05 EC250 Marzocchi stock shim arrangement ?

[ferguscawley]

Hi all

I have my friend's 05 EC250 front forks apart at the moment. He was complaining of zero damping and constant crashing in the woods.

Anyway, to cut a long story short, I disassembled the forks to find that on both legs, the lower shim stacks had come apart and the shims have fallen out and got 'mashed' up in use. The bike had been re-valved by the previous owner so I reckon the damage was done there.
I want to return his forks to stock so I am looking for the shim arrangement for both compression and rebound on the stock EC250 Marzocchi fork (05).
I have looked for hours online to try to find this and cannot find a definitive answer.

Does anyone know what the shim arrangement should be on this bike ?. (the valves have the 1mm bleed hole, not the 2mm hole as on the 06 zokes).

Any help would be greatly appreciated.

Many thanks

Fergus

[iancp5]

Reminds me of when I had mine rebuilt. I arrived to collect the bike and the suspension rebuilder held out a handful of mangled shims and enquired; "what was it like to ride".

[ferguscawley]

Did they look like this ?

Friend is a hard rider and was constantly crashing, usually quite spectacularly. I have set of shims ordered from Marzocchi but need the arrangement / order so I can get the thing normal again.

Fergus

[iancp5]

Originally Posted by ferguscawley

Did they look like this ?

Friend is a hard rider and was constantly crashing, usually quite spectacularly. I have set of shims ordered from Marzocchi but need the arrangement / order so I can get the thing normal again.

Fergus

No, not that bad!

[bergerhag]

Have you seen this thread?
http://gasgasrider.org/forum/showthread.php?t=700

[GMP]

What does the inside of the cartridge look like?

[ferguscawley]

Originally Posted by bergerhag

Have you seen this thread?
http://gasgasrider.org/forum/showthread.php?t=700

Yes I have. Only issue I have with that thread is that the 05 bike in question is a DE200. Maybe the EC250 is the same ?. I don't know for sure. Excellent thread though. I learned loads from it.

This forum has been a mine of information to me so far. My GG300 is by far the best enduro bike I have ever owned (and I have owned / modified quite a few).

On thursday I hope to speak with one of the gurus from Marzocchi UK (Dan). Maybe he will tell me what I need to know. In the meantime, if any of you can help then I would be delighted.

All the best
Fergus

[ferguscawley]

Originally Posted by GMP

What does the inside of the cartridge look like?

Believe it or not, it actually looks OK. A little scuffed (more like honed) perhaps but nothing major. I reckon damage has been caught early.

Bike is not used that often but when it is, it hurts

Fergus

[GMP]

Be sure to change the rings on the rebound pistons, as the teflon coating is most likely damaged.

[ferguscawley]

Originally Posted by GMP

Be sure to change the rings on the rebound pistons, as the teflon coating is most likely damaged.

Will do, thanks.

One more question, should (is) the valving/shimming on the rebound valve be set the same as the compression valve ? i.e. the same shim sizes and arrangement ?

Thanks again

Fergus