Tech Tuesday - Change the Seals and Fluid of Your Marzocchi 44 Fork

Feb 13, 2012 at 20:28

Marzocchi's 44 fork has been gaining traction among the sport's elite bikehandlers for good reason: it shreds technical descents as well as most large-chassis freeride/AM forks - an it is a must ride for anyone in the market for a super-capable 32-millimeter-stanchion slider. Pinkbike readers asked us for a tech video that shows how to overhaul the 44 while Marzocchi works on getting its version up and running. We also have been pressed to return to the TT video-edit format. You asked, we delivered. In this Tech Tuesday Marzocchi suspension guru Ronnie Dilan walks us through the steps to change the seals and suspension fluid of the mid-travel 44 fork. Scroll down for the video, or take your time and read the intro text - your call.

Ronnie Dilan makes it looks easy. Dilan has been sorting out suspension and customer's tech questions for much of the time that Marzocchi USA has been in business.

Which Marzocchi 44 Fork?

There are a number of 44 fork models, and in this Tech Tuseday, we focus on the top three: The 44 Micro Switch TA, the 44 RC3 Titanium and the demonstration model for this this tech piece, the 44 Micro Ti 29. While there are minor differences in the three forks, Ronnie says that the steps to disassemble, replace the seals and reassemble them are nearly the same. Give him a shout if you have any questions about your particular fork.

(From left) Marzocchi's top trail forks - 44 MIcro Switch TA, 44 RC3 Titanium and our subject fork, the 44 Micro Ti 29.

Tips: While the following tech edit covers every step quite well, we'd like to add that eye protection is a must when you are dealing with sharp tools, chemical fluids and small missiles like errant C-rings. Use it. Also, Ronnie slipped and said 'oil' when he was lubricating the seals and wipers before assembling them into the lowers. He recommends lightweight low-friction grease as shown in the edit. Contact Ronnie at Marzocchi's tech center at techron@marzocchiusa.com for the inside story of any Marzocchi suspension product.

How to Change the Seals and Service a Marzocchi 44 Fork

You need to upgrade your Flash Player
Click here to install it

Views:9436 Faves:68 Comments:4 Add to my Favorites

Video edit by Aaron LaRoque

After watching the Marzocchi 44 fork Tech Tuesday edit, I am...

...prepared to service my own '44.
...hesitant to give it a go. Looks a bit too complicated for my skills.
...curious to see what is inside other forks as well.
...moving on, nothing for me here.

Responses: 1066 Faves: 1 Comments: 1

Past Tech Tuesdays:

TT #1 - How to change a tube.
TT #2 - How to set up your SRAM rear derailleur
TT #3 - How to remove and install pedals
T #4 - How To Bleed Your Avid Elixir Brakes
TT #5 - How To Check And Adjust Your Headset
TT #6 - How To Fix A Broken Chain
TT #7 - Tubeless Conversion
TT #8 - Chain Wear
TT #9 - SRAM Shift Cable Replacement
TT #10 - Removing And Installing a Headset
TT #11 - Chain Lube Explained
TT #12 - RockShox Totem and Lyric Mission Control Damper Mod
TT #13 - Shimano XT Crank and Bottom Bracket Installation
TT #14 - Straightening Your Derailleur Hanger
TT #15 - Setting Up Your Front Derailleur
TT #16 - Setting Up Your Cockpit
TT #17 - Suspension Basics
TT #18 - Adjusting The Fox DHX 5.0
TT #19 - Adjusting The RockShox BoXXer World Cup
TT #20 - Servicing Your Fox Float Shock
TT #21 - Wheel Truing Basics
TT #22 - Shimano Brake Pad Replacement
TT #23 - Shimano brake bleed
TT #24 - Fox Lower Leg Removal And Service
TT #25 - RockShox Motion Control Service
TT #26 - Avid BB7 Cable Disk Brake Setup
TT #27 - Manitou Dorado Fork Rebuild
TT #28 - Manitou Circus Fork Rebuild
TT #29 - MRP G2 SL Chain Guide Install
TT #30 - Cane Creek Angleset Installation
TT #31 - RockShox Maxle Lite DH
TT #32 - Find Your Tire Pressure Sweet Spot
TT #33 - Three Minute Bike Preflight Check
TT #34 - MRP XCG Install
TT #35 - Stem Choice and Cockpit Setup

TT #36 - Handlebars - How Wide Affects Your Ride
TT #37 - Repairing A Torn Tire
TT #38 - Coil spring swap
TT #39 - Trailside help: Broken Shift Cable
TT #40 - Installing a Fox Float Air-Volume Spacer
TT #41 - Replace the Seals on Your 2011 RockShox Boxxer World Cup Fork
TT #42 - Clean and Lubricate Your Fox F32 Dust Wiper Seals
TT #43 - Thread Locker Basics
TT #44 - Install a SRAM X.0 Two-By-Ten Crankset
TT #45 - VPP Suspension Bearing Service
TT #46 - Rotor Straightening
TeT #47 - Finding and fixing that creak
TT #48 - Bleed and Service Magura Marta Disc Brakes
TT #49 - Cup and Cone Hub Basics
TT #50 - Install and Adjust Pedal Cleats
TT #51 - Cup and Cone Hub Rebuild
TT #52 - Converting Mavic Crossmax SX Axles
TT #53 - Cassette Removal and Installation
TT #54 - Cane Creek AngleSet Installation
TT #55 - American Classic Tubeless Conversion
TT #56 - Wider Rims Are Better and Why Tubeless Tires Burp Air
TT #57 - Pedal Pin Retrofit
TT #58 - Bleed RockShox Reverb Remote Lines
TT #59 - Cutting Carbon
TT #60 - Silence That Squeaky Disc Brake
TT #61 - Five Minute Wheel True
TT #62 - Removing Bike Rack Rattle
TT #63 - Inside Shimano's Shadow Plus Mech and How To Adjust It
TT #64 - Steerer tube length

Visit Parktool.com to see their entire lineup of tools and lubes

Must Read This Week

1. Free “STRENGTH IN NUMBERS” Replay - ALL DAY 120578 reads
2. Chris King's Noble Vision: Products Near Perfection and Earth-Friendly Manufacturing 30832 reads
3. Chris Akrigg - The Turning Point 27661 reads
4. Whistler Bike Park Opening Day 2012 26165 reads
5. Movies for Your Monday 26054 reads
6. Tech Tuesday - What a Negative Spring is and Why it Makes the Coil-Spring Nearly Obsolete 24117 reads
7. 2012 Red Bull Berg Line - And the winner is... 23392 reads
8. Life Behind Bars - Episode 1 - Video 23327 reads

97 Comments

Score Time

+ 33

WAKIdesigns (Feb 14, 2012 at 0:55)

I miss servicing Marzocchi... could buy one just to change oil in it. Freshly serviced openbath fork is the sht!

Nothing to Mike or Richarsd TTs but I really appreciate hearing servicing advices from "factory technician", so it would be great to see few more of such kind. That one was so great, with so much details, Totaly appreciated PB!

johnny-compton (Feb 15, 2012 at 14:28)

please make videos like this instead of picture tutorials! you get so much more detail and you see exactly what you have to do!

[Reply]

+ 19

I-CanDoRideTheBike (Feb 14, 2012 at 0:18)

Pinkbike needs to do a how-to on lowering your travel using only a toothpick and a marshmallow.

bubbaleech (Feb 14, 2012 at 0:24)

Throw in a lighter and you have got yourself a s'more.

DH-Til-I-Die (Feb 14, 2012 at 12:40)

Not being funny... Why is there a Rockshox sticker in the toolbox ? lol

benthirlwell (Feb 14, 2012 at 18:09)

And a Fox decal

ryanharozero (Feb 15, 2012 at 9:28)

fox head is fox gear/ clothing. fow tail is fox racing shocks. yes it is one in the same but still.. rockshox is funny tho. nothing wrong with it. they are both great shocks so why not be a fan of all suspension not just your own

[Reply]

+ 16

fuore51 (Feb 14, 2012 at 4:46)

Good video, well explained!

[Reply]

+ 10

RideItAll (Feb 14, 2012 at 8:26)

Ronnie is the shit. Always helpful on the phone, always helpful on race day. Marzocchis are what every product should be: user serviceable without 17 1/2 proprietary tools.

[Reply]

warranty-face (Feb 14, 2012 at 9:29)

Honestly the entire process takes longer to explain then it does to complete. If you have most of the tools and a clear understanding of the job you are getting into it just makes things easier in the long run. I have seen other video clips done for rebuilds and they don't tell you that a detent ball is going to fly across the room and kill your hamster..lol. It might seem like excess information and a time wasted but if you have already serviced a couple of forks then it just ends up being useful information to keep in mind.

[Reply]

Chesterboy (Feb 14, 2012 at 9:47)

18:00 "... the balls aren't gonna go anywhere. Kind of like getting married." LMAO!

Draggon (Feb 15, 2012 at 9:23)

They go straight into the wife's purse......that's where they go.

[Reply]

UncleCliffy (Feb 14, 2012 at 0:35)

I'm guessing this fork could've went 2 seasons without needing any servicing...

Lehel-NS (Feb 14, 2012 at 1:01)

or more

[Reply]

ASPOCKALIPS801 (Feb 14, 2012 at 1:16)

Oh thank god Mazocchi did this one, and made it a video! I love to see a video from some that dose this day in and day out, now I can really say I learned from this.

eldofreeride (Feb 14, 2012 at 8:34)

he made removing the oil seals look so incredibly easy. I have rebuilt my RS totems many times and they are a bitch to get out! It required an insane amount of force to pop them out.

[Reply]

SHARK555 Plus (Feb 14, 2012 at 1:12)

blindfold him.

[Reply]

neimbc (Feb 14, 2012 at 9:28)

Ron, you were very thorough! Great job. Instead of throwing the foam seal away, how about cleaning it, and then instead of the fork oil, you use a fine quality grease like slick honey?

warranty-face (Feb 14, 2012 at 9:33)

It ends up running dry over time and just makes the fork feel tight. I have tried a few different type's of lubrication on the foam wiper but always end with the same result.

deadatbirth (Feb 14, 2012 at 9:45)

they do use a fine grease in place of the foam ring. the grease is much finer then slick honey too

[Reply]

vilarichard (Feb 14, 2012 at 6:54)

Peeling a decal protector with his gloves on?.... This guy Ronnie must be my father!.

[Reply]

shikokukichiguy (Feb 14, 2012 at 7:12)

Perfect timing, as mine arrives Thursday!

[Reply]

HellslayeR (Feb 14, 2012 at 5:34)

Really good Tech Tuesday! I hope there will be this kind of video for all of the 2012 Marzocchi forks, im very interested especially in the 888 and 66 types.

deadatbirth (Feb 14, 2012 at 6:21)

Chainreaction did a video last year on how to do seals and oil on a 888. check youtube

[Reply]

deadatbirth (Feb 14, 2012 at 6:21)

djtechron is the man!

[Reply]

El-Warpo (Feb 14, 2012 at 11:51)

This fork is not more complicated than a RS Air U-Turn. Old ones perticularly, had c-clips and tons of ball detents under the adjuster cap, I can't remember from memory if 5 or 4 for the Air U-Turn.

It's not mentioned on the video, but some carts may make your life miserable if you don't have an air tool to drive the 12mm foot nut. The rod may spin along with the nut and you may not be tightening that thing until cows come home (or at all). In that case, I thread the cart on the crown, lock it and then try to compress the nut while I tighten the foot nut. Then you can reopen the top cap and fill with oil.

Similar for air cartridges, just put some pressure in them and tighten the foot nut. Cartridges without a lock out like RC3 may be more difficult as you can't push the end of the cart against the bottom of the lowers to prevent it to spin.

Yes, I know... who doesn't have power tools. Well, some of us cheapos don't.

deadatbirth (Feb 14, 2012 at 12:12)

that is a very good point. having a air gun or fast drill can be very helpful, especially with cartridge service

warranty-face (Feb 14, 2012 at 12:24)

If you experiance slip when you are trying to tighten the footnut on your fork just use a dab of Finish Line Fiber Grib on the base of the cartridge. Just make sure to have eerything very clean and oil free and it will bite down on the first try. Locking the cartridges in the crown won't always work to secure the footnuts into place on our forks. And rememeber JUST A DAB!! it works very well in all cases.

Ronnie

[Reply]

thomasmb (Feb 14, 2012 at 1:58)

So when the bushings had there best time they just replace the complete lowers...?
Wat a waiste of material...

Lehel-NS (Feb 14, 2012 at 3:07)

I had to watch that part a few times, because i did not believe what he said.... I still don't get it. Why would a person do that, instead of just, changing the bushings?!

baca262 (Feb 14, 2012 at 6:43)

because they can't get the tolerances with replacement bushings, new bushings would require sizing an honing to get close to a new casting with factory bushings.

Lehel-NS (Feb 14, 2012 at 7:34)

I have never heard anything like that before. I thought that there is no difference between the bushings (at least not enough to notice it)?!

baca262 (Feb 14, 2012 at 13:01)

if castings had nicely machined bushing seats, it wouldn't matter. but every casting is different and bushings need to be resized accordingly, the tolerances that make the difference between too much stiction and sloppy fit are very small.

btw, it can be done but it's a pain in the ass and you need lots of tooling as the guy said in the video.

spyretto (Feb 14, 2012 at 16:23)

I was also wondering about that part. But it makes sense, the complete lowers are a lot cheaper than the tools. Besides how often do you have to do deal with bushing play...

[Reply]

hmanstylez (May 11, 2012 at 8:34)

Found this vid when I was looking at tearing apart my Marzocchi Ti44 and was gonna give it a go. Happened to call Marzocchi for Parts and got a chance to talk to Ronnie, who had me come in so he could go ahead and do the work for me.

I will say that dude knows what he's doing! I LOVE this fork too. Buttery smooth and tons of adjustments.

[Reply]

wall-e (Feb 14, 2012 at 0:31)

i wait for a video about marzocchi 55R service.i couldn't find anywhere a manual or a video about "how to service your marzocchi 55R".

if anyone have seen a kind of this video, please give me a link with it.

thank you

wilkey (Feb 14, 2012 at 8:39)

call marzocchi and they will send you a video how to. they did it for me last year when i was turning an 08 55r into and open bath fork

mountguitars (Feb 14, 2012 at 9:01)

do you mean the 08 55R's weren't open bath before?

deeeight Plus (Feb 14, 2012 at 10:33)

I do believe marzocchi is switching from open baths to sealed cartridge dampers on many models as it is the superior way to do it (from a performance standpoint).

Marzocchiusa (Feb 15, 2012 at 9:25)

Marzocchi is not switching to sealed cartridges and a completely sealed cartridge has many drawbacks to an open bath system. The RC3 dampers are a complete open bath system where oil continually cycles through the cartridge. Our new CR and LR dampers are described as a "Dynamic Bleed" system where oil is contained in a cartridge is allowed to circulate, this system removes the possibility of ever "blowing" a cartridge and losing the damping function.

trailchef (Feb 16, 2012 at 1:35)

didn't Marzocchi run into problems when they stopped using open bath?

wilkey (Feb 18, 2012 at 14:18)

i think the 08 was one of the earlier sealed cartridge forks they did. and yeah they did have problems. they would hydro lock. which sucked because you would end up during one of your rides working your way from 6in of travel to 2in. made for a rough ride and you can fix it by drilling two or maybe it was 3 small holes in the cartridge making it an open bath.

wilkey (Feb 18, 2012 at 14:20)

oh maybe it wasnt sealed cartridge. but it was some sort of cartridge that was sealed in the 55r

[Reply]

roach1 (Feb 21, 2012 at 14:43)

Hi Marzocchi users, i have 55 rc3 ti and i made everything suggested to improve the fork, oil change, remove the foam ring, remove the coil plastic. The problem is stickness, the fork is not smooth, is like "hiccups" on the car park test. I have the compression all to the minus (-) the coil compression all to the minus (-) and no air on the damper side.
What should i do more to turn this fork to the buttery felling????

[Reply]

NastyRider (Feb 17, 2012 at 13:42)

I just rebuilt one of these for my friend, and a local self proclaimed Marzocchi Factory tech had wrapped the coil in CLEAR PACKING TAPE. He said he was out of shrink fit, I dont know about anyone else but tape and oil do not work together,and had way to much oil in it all I could do is laugh its people like this who give shops a bad name. And this guy owns the shop.

[Reply]

johnovey (Feb 14, 2012 at 10:57)

Just got a 44rc3ti, love it, but why not offer an online maintenance manual like every other brand does?
Anyone been able to find a service manual or video for the 44rc3ti (2011) out there?

Marzocchiusa (Feb 15, 2012 at 9:26)

We are working on it and thanks for the support.

[Reply]

boylagz (Feb 14, 2012 at 10:20)

Emailed Ron a couple of times for questions/servicing on the 66. Really helpful and real prompt with the replies, provided they service things left and right, all day everyday. Really appreciated.
Now only if we all had those tools...

[Reply]

spyretto (Feb 14, 2012 at 16:19)

Thanks for the video, but where is the part about the RC3? And can you please clarify the correct way to read oil quantities
from the Marzzochi site?

hooverGiant (Feb 14, 2012 at 20:27)

The measurement units on the webpage are in CC's. Cubic centimeters. Or Millimeters, same thing.

spyretto (Feb 15, 2012 at 11:51)

That's what I mean. Are they cc's of oil quantity or mm's of the oil level measured from the top with the fork compressed?

[Reply]

abzillah (Feb 14, 2012 at 0:28)

Is it me or are there a lot of little parts under the knobs on top of the fork compared to fox and RockShox?

[Reply]

kjones6942 (Feb 14, 2012 at 0:48)

Glad they did a video

[Reply]

Alexdeg (Feb 14, 2012 at 1:21)

Good tips! But...I d stay clear from the brake clean; it ll likely damage the bushings and a proper clean within the lowers with a dowel and lintfree rag won t harm at all.

warranty-face (Feb 14, 2012 at 12:28)

You can use the Maxima Suspension clean on every componenet of any fork of shock. It is harmless to all rubber and teflon material in most suspension products. brake cleaner is just harsh and from personal experiance it is hard to work with in small areas.

[Reply]

mountguitars (Feb 14, 2012 at 8:23)

this is so complicated. no wonder fox separates the cartridge from everything else. changing oil and seals on a fox is probably the easiest of any fork. even their rear shocks, so easy to replace the seals. but hey, i like marzocchi coz you don't need to service it that often compared to the other forks out there.

aceospades1250 (Feb 14, 2012 at 10:41)

It's easy to replace seals on all forks. Fox forks and shocks don't have user serviceable dampers unlike rockshox and Marz. You have to send them in for service every time.

[Reply]

b1k35c13nt15t (Feb 14, 2012 at 17:22)

"Kind of like being married" Ha! Ronnie is a HARD-WORKING tech. He has done his share to repair Marzocchi's reputation.

[Reply]

jcklondon (Feb 14, 2012 at 15:12)

Great video, very through and logical. People complaining it's too detailed need to top up their Ritalin scripts.

[Reply]

hooverGiant (Feb 14, 2012 at 10:21)

I have an 2010 Marz 44 TST2 Micro air fork. Can i use these instructions for a guide line for my fork? THANKS!

hooverGiant (Feb 14, 2012 at 10:21)

And oil level?

deadatbirth (Feb 14, 2012 at 12:13)

yes. and oil levels can be found on their site

[Reply]

DHrider939 (Feb 14, 2012 at 8:15)

Wish I could afford a Marzocchi or at least the good models of SR SUNTOUR *sadface*

[Reply]

Tehran-Rider (Feb 14, 2012 at 4:14)

do Marzocchi dust seals fit inside a Boxxer?

warranty-face (Feb 14, 2012 at 12:26)

No the seal will not work on a Boxxer.

baca262 (Feb 14, 2012 at 16:34)

fox skf's do, people say it dramatically decreases stiction

[Reply]

voltagerider Plus (Feb 14, 2012 at 9:30)

What a great Marzocchi tech! Wink

[Reply]

wilkey (Feb 14, 2012 at 8:40)

so many sharp pointy metal objects inside the lowers..... it gave me the butt hole puckers.

[Reply]

coyoterun (Feb 14, 2012 at 17:04)

god, how many freaking tools you need just to replace the oil and seals? I am spoiled from Fox Shox.

[Reply]

MrJackDeluxe (Feb 14, 2012 at 2:41)

We need a same how to for 66 forks!!

[Reply]

bennett346 (Feb 14, 2012 at 4:01)

that looks way more complicated than servicing my revelations

[Reply]

jeanfrancoisalbert (Feb 14, 2012 at 14:16)

Can you guys do 888 RC3 EVO Ti please!!?

deadatbirth (Feb 16, 2012 at 13:26)

check chainreactions video on how to do it

[Reply]

Mtbzach (Feb 14, 2012 at 6:11)

Lovin' the Rockshox sticker on his tool box lol

mountguitars (Feb 14, 2012 at 9:03)

and fox too!

deadatbirth (Feb 14, 2012 at 9:47)

fox clothing is not fox suspension

mountguitars (Feb 14, 2012 at 10:15)

haha, i forgot about that. hopefully, they don't make rockshox clothing as well. LOL!

[Reply]

patatta (Feb 14, 2012 at 13:04)

It´s good that they had filming movies again instaid of pictures

[Reply]

goosecock (Feb 14, 2012 at 23:34)

Thanks for bringing the videos back!!

[Reply]

dirtydroog (Feb 14, 2012 at 4:03)

I'm going to go ahead a end that video early

[Reply]

cfuent374 (Feb 14, 2012 at 18:23)

sucks for trying to get parts for these forks because their going out of business.

icekoldskee (Feb 14, 2012 at 20:09)

what are u talking about

hooverGiant (Feb 14, 2012 at 20:28)

What the hell are you talking about... ?

tysonw (Feb 14, 2012 at 23:24)

http://www.vitalmtb.com/news/news/Marzocchi-Facing-Financial-Troubles-May-Close,381

Seems like it was talk, no word on if it's official or not

Marzocchiusa (Feb 15, 2012 at 9:28)

Seriously?

[Reply]

Below threshold threads are hidden

Zhiloreznik (Feb 14, 2012 at 3:58)

Quick tech video? You must me joking. The damn thing is way to complex compered to other makers. You really have to be careful not to lose all the parts. They need some Keep It Stupid Simple way of doing things.

[Reply]

GloryNZ (Feb 14, 2012 at 0:51)

My god, what a mission to do simple maintenance!! Fox is soooo much easier.

pmorgan (Feb 14, 2012 at 1:56)

I was just thinking the same thing. the longer the vid went on I would had my 40,s striped and back together 3 times.

GloryNZ (Feb 14, 2012 at 1:58)

So true, it just kept going and going haha!

pbuser102331 Plus (Feb 14, 2012 at 4:57)

40 is a coil sprung fork this is air so it's bound to take longer.

GloryNZ (Feb 14, 2012 at 7:41)

Either way, still a butt load more steps. I'll stick to my 40's Yaaaaawn.

mountguitars (Feb 14, 2012 at 9:05)

the thing with fox is they have the cartridge separate from the lubrication so its much its easier to change the oil and seals on a fox even if its an air fork. i did my F100 and it was soooo easy. the only folks that would tell me otherwise are the folks who haven't tried changing the oil and seals on a fox but have or like marzocchis. true?

+ 12

kramster (Feb 14, 2012 at 9:13)

I'd rather spend twice as long to do something 5 times less often.

deadatbirth (Feb 14, 2012 at 9:47)

^^ exactly

Jimbur (Feb 14, 2012 at 11:46)

@GloryNZ, Please don't try to compare this fork with your Fox 40. It is an entirely different component designed to do a different task then barrel down a mountain at top speed. I swear, as soon as someone sees or owns a 40 they become the biggest fanboy and nothing in their mind will ever compare even if it a totally different beast. Even though a Fox fork may be your cup of tea, its going to take a s**t ton more maintenance than a Marzocchi and that's a fact.

Try climbing 7k+ feet on a 40 then compare it to a Zoke 44 please. I think you'd have a different opinion.

GloryNZ (Feb 14, 2012 at 12:32)

Stop getting your lycra all in a twist. Im sure its an amazing fork, just rubbish amount of work to do simple maintenance. I'll stay well clear. *Fox Fan Boy*

warranty-face (Feb 14, 2012 at 12:46)

GloryNZ I am sorry that you feel the video is a little to long of a description for a quick service. In this case I have to go into every little bit of detail possible to make sure that the video is clearly understood by a first time mechanic and also by someone who has serviced many suspension products. Keep in mind that you have probably serviced your fork 10-20 times since you have purchased it, so you have lots of experiance with a ll the small details that you will encounter during a quick service. Imagine having to make a very descriptive video for all viewers to understand how simple the procedure can be without costing twice as much due to a poor decision or hasty move. Realistically this service takes 8-10 minutes to complete by an experienced tech who is cautious the entire time.

[Reply]