Marzocchi DJ Travel Reduction

[slapnut]

If 130mm is too much then look here: http://home.insightbb.com/~d.may/index2.html

[mudanoman]

I am going to be performing the 4inch reduction modification on my 2003 DJII. Any tips to share before I proceed? Thanks. -Ivan

[wddung]

Originally Posted by mudanoman

Any tips to share before I proceed?

Remember, you're working with an open bath system that functions both as a lubricant and damping fluid, which for all practical purposes simply means the oil level is critical to proper fork dampening (compression and rebound).

If available, check the fork manual for recommended oil level. Otherwise, call Marzocchi customer service.

-Dung

[mudanoman]

Thanks for the info. I performed the modification today at the bike shop. I did it a little bit different than the method mentioned in the site above. Basically, the Marzocchi reduction kit consists of a ~20mm top out spring that is used in conjunction with the existing top out spring (in my case I used the spring instead of the PVC pipe). Since the general idea of the fork reduction is to chop the top spacing and move it to where the top out springs are (think of a balance), I decided to cut the top spacer by 25.4mm (1 in.) and add the respective spacing where the top out springs are. As mentioned earlier the Marzocchi reduction kit consist of ~20mm springs, shy of the 25.4mm chopped from the top. With the help of my bud at the machine shop, I was able to get an accurate 5mm spacer to use with the ~20mm top out spring on the bottom. So effectively, I have taken 25mm on the top and moved it to the bottom. For fork oil, I used Golden Spectro 125/150 fluid which is equivalent to 7.5wt. and topped it off to 50mm from the top (when the fork is fully compressed with no springs). After carefully reassembling the fork with a generous application of Slick Honey, I hade myself a very plush 4inch travel Marzocchi DJII. Even my RockShox fanatic buddy was amazed. Pics to come when it gets mounted on the SX. Gotta run. -mm

[dirtjumper415]

can anyone help me out with a dual air dirtjumper i think its the 2003
its got 130mm and its way too big for my brothers chameleon. im trying to get it as small as possible.. 80mm would be where i want it.