Marzocchi assembly

[Paul Harris]

Hi there - need advice! Installed new fork seals in my 40mmm forks - 40x52x10. I can't get them to seat low enough to fit the wipers. Put the washer on top, then circlip as advised, but the groove the circlip sits in doesn't allow enough room for the wiper? I also found that the left leg had long spring, 2 short and 1 top out, but right had no top out.
Hi

[Momus]

Seals of the right ID and OD can come in different heights.. you may have a 10 when you need an 8..

[bigk]

40 x 52 x 10 is correct size for 40mm Marzocchi in KTM. The wipers don't seat that well, you have to push them in carefully but it's still a bit dicky, especially if the fork leg has a dent or is out of round. You should have 1 x long spring, 1 x short spring & 1 x top out spring in each leg. Obviously someone previously got it wrong & put the "missing" top out spring in the wrong leg, in the wrong place.
K

[Paul Harris]

Thanks guys
I should have checked the height of these seals - I can't see what else could cause this but that the seals are a few mm higher. I think I'll trim the covers and silastic them in. Should be fine...

[ozktm]

Pages from Chassis Parts manual for your Forks showing assembly:

https://drive.google.com/open?id=10IC4dtcmw23DjnAyRLN1x3g0RaKUZeuo