48mm Marzocchi fork tools

[GMP]

Guys with the new 48mm CC Zokes, what tools are required for complete disassembly and service of the fork? I know the 49mm end cap wrench and 48mm seal driver are obvious, but what about the other cap wrench tool, cartridge/rod holder, etc? Also what KYB springs fit? Thanks.

[GMP]

Since I couldn't find one, I made a compression cap tool. Started with a cheap steel KYB cap tool, and turned out the center section on a lathe to form an octagonal ring with a 30mm ID. Welded on a 1" 1/2" drive socket. Cleaned up the welds a bit with a Dremel for a little more clearance for the PFP. Turned out OK, especially considering I have no Tig/Mig and used a stick welder with a 7018 rod.

[thumperrider1]

Very Nice! finally started my bike tonight and took a few laps around the yard. Yes, it's stiff as a board, so looking forward to getting 3 hrs on it tomorrow to loosen things up.

[twowheels]

Originally Posted by thumperrider1

Very Nice! finally started my bike tonight and took a few laps around the yard. Yes, it's stiff as a board, so looking forward to getting 3 hrs on it tomorrow to loosen things up.

There's a couple ways to skin this cat - Clay has suggested running one turn IN of PFP and backed out compression, or you could back the PFP all the way out and start with a little firmer compression.

Either way you should decide before you bolt your bars down too solidly - there's precious little room from the bottom of the bar to the top of the fork leg, especially with the bars mounted in the forward position.

[wence]

I have lifted my bars and am about to cut down a socket and weld an arm onto it.
All good.
By the way the suspension was setup real weird when I received my bike and it still handled like a dream.
Cheers Mark

[GMP]

Is the top of the PFP knob flush with the fork cap or taller? If taller how much? Could you just get a 22mm six point box wrench on it with a little grinding?

[thumperrider1]

With my flexx bars mounted I can't get to anything. Not even the bleeders.

I ran the forks yesterday 1 click in from full out on the compression and the PFD one turn in. The forks felt solid with zero harsh spots. I still have 2-3 inches of travel I'm not getting to use. I'm 150lbs so will have to see if 4.0's or 3.8's are in my future. I figured I would get 8-12 hrs on it first to loosen it up.

[GMP]

Got a pic? Perhaps grinding a tool and shimming the bars up just a hair. Also, what thread are the bleed screws?

[twowheels]

Originally Posted by thumperrider1

With my flexx bars mounted I can't get to anything. Not even the bleeders.

With the stock spacers (3mm) under the bar clamp and Flexx bars you have 6mm max to get under the bar and onto the PFP. This is especially an issue if you run the bars in the forward position.

I'm prototyping some tools to get to the PFP and compression adjuster.

[GMP]

It would be nice to have a small tool that you could use on the trail for testing changes.