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Broken Marzocchi Dirt Jumper 2.... FIX

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Broken Marzocchi Dirt Jumper 2.... FIX
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flag sye77
Posted: Dec 29, 2012 at 12:41 Quote
Heres some tips to help your dj 2 fork if the rebound cartridge has blown.
Im not responsible if your already broken fork does not work after this mod Wink
Proceed at your own risk !!!

Tool list:
drill
1.5mm drill bit
hammer
punch
fork oil (7.5wt if your light or 10wt if your heavier)
tape measure
marker pen
socket set
GOGGLESEek

1. Remove Cart by lifting the plastic adjuster off to reveal the top nut, undo with socket...
broken dj2 fork fix
  broken dj2 fork fix
2. Slowly turn upside down and drain the bath oil...
broken dj2 fork fix
3. Use socket to undo the bottom lock nut...
broken dj2 fork fix
4. Remove Cart and clean the bath oil off...
broken dj2 fork fix
5. Measure and mark 21mm from the hexagon nut (bottom), then use your punch and hammer to mark the Cart...
broken dj2 fork fix
5. Put your goggles on and get ready to drill or use a hobo deflrctor on your drill!!! Oil may squirt out so its best you do this in a safe enviroment. The cartridge will lose pressure. To get all of the oil out cycle the cartridge (you may need to wait untill the next hole)
broken dj2 fork fix
broken dj2 fork fix
6. Measure, mark then Punch a dent 35mm from the hexagon nut and drill through. Cycle the Cart through is stroke to remove the remaining oil, be carefull !!!
broken dj2 fork fix
7. 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 from the chamber to hold the piston in place.
broken dj2 fork fix
broken dj2 fork fix
8. Measure, mark then punch a small dent 12mm from the top and drill through.
broken dj2 fork fix
9. Double check that there is no oil left in the cartridge by giving it a few last full strokes. Put the cartridge back in the fork and tighten the bottom nut (dropout end). From the crown end add 160cc of fork oil in the leg.(this can be fine tuned by by adding or removing a little oil) of fork oil in the leg.
broken dj2 fork fix
10. Use your socket to put the top cap back on then attatch the plastic dial
broken dj2 fork fix
11. Enjoy Smile
flag nordland071285
Posted: Dec 31, 2012 at 5:52 Quote
sweet post man, thanks
flag sye77
Posted: Dec 31, 2012 at 6:12 Quote
nordland071285 wrote:
sweet post man, thanks
Happy new year Beer
flag Whoohoo
Posted: Mar 26, 2014 at 4:48 Quote
Thanks for the pics - saved me from drilling in the wrong spot! Just did this fix on my 2009 DJ2s, and they now work better than ever.
flag sye77
Posted: Mar 27, 2014 at 5:49 Quote
No problem, it's a good fix !
flag simoride26
Posted: Dec 30, 2014 at 13:56 Quote
Hey Dude i have some this problem in my Dj 2 2008 is that best solution for fix it
and can u explain to me step 7 plzzz i don't understandd Madder Madder
flag sye77
Posted: Dec 31, 2014 at 5:22 Quote
It worked a treat on mine ! Step 7. Inside the cartridge there is a piston. You need to make sure it is pushed all the way down as you need to trap it in place (with the hole punch that you use to make dents and this then stops the piston moving).
Hope this helps !
flag simoride26
Posted: Jan 1, 2015 at 4:28 Quote
hey man again sorry for that but i want be sure for step 7 (did i make punches all the way around the bottom at 15mm to hold the piston in place ????) how many hole ?

photo
also i find video in youtube show u how : https://www.youtube.com/watch?v=iw0XV-268c4 Smile is that allright ??
flag simoride26
Posted: Jan 2, 2015 at 14:26 Quote
plz man when i finish for my dj2 2008 i will add oil 190 mm yes ?
flag sye77
Posted: Jan 3, 2015 at 11:05 Quote
in step 7 you use the punch to dent it to trap the piston inside, do it all the way around the cartridge. You add 160cc of oil into the fork leg
cheers
flag simoride26
Posted: Jan 3, 2015 at 14:11 Quote
ahh ok Smile i make holes all the way around cartridge
but i see in marzocchi website (Dj 2 2008 add 190 cc oil from left side and right side )
thank youu mann so so much for explain to me and save my dj Smile
flag sye77
Posted: Jan 4, 2015 at 5:19 Quote
Not holes but dents : )
flag simoride26
Posted: Jan 4, 2015 at 15:17 Quote
shittt man im bad in english !!!
i find that video but in russian again Frown but i understand
is that true bro !!!
https://www.youtube.com/watch?v=iw0XV-268c4
flag simoride26
Posted: Jan 7, 2015 at 5:15 Quote
sye77 wrote:
Not holes but dents : )


Thank you man so so much now i did it !!!!!! i save my fork yeaaaahhh really thanks its work fineee
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