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  1. #1
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    really need your help with my marzocchi dirt jam pro fork

    Hi, i just bought a kona scrap came witht the 100mm dirt jam fork

    one leg have air oil and the air side leg should have a internal rebound adjuster to be adjusted with a " 12mm tee-key" its covered with oil, the color of the oil is kind grey/black yellowish. is that color normal? also the air side leg is almost covered by oil . the other side is dry.


    the other side have spring and no oil inside there is also a lot of grease on the spring, also the top cap is a preload adjuster with no o-ring or seal to keep the dust out, do all this sound normal to you?

    the fork pushes down and comes back real real slow, i can here the oil moving and compressing while is bouncing back

    also, i tried to pump the air to spec from the user manual, i couldnt cuz my tire pump have a adapter thats too big to fit the nut of air valve on the cap of fork. is there a slimmer adapter i can buy that attaches to my pump and smaller enought to fit?

    im a total noob about this fork stuff. please give me some hints of what i should do to make it normal.


    thanks in advance







  2. #2
    rebmem rbtm
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    Service Manuals
    2005 Dirt Jam Pro: http://my-sport.spb.ru/manual_1/2005-dirt-jam-pro.pdf
    2006 Dirt Jam Pro: http://my-sport.spb.ru/manual_1/2006-dirt-jam-pro.pdf

    Tire pumps aren't very good for pumping up forks and shocks.
    Buy a shock pump something like the following one.
    http://www.jensonusa.com/store/product/PU406C00-Buzzys+Pollinator+Shock+Pump.aspx

  3. #3
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    "one leg have air oil and the air side leg should have a internal rebound adjuster to be adjusted with a " 12mm tee-key" its covered with oil, the color of the oil is kind grey/black yellowish. is that color normal? also the air side leg is almost covered by oil . the other side is dry."

    No not normal at all. The oil in the leg should be a nice clear golden color, not gray. Time to change the oil. As for the oil all over the out side of the leg, that indicates an oil seal problem/leak. Time to replace the wipers and seals.

    "the other side have spring and no oil inside there is also a lot of grease on the spring, also the top cap is a preload adjuster with no o-ring or seal to keep the dust out, do all this sound normal to you?"

    Perfectly normal for the spring side cap to have no o-ring. Since there is no oil in the leg there is nothing to leak out. The threads of the top cap are sufficient to keep the dirt out. However, that grease on that spring looks terrible!, it's filthy. Time to tear the fork down and clean and re-lube. Oh and there is some oil in that fork leg. It's just not that much and it's in the lower part of the fork so you wouldn't see with only the top cap removed.

    "the fork pushes down and comes back real real slow, i can here the oil moving and compressing while is bouncing back."

    Hearing oil move during compression and rebound in an open oil bath fork like the DJ is perfectly normal. However the slowness of the rebound indicates that the adjuster is in the full closed position, or nearly so. You'll need to adjust the damper so that it is more open. Use a 12mm "Tee Key" and decrease the rebound damping as noted in the instructions.

    "also, i tried to pump the air to spec from the user manual, i couldnt cuz my tire pump have a adapter thats too big to fit the nut of air valve on the cap of fork. is there a slimmer adapter i can buy that attaches to my pump and smaller enought to fit?"

    No there is no adapter that will allow you to use a tire pump to pump up your fork. You need a fork/shock pump to fit. The reason being is shock and fork air chambers are very small in volume. Tire pumps push a huge amount of air by comparison and thus wouldn't be very accurate. That's why they make it so a tire pump doesn't fit. So get a fork pump.

    "im a total noob about this fork stuff. please give me some hints of what i should do to make it normal."

    The bottom line is, judging from the pictures you've posted, this fork needs to be torn down a complete cleaning, all the seals replaced, and fresh lube and oil. From the color and condition of the oil and grease the fork has obviously be neglected for some time. So either get the parts you need and go to it, or get it to a good shop and have them do it. That's the only way you'll get the fork "back to normal".

    Good Dirt
    "I do whatever my Rice Cripsies tell me to!"

  4. #4
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    just downloaded the manual for the fork, very helpful

    whats this 12mm tee key to use to adjust the fork, i did a google search some people say is a size 8mm allen key . some peopel say you can fit a very small diameter allen socket with a long extension. does any of you have experience with this type of internal rebound adjustment?


    i see the manual says use 220ml SAE7.5w oil for air size leg, where would be a good place to buy the oil? is there other alternative to use as fork oil? i looked fork rebuild videos on youtube, some of the oil is red, is it automatic trans fliud?

    also what type of grease should i use for the spring ? Squash you mentioned that there is some oil in the spring size leg , and how much oil to pour in there?


    thank you guys so much for taking your time reply, i really appreciate it.




    Quote Originally Posted by cobba View Post
    Service Manuals
    2005 Dirt Jam Pro: http://my-sport.spb.ru/manual_1/2005-dirt-jam-pro.pdf
    2006 Dirt Jam Pro: http://my-sport.spb.ru/manual_1/2006-dirt-jam-pro.pdf

    Tire pumps aren't very good for pumping up forks and shocks.
    Buy a shock pump something like the following one.
    http://www.jensonusa.com/store/product/PU406C00-Buzzys+Pollinator+Shock+Pump.aspx
    Quote Originally Posted by Squash View Post
    "one leg have air oil and the air side leg should have a internal rebound adjuster to be adjusted with a " 12mm tee-key" its covered with oil, the color of the oil is kind grey/black yellowish. is that color normal? also the air side leg is almost covered by oil . the other side is dry."

    No not normal at all. The oil in the leg should be a nice clear golden color, not gray. Time to change the oil. As for the oil all over the out side of the leg, that indicates an oil seal problem/leak. Time to replace the wipers and seals.

    "the other side have spring and no oil inside there is also a lot of grease on the spring, also the top cap is a preload adjuster with no o-ring or seal to keep the dust out, do all this sound normal to you?"

    Perfectly normal for the spring side cap to have no o-ring. Since there is no oil in the leg there is nothing to leak out. The threads of the top cap are sufficient to keep the dirt out. However, that grease on that spring looks terrible!, it's filthy. Time to tear the fork down and clean and re-lube. Oh and there is some oil in that fork leg. It's just not that much and it's in the lower part of the fork so you wouldn't see with only the top cap removed.

    "the fork pushes down and comes back real real slow, i can here the oil moving and compressing while is bouncing back."

    Hearing oil move during compression and rebound in an open oil bath fork like the DJ is perfectly normal. However the slowness of the rebound indicates that the adjuster is in the full closed position, or nearly so. You'll need to adjust the damper so that it is more open. Use a 12mm "Tee Key" and decrease the rebound damping as noted in the instructions.

    "also, i tried to pump the air to spec from the user manual, i couldnt cuz my tire pump have a adapter thats too big to fit the nut of air valve on the cap of fork. is there a slimmer adapter i can buy that attaches to my pump and smaller enought to fit?"

    No there is no adapter that will allow you to use a tire pump to pump up your fork. You need a fork/shock pump to fit. The reason being is shock and fork air chambers are very small in volume. Tire pumps push a huge amount of air by comparison and thus wouldn't be very accurate. That's why they make it so a tire pump doesn't fit. So get a fork pump.

    "im a total noob about this fork stuff. please give me some hints of what i should do to make it normal."

    The bottom line is, judging from the pictures you've posted, this fork needs to be torn down a complete cleaning, all the seals replaced, and fresh lube and oil. From the color and condition of the oil and grease the fork has obviously be neglected for some time. So either get the parts you need and go to it, or get it to a good shop and have them do it. That's the only way you'll get the fork "back to normal".

    Good Dirt

  5. #5
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    "Squash you mentioned that there is some oil in the spring size leg , and how much oil to pour in there?"

    Sorry, my bad. I was thinking about the Dir Jumper fork not the Dirt Jam. The Dirt Jam uses grease in the spring side leg. As for what to use, something like Buzzy's Slick Honey works very well.

    Good Dirt
    "I do whatever my Rice Cripsies tell me to!"

  6. #6
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    can i use ATF as fork oil?

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