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Discussion Starter · #1 · (Edited)
Posting this as an FYI for anyone who may run into this problem. For the whole story from the begining see this thread: http://forums.mtbr.com/showthread.php?t=187653&highlight=66sl

The fork has 99 miles on it now, is 30 days "old", and though it has been "softening up", it's still EXTREMELY notchy / sticky in the lower range of its travel, as if there's a problem w/ the stanchions in the extended postions.

Now a NEW manifestation of the problem:

During my last ride, a fast rocky 5 mile DH, the fork actually "LOCKED UP" :eekster: about 2 inches into its travel - it was instantly a full rigid! :madmax:

This happend mid-ride - no I did not alter any of the pressures - neg pressure on the trail after lock-up was 75psi as always.

I drained and refilled all chambers several times on the trail, trying to get some movement to save my body from the brutal jolting. But even after increasing air pressure in the pos chambers from 20psi to 25, to 30, and eventually to 45psi per leg, the fork just continued to lock-up in the same spot and not extend to full length unless I forcibly pulled it to extension with my arms - which was really difficult!

Even after pulling it out to full extension though, as soon as I weighted the bike it would lock up again, in the same plce.

It seems the stanchions are binding on the lowers, but I don't know for certain.

Being alone up on the trail, darkness approaching, I had no choice but to carefully ride down w/o front suspension. At one point the suspensionless bike bucked me off in a BAD cliffy spot and I sprained my ankle severely - out for three weeks at least, crutches and all...

Right now, in my garage, I have to pick up the front of the bike and slam the tire on the ground in order to "break" the lock-up and get the fork to extend. Predictably, when I sit on it and roll down the drive, it locks right up again. Slam the front down to free it, repeat... :madman: This condition persists with any pos pressure from 20 to 45 psi, 75 neg, 0 compression, 0 rebound.

Crazy, huh! Got a lemon I guess:rolleyes:

Zocchi has not responded to email in over 10 days, so I'll call them tomorrow.
 

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Elitest thrill junkie
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Some of the 66s left the factory with slightly twisted lowers. That would do it.

Contact marzocchi, they've been pretty good about replacing them so far.

Don't ever email a bike company. Most of them don't have enough extra money lying around to have someone answer emails 24/7, because that's what it would take to actually answer all of em.
 

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Rollin' you need to send your fork back for service. It has multiple issues that marzocchi should take care of as warranty work. Your fork will be gone for at least two weeks, but the wait will be worth it. I sent mine in for the twisted lowers and real notchy bushing thing. They replaced the lowers. The fork I got back no way resembles the fork I sent them. It was worth the wait.
I repeat, you will not be able to fix it yourself. Call marzocchi, explain all your forks problems to them, they will give you a return authorization number. Good luck. Call them, don't e-mail them.
 

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not so super...
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Like Renny said - Call 661-257-6630 opt3


Hope you like White lowers. They are out of black and any lowers that get replaced will be white - including mine. They didn't say if/when they would get any more of the black lowers.

Hope you have a back-up fork. Mine was shipped 3 day on the 15th of june and it is still 8-10 back in the repair queue. Could be another 2 weeks before I see it again.
 

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Jayem said:
Some of the 66s left the factory with slightly twisted lowers. That would do it.

Contact marzocchi, they've been pretty good about replacing them so far.

Don't ever email a bike company. Most of them don't have enough extra money lying around to have someone answer emails 24/7, because that's what it would take to actually answer all of em.
Just wondering here... Have people become so afraid of human interaction that they must email instead of calling nowadays? More often than not a phone call gets things done faster than an email.

BTW, toll free # to Marzocchi USA, 800-227-5579.

Brian
 

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The lowers on my 66SL are slightly twisted...

However, it is as smooth as silk and the lowers don't seem to affect it at all. I just have to push the lowers into line when I insert the axle. I did contact Windwave (marz UK) about this and was told not to worry about it. I'll be in Whistler for the next 2 months, so if a problem develops I guess I'll just get it warranteed.
 

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Brian, can you enlighten us? Statistically speaking, there has been a high occurrence of these twisted 66 lowers, and tight bushing/seal issues. Why didn't marzocchi just issue a recall?
 

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Renegade said:
Brian, can you enlighten us? Statistically speaking, there has been a high occurrence of these twisted 66 lowers, and tight bushing/seal issues. Why didn't marzocchi just issue a recall?
Once we saw a few of these we did a 100% inspection on all 66 models here. We know a few had got out but it wasn't enough to warrant any kind of recall. So we have been dealing with them on a case by case basis.

Brian
 

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Discussion Starter · #10 ·
SSINGA said:
...Hope you like White lowers. They are out of black and any lowers that get replaced will be white - including mine. They didn't say if/when they would get any more of the black lowers...
NOOOO! :cryin: No white lowers, please tell me it's not true...:shocked:

I did not think I was so vain as to care about such things as the color of components on my bike:blush: Guess I've leaned differently! The way it's worked out, every component on my black Supermoto is black. To have a white fork on it...:bluefrown: I'd wait all summer if I must to avoid white lowers. Well, that's easy because (1. I travel 18-24 days per month in the summer for work. (2. my ankle ist kaput for at least a month, and (3. the USFS, local counties and state have rightfully closed essentially ALL of the land in N. AZ due to extreme fire danger - a condition unlikely to resolve itself before Labor Day.

Oh wait, the Crested Butte trip in Aug??? Hmm... well, hardtail is fine for 90% of the trails there anyway...
 

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Discussion Starter · #11 ·
Brian Peterson said:
Just wondering here... Have people become so afraid of human interaction that they must email instead of calling nowadays? More often than not a phone call gets things done faster than an email.

BTW, toll free # to Marzocchi USA, 800-227-5579.

Brian
Yeah, I hear ya Brian, and agree completely.

My lifestyle is quite different from most folks, though. I'm a guide in the Grand Canyon and Utah back country. This time of year I spend 18-24 days per month on the road, and am with clients 12-14 hours a day. When I do have a cell signal, and am in a position to make a personal call, it's usually after 9pm.

However, a few locations I stay at regularly have internet access, so for me email is often the ONLY method I have of contacting businesses which operate during normal business hours.

I was able to talk with Mike @ 'zocchi today. Got an RA. Sending the fork to LA...
 

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Brian,

I was told by Windwave that although the lowers on my fork are twisted, if I have not experienced any problems with the forks performance so far then I should be OK. Is this true? They are gonna take one hell of a pounding in Whistler over the next 2 months, so I hope that if I do have a problem then I can get it dealt with by Marzocchi in Canada...
 

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If you haven't had any isssues as of yet, then you'll probably be fine. But if you have a problem while in Whistler, Marz Canada should be able to take care of you.

Brian
 

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Brian Peterson said:
Once we saw a few of these we did a 100% inspection on all 66 models here. We know a few had got out but it wasn't enough to warrant any kind of recall. So we have been dealing with them on a case by case basis.

Brian
Thanks for the insight Brian. Now what can you do about getting my fork back to me :cool: :p
 

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I've now got 6 hours in on the reworked fork. Butter central. Sooooooooooo much better than original.
Too bad the white ones aren't as good as the black ones.:thumbsup:
 

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Discussion Starter · #18 ·
Great news!

Renegade said:
I've now got 6 hours in on the reworked fork. Butter central. Sooooooooooo much better than original.
Too bad the white ones aren't as good as the black ones.:thumbsup:
This is encouraging! :thumbsup:
 

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SSINGA said:
Thanks for the insight Brian. Now what can you do about getting my fork back to me :cool: :p
Not my department... :D I just ride them and sell them... I don't fix them....:p

Brian

PS.. Being 8 to 10 forks back isn't that bad.... Our guys crank them out pretty quick..
 

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Renegade said:
Too bad the white ones aren't as good as the black ones.:thumbsup:
is that discrimination or are you profiling all white forks as bad? :eek:
 
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