about me...

Dan Jones has been the marketing & tech guy for Windwave since 1998. I have worked directly with the Marzocchi brand firstly as a technician and then still to this day as the UK brand manager.

I have worked in the cycle trade since 1993 and have been an active mountain biker since 1991. I have ridden and owned most Marzocchi's over the years and I have built up a personal collection that includes a NOS PF1, RAC Coil and many Z1's amongst others!

Although I will try to reply to as many comments as I can, it is not always possible due to other commitments. thanks!





68 comments:

  1. Hi Dan, i have the 350 NCR Titanium forks and also the 053 S3CR2 rear shock and i cant fin anywhere the suggested PSI amounts for these units based on rider weight. The manual does not include them, on one who i bought the bike off doesnt know it and im struggling to find anywhere else, the last resort was to ring Windwave. Many thanks Ben.......im 115 Kilos

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  3. this type of set up info is something I know Marzocchi/ Fox is working on, however its not as simple as it sounds! all bikes have different leverage ratios and spring curves so a one pressure fits all from the suspension manufacture should only be a guide. Ideally the bike manufactures will spend a little time on set up (with the suspension manufacture) to get the units working best for the bike, from this set up you can get more accurate guides. The simple rule if none of the above is available is to set the pressure up working on sag rates, so basically ignore the gauge and concentrate on getting something like 30% sag. The fork and shock can be made more stable with low speed compression and the rear shock can be made more progressive with high speed compression.

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  4. Hi Dan, just wondering if you can give me an idea of where I can get old marzocchi parts in reference to this post: http://marzocchiworkshop.blogspot.com.au/2013/02/workshop-fixing-5533-and-dj-cartridge.html

    Have had a look around for the Y703897 part but can't find it anywhere online!

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  6. Hi Dan, I have a shock Roco Air TST, where can i buy seals for this ??
    Hope u can help me... the technical support here in Chile is not working well. Thanks in advanced.
    I found a seals kit in ebay ( http://www.ebay.com/itm/Marzocchi-ROCO-Air-R-TST-TST2-WC-VERY-IMPROVED-Oil-Seal-Kit-/301200517470 ) Fit to my shock?
    Great job & thanks for share the videos and info.

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  7. Hi Rodeigo, you need to contact:
    PEDRO'S
    Ruben Barrales 1747 - Lo Barnechea- Santiago
    Phone: 22 16 04 10
    Web site: http://www.pedroschile.cl
    Distributor for: Chile

    Pedro is the BEST in the business!!

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    Replies
    1. Yeah I know.. I contacted them but there is not a pleasant experience.
      Say they have no spare parts. That's why I ask if there is any place to get spare parts.
      Thanks for the prompt response.

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  8. 2010 26" 44 tst micro ti question.
    Have been using the lock out option with compression damping fully wound on to provide a complete lockout option. I now want to play with the compression setting more. Q1: With the compression fully wound out is this setting exactly the same with the lockout lever selected on or off?
    Q2: When playing with the compression should the sag of the fork be set with the lock out on or off, does it make a difference? Any setting hints for this system as very little info available/ found.
    Ta Neal

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  9. The gold knob controls the compression gate and the lever activates it. So it you give the fork maximum gate then activate the lever the fork will lock out, if you give the fork minimum gate then use the lever the fork will run with a higher low speed compression damping. So with the lever on you can wind the gold knob on more to give varying degrees of low speed compression damping all the way to lock out.
    Most performance forks use low speed compression damping, so I would play with this to get the best set up.

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  10. Hi, I have a 2013 55 R - 160, on here it says 220ml, but on the marzocchi website it says 150ml. Which would it actually be? Cheers

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    1. 220ml is the total volume which includes the damper. If the damper is bled and full you put 150ml in the lower leg

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  11. Hello, I have a new 2013 corsa SL 29er fork that holds air fine when not being ridden but will lose about 30/35 psi over the course of a ride.

    At first I just thought the fork was bedding in/ getting plusher but checking the air it has lost 30/35 psi. Doesn't seem to go below 60 psi though.

    Have you seen anything like this before? I have contacted the place I bought it but wondered if there was anything you could suggest.

    Thank you,

    Adam.

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  12. if the fork sinks in to its travel the positive air is leaking in to the negative chamber, this will result in a lower positive chamber pressure and also the fork sucking down. As you don't mention this I'm sure its just the main air valve that is a little sticky, these use standard shreader cores (like an inner tube) so swap one out for a new core and give it another go?

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  13. I'll give it a try,

    Thank you.

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  14. Hello, again.

    Changed valve and thought I'd sorted it but tonight it's some thing. Lost half its air. It's not sucking into the travel it just progressively gets softer throughout the ride. Don't suppose you have any other ideas before they go back. Just feel like I could lose the fork for a couple of weeks for something I could sort out at home.

    Really appreciate your help,

    Adam.

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  15. ok, it has to be something top plug related, it may be the surface the core is sealing against or the plugs o-ring? I would suggest removing it cleaning it and inspect for anything that could stop it sealing?

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    1. Just thought I'd let you know that I eventually sent it off after having no joy. Change of o rings seems to have sorted it.

      Thanks for you help.

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  16. Again, thanks for the reply.

    Will have a look, see if there is anything obvious.

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  17. Hi Dan!

    I'm reading the oil level charts for 350 NCR Ti. I have a 2015 model, but how come the oil levels are switched on the 2016 model? Which leg should have 200 ml, the DBC leg or the ti coil leg?
    2015 350 NCR TITANIUM - 160 Volume (CC) RH 25 LH 200
    2016 350 NCR TITANIUM - 160 Volume (CC) RH 200 LH 25
    Also, does the DBC cartridge need to be bled or not? Thanks!

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    Replies
    1. the volumes quoted are from completely empty and include the DBC. So if you are doing a lower leg service 25cc per leg is all you need. The cartridge has a volume, but the reality is you just fill it up and put the cartridge top back in and and excess will just expel.

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    2. Ok, so 200 ml is for the DBC side when emptying/refilling it totally. Otherwise 25 ml in both RH and LH when doing just lower leg service? Just got confused since the table above switched 200 and 25 depending on the model year. Thanks!

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  18. Hi Dan,

    I am a big fan of Marzocchi but I have some problem on damper service. I owned one 350 ncr and 350 ncr ti since 2015 and I think they should have service for DBC damper. Due to some problem, Hong Kong have no dealer to do any service(but my 350 ncr bought in UK :P). Therefore, may I have a guide line or service manual for 350 ncr DBC damper?

    Thank!!

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  19. Hi Dan,
    I'm looking for the correct oil levels for my MX COMP29 C.85 2004.
    Should I use the 850671 or the 850690 Oil and Dust seal kit?
    Thanks

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  20. the oil level is actually the same as the 26" MX Comp, so 45mm from the top when fully compressed. For seals, yes use the standard 30mm seal kit 850690

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    1. Hi Dan,
      Today I've opened my foek for the first time.
      The oil levels are 3.4 and 4.7mm(this one leaked some oil).
      Still go for 4.5mm?

      To increase the travel of the fork is it ok to remove the black plastic spacers from the damping rods?

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    2. yep, originally the fork would of been machine filled, but who knows whats happened between then and now, so re-fill to 45mm in both legs. If the spacers are the same on both sides, then yes they are ok to remove, just make sure the top out springs are still in place and double check the cir-clip is correctly seated when re-fitting the rod in to the base of the stanchion.

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  21. Hi Dan, today I have opened the box of my new Marzocchi 380 r2c2 Titanium and I discovered that two of the five controls (high speed compression and high speed rebound) are completely blocked. It ia absolutely impossible to turn these two controls. Any idea or suggestion? Thanks, regards. andrea

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    1. They are probably wound all the way one way. I would pull them off clean them and re-assemble before attempting to turn them, but if in doubt I would take them back and let your shop sort them out?

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    2. Dan, in my fork box there is a second coil. Nothing is written so I have no idea about the hardness of this second coil! there is a sticker above the fork with written "k6,5" and for sure it is the hardness of the inner coil (altready installed). But what about the second one? is it titanium? is it steel? what is his hardness? thanks! best regards Andrea!

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    3. Hi Andrea,
      the fork is shipped with the hard Ti coil spring installed in the fork, in the box there is a steel x-hard spring included for you to try if you want to see the difference in the way the fork performs.

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  22. Hi Dan ! awesome page i'll keep it as a future reference, I just bought a set of pretty much new marzocchi mx pro 105 mm w/ ETA 2004 at my local bike shop's annual garage sale for 40 $ :) was wondering if a lockout lever for them exists. (otherwise i'll just design one or modify one from another brand)

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    1. thanks for your feedback Marco! the original lever 549077AD is no longer available from Marzocchi and looked like this: https://www.google.co.uk/search?q=Marzocchi+ETA+lever&espv=2&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiEgPvZv_bSAhXDDsAKHZ_zB9oQ_AUIBygC&biw=1680&bih=920#imgrc=f8s2Y7QzkEFs2M:

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  24. Hi Dan,

    i just bought a used 2008 corsa sl wc and want to give it a little extra love.
    unfortunately i didn't find a lot of documentation on this model.
    i found the service manual for the tst micro damper. Oil volume for the lowers is stated with 10ml on the marzocchi support site. the oil level chart on this blog states 50ml for the right leg (sfa air spring) and 20ml for the left leg (micro TST). what should i use?

    Do you have a service manual for the sfa spring? anything i should know when disassembling?

    best regards
    Georg

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    1. over the years Marzocchi throttled back on the oil volumes in favour of rebuilding with grease, this is especially relevant for air cartridge forks as any oil ingress can kill the performance. I would stick to modern practice of the 10ml in the leg and make sure the seals and any o-rings are properly greased. We use Buzzy's Slick Honey grease. I dont have anything on the SFA cartridge I can post up but its fairly obvious how it comes apart and just grease everything!

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  25. Hi Dan,

    thanks for the quick reply. sounds great, i think i'll get it sorted.
    i'd also like to soften the damping a bit since the fork will be fitted to my daughters bike and she's just about 30kg. Marzocchi 7.5wt oil has a cst@40 at around 27 right. got a 5wt damper oil with a cst@40 of 16. is that too thin?

    best regards
    Georg

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    1. yes 5w is a good idea, you could even look at the Ohlins rear shock oil, I think this is rated at 2.5w and is great for small closed dampers.

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    2. I will start with the Fox r3 5wt which I have here. If still too thick I'll switch to 2.5 silkolene.

      If I have to replace o-rings which material should I choose? Is NBR 70 shore alright?

      Best regards
      Georg

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    3. For obvious reasons we have been using Fox Oil, its very good! A standard Nitrile 70 durometer O-ring is perfect for the job.

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  26. Dan, in the MArzocchi 380 c2r2 titanium is there a reccomended space needed between the upper crown and the end of the two stanchions. Now between my upper crown and the end of the stanchions (where the regolations are) there is 1 or 2 millimeters. Is this ok? thanks!

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  27. as long as the lower crown is within the stanchion markings and the upper crown is completely on the stanchion part you are good.

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  28. Hi Dan, how are you??... I´m writing you because I have a 2006 66 VF2LT and I can get the rebound working properly with the 200ml of oil in the rebound side. If i rise the oil level on the rebound side the rebound works perfect, but im not able to use the 190mm of travel. do you have any tip to solve my problem? thank you very much!!

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    Replies
    1. remove the top caps and spring and look inside the stanchion with the fork extended, make sure the oil is covering the top of the damper rod. If it is exposed the damper becomes starved and will stop damping, if you cant see the damper for oil then you will loose travel. A visual inspection is a simple way of getting the damper working if you are unsure oil oil volume/ height. This will be the bare minimum amount of oil and you may have to add 5ml/ 10ml/15ml to get some progression back in the fork?

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    2. I did just what you say and the fork started working as it should. thank you very much!!

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  29. hello Dan, I have a 320 lr 2015 i want to do the oil service its the same like 350 ncr?

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  30. yes the same, also there is a LR cartridge bleeding video to make life easier!

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    Replies
    1. How many oil need to use? I was putting 10cc (7.5W) and I think the fork have a lot o sag and run all the travel and the LR lock it doesnt work?

      Thank You

      Luis Galaviz

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    2. Hi Dan, I have a 2014 380 C2R2 and the cartridge is leaking by scratches. So I'm looking for a cartridge replacement. Can you help me with that?
      Thanks
      Davelin

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  31. Hi Dan, I want to thank you for the taking the time to create this wonderful site!

    I also wanted to ask what I hope is a simple question, is there a way to remove the dust wipers without removing the lowers? I bought a 29er 44 Micro STA fork and it feels a little sticky, so my thoughts were to 1. remove the foam rings (as they no longer come with the seal packs) if they are there, and 2. add slick honey/ fox float fluid (very small amount) to the area between the oil seal and the wiper. I would like to do this without removing the lowers so I don't get into the oil below... any thoughts on this plan?

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    1. Thanks William!
      With the 44 you have no real choice but to drop the legs off as the risk of mashing the dust seal or worse scratching the stanchion is to high. Junk the foam ring if its in there and pack out with Slick Honey, it will work wonders!

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    2. Thanks Dan! I do appreciate the reply!...

      The fork is brand new on a new bike build that I just finished yesterday, after a little riding around the neighborhood it feels like the fork has "Plushed" up nicely. I think i will wait for a bit until i service the fork to remove the foam seals and pack with slick honey. A

      Again Thankyou for you help!!!!

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  33. Hey Dan,

    One more question, do I need to stick to the 7.5 wt oil listed on the marzocchi website in the lowers for my 44 Micro switch TA or can I use 10 wt fox oil instead?

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  35. Hi, I have a careers banshee x with marzocchi 55r forks. I have misplaced the nutoff the end of the quick release axel. Do you have any idea where I can find 1?

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  36. Hi, I have a 2015 350 NCR Ti (coil), it's possible to extend the travel from 160 to 170mm ? and if it's possible, which parts do I need to buy? thank you!

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  37. Hi I have a near new Marzocchi 350r (coil + air assist). It seems very stiff for my weight/riding. I'm not using any air pressure in the assist part. Will adjusting the oil level/weight soften the fork at all?

    Thanks

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  38. Hey Dan, thanks again for your advice. I opened up my fork today and packed the area where the foam seal we're with slick honey then coated everything I could get to without opening the cartridges with slick honey as well including the bushings in the lowers then added finish line 7.5wt oil... It's better than any fox I have ridden now. Much better. So again thank you.

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  39. Hi Dan, thanks for your blog. I have a 888 VF2 2006 but after compression, when the fork is rebound it noises clonk. it doesn't matter rebound damper is open or close.
    Do you an idea about where is the noise? it sounds like a metalic spring.
    I try to put in the spring
    Heat shrink, but i can't introduce now at the stanchions.

    thanks

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    Replies
    1. is it hydraulic or mechanical? if its hydraulic, check the quality of oil, check the damper rod top. If its mechanical its probably the spring deflecting and the spring needs the cover on it.

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  40. Hi Dan,

    One more question. I have finally been able to get out and ride the fork for some miles now. I have noticed that when the TST side is adjusted more to the "hard" setting a small click or notch it becomes evident when the fork is compressing over small bumps. It only is at the beginning of the fork travel, does not happen while the fork is actively absorbing multiple small bumps in a row, and does not come back until the fork has been inactive for a short period of time and the fork compresses again.

    If I dial the tst to the "soft" setting, the click or notch disappears completely. I am assuming the tst is a sort of platform for the fork to unlock during small bumps or stay locked out? is this correct?

    Again thanks for all the help so far I do appreciate it.

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  41. Hi Dan, I am from South Africa. We have no Marzocchi agent here that I am aware off at the moment. I broke off the bottom valve of my PAR. It is a 66 RC2 (2007). Can you point me in the direction of some part suppliers in the UK please. I can email pics if that helps. Thanks , Myles

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    1. try one of these dealers: https://drive.google.com/open?id=1w-_Qp6Dx8V_shpzbQOgIcbyxhaQ&usp=sharing

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  42. Hi Dan, I have a 2017 NCR 350 Ti fork which is superb except it is slightly oversprung for my weight. Can I do anything effective with a lower weight oil, and is there a softer spring available please?

    Second question - I also have a 350 NCR fork with the remote lockout. I'd prefer the lockout knob - is it possible to by that please?

    Many thanks, Marcus

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