05-06 Marzocci valve specs
 

I happen to have two sets of forks appart today. An 05 DE200 and a 06 DE300. I found the Base valving is quite differant between the two years. The valves themselves are differant also as the 05 uses a 1mm bleed hole in the side of the port and the 06 uses a 2mm hole. Other notable differances is the 06 uses a bleed shim on the face with a 22mm shim that covers the ports. The 05 does not use a bleed shim but uses a smaller 21mm shim that does not cover the ports completely allowing some bleed. The cartridge, damper rod, bottoming cone and rebound valving is the same on both years. Only the base valves differ. Here are some pictures showing the differant shim stacks and differant size bleed hole in the base valves. Anyone have any imput on why the changes? Dave

I heard about them using the bleed shim. If you thought it was soft I guess you know why now. I assume that bleed hole in the base valve is the path for the comp adjuster?

I wonder if the Husky Zokes use the same base valve? I know they don't use a bleed shim. Even the heavier TE450 stays up in the travel nice without being harsh in the rocks.

What does the rebound/midvalve (checkplate?) look like?

The bleed hole is in the port that the oil flows through the shims. It appears to be a by pass for one port. The mid valve is a check plate . Dave

Wonder why the obsession with so much bleed?:confused:

Do you like the fork better than a WP, especially on the sharp edge (HSD) stuff?

Have any of you guys revalved your own 05 or 06 forks? What shims stacks did you use. There doesn't seem to be a lot of info on these forks anywhere so we might as well start a thread here. The first thing I am going to try is removing the 11 bleed shim on the face of the valve to see if this helps get rid of the mushy lack of feel these forks have. I don't know if this will make much differance with that big 2mm hole in the 06 port. Has anyone tried plugging the hole? Thanks, Dave

Pull the bleed shim and first crossover.

I am sooo happy to see KTMLew in this forum! Welcome! Thanks to this guy I have a great Ohlins fork... (and it wasn't at all great before...)

Putting a radius on the tubes to allow the upper bushing to float to prevent binding and prevent wearing the hard coating off the inside of the tubes was suggested by Terry Hay. Here is a picture of the tubes after I ground them. Not as pretty as turning them in a lathe but still gets the job done. Dave

It's amzing they STILL haven't fixed the bushing land?

valve specs
 

This is what l used on my 05 forks. 4 22x12, 14x10, 20x10, 18x10, 16x10, 14x10, 12x10 and 25x11