year of the 888 I can. Just not the 888RR from 2004. Go figure. I'm just going to start tearing it apart.
     
  16. jamesdc

    jamesdc New Member

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    Thats the easiest way, they are really simple forks. My only suggestion is dont go by oil volume, go by oil height. Call marzocchi and ask what the oil height is on you fork with the springs removed and the stanchions compressed.
     
  17. Bryguy17

    Bryguy17 A little Shaggy

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    Ya. That's what I would do too. Even if it's not the same fork exactly, I could see the '05 being pretty similar to the '04, so maybe use something like that as a guideline.
     

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