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2008 Marzocchi Dirt Jumper Nitro Rebound Cartridge Conversion

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2008 Marzocchi Dirt Jumper Nitro Rebound Cartridge Conversion
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flag TheCanuck
Posted: Jul 8, 2010 at 22:55 Quote
I recently did a conversion of a 2008 DJ2 seized rebound cartridge from nitro into an open bath system by using these instructions (https://www.pinkbike.com/forum/listcomments/?threadid=68756). Although without diagrams I found it a bit hard so I'm going to rephrase them a bit and add some. Assuming that the rebound cartridge has already been taken out...

The following tools are needed:
drill
1.5mm drill bit
hammer
punch
fork oil
metric tape measure
marker

1. Punch a small dent 21mm from the hexagon nut (bottom), then drill through. Oil will squirt out so its best you do this... Where you don't want oil to quirt out. The cartridge will lose pressure. To get all of the oil out keep pumping the cartridge.
Unsecure image, only https images allowed: http://i292.photobucket.com/albums/mm25/medley_81/step1.png
2. Punch a small dent 35mm from the hexagon nut and drill through.
Unsecure image, only https images allowed: http://i292.photobucket.com/albums/mm25/medley_81/step2.png
3. There is a compensator piston inside the cartridge. Make sure that is at the bottom (hexagon nut). You can do this by tapping it down until you see it go by the 35mm hole you just made. Then make punches all the way around the bottom at 15mm to hold the piston in place.
Unsecure image, only https images allowed: http://i292.photobucket.com/albums/mm25/medley_81/step3.png
4. Punch a small dent 12mm from the top and drill through.
Unsecure image, only https images allowed: http://i292.photobucket.com/albums/mm25/medley_81/step4.png?t=1278654890
5. Double check that there is no oil left in the cartridge by giving it a few last pumps.

6. Put the cartridge back in the fork and start out with 160cc of fork oil in the fork. It should vary depending on your weight though.

Sometimes this procedure does not work, do not blame me for whatever happens to your already broken cartridge Big Grin
flag chris1995
Posted: Jul 11, 2010 at 1:26 Quote
thanks for this mate been wondering where to find this mod, just one question why do you have to punch holes in the bottum to hold the comonsator piston, in the other thread this was not mentioned???
flag TheCanuck
Posted: Jul 11, 2010 at 9:09 Quote
chris1995 wrote:
thanks for this mate been wondering where to find this mod, just one question why do you have to punch holes in the bottum to hold the comonsator piston, in the other thread this was not mentioned???

Im not too too sure, but I think it is to let the oil move freely through the hole drilled at 35mm up to the one at 12mm from the top, the piston is no longer needed so you have to get it out of the way and at the bottom. Hope that makes sense. Tell me how it goes if you do it, and don't punch holes, only small dents to hold it in place.
flag voltagerider
Posted: Sep 5, 2010 at 16:05 Quote
160cc total in the fork leg? It says 175 on marzocchi website when check in "oil levels"...
flag TheCanuck
Posted: Sep 6, 2010 at 8:15 Quote
Do what you will, but this isn't actually an oil fork, its a conversion into an oil fork.
flag voltagerider
Posted: Sep 6, 2010 at 8:22 Quote
TheCanuck wrote:
Do what you will, but this isn't actually an oil fork, its a conversion into an oil fork.

I'm talkin for a 2007 dj2...
flag TheCanuck
Posted: Sep 6, 2010 at 8:23 Quote
And I'm talking for a 2008 DJ2, but they're relatively the same so 175cc is good.
flag voltagerider
Posted: Sep 6, 2010 at 8:26 Quote
TheCanuck wrote:
And I'm talking for a 2008 DJ2, but they're relatively the same so 175cc is good.

I know but I thought that an open bath system needed more oil...
flag TheCanuck
Posted: Sep 6, 2010 at 8:28 Quote
I did this to my DJ2, its working fine with 160cc.
flag voltagerider
Posted: Sep 6, 2010 at 8:29 Quote
TheCanuck wrote:
I did this to my DJ2, its working fine with 160cc.

Ok well thanks man. I will probebly give it a try.Smile
flag TheCanuck
Posted: Sep 6, 2010 at 8:35 Quote
Make sure you empty all of the air out, it will make taking it apart much easier.
flag voltagerider
Posted: Sep 6, 2010 at 8:37 Quote
TheCanuck wrote:
Make sure you empty all of the air out, it will make taking it apart much easier.

In the rebound cartridge? Is it at the top or bottum?
flag TheCanuck
Posted: Sep 6, 2010 at 8:41 Quote
No, the other side. Then you take the rebound cartridge out.
flag voltagerider
Posted: Sep 6, 2010 at 8:43 Quote
Ok you mean the air valve on top of fork leg? I already know that haha.
flag TheCanuck
Posted: Sep 6, 2010 at 8:56 Quote
Alright, good luck, tell me how she goes.
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