2009 TE310 Marzocchi Shiver 50mm forks refill procedure? Manual is confusing..

i Guys
The manual for these forks is really confusing me:

it says; 725 ml of oil per leg - i've never put this much in a fork in my life... indeed only 500 ml of oil came out of one leg and 370ml out the other. My usual mechanic says cartridge forks are usually about 330 ml, non cartridge forks about 500..

It says; "lift the slider completely on the stanchion tube" - if I fix the silver/chrome part to the floor and lift the outer part (the black tube) as far as it will go (as if i was just about to knock the seal out) two holes drilled in the chrome part are revealed. pouring 725 ml of oil in causes a lot of oil to pour out of these holes

It says "lower the slider on the stanchion until it reaches the dust seal stop of the wheel axel clamp" - if I slide the black tube down all the way until the dust deal comes into contact with the wheel slider clamp, and add 725 ml of oil, the oil pours out the top of the compressed tube assembly and all over the place

It shows a picture of a hand pouring oil in and says for a TE the oil height would be 140 mm below the top of the black tube when arranged such that the inner rod's screw thread is just poking out of the black tube.. but doesnt say where on the suspension slide the black tube is - slid to the bottom? If I hold the black tube and the screw-ended rod and slide the chromepart out as far as it will go (before the screw ended rod wants to get dragged down with it) then top up to 140mm, I use a litre of oil


Just wondering if anyone can give a step by step, as this manual page isn't helping me much (attached), cheers guys

On my 630, it was the same story. I dumped a lot more oil in than what was in there. Manual calls for 600ml per leg. Seems to work just fine on 600ml.

In the endmy step by step was:

Ensure the top cap (with the bleed valve) i removed from the threaded rod
Remove the spring
Push the chrome slider all the way inside the black outer tube
Push the threaded rod all the way down too
Pour half the oil in and wait for bubbling to stop
Pump threaded rod up and down fully a few times
Fill oil to 120mm below rim of outer black tube - i used a normal desk ruler as a dipstick - when inserted so 120mm was level with the tube top, the oil should be level with 0

All in, I got aboutl 950ml of oil back in which adds up pretty much to what I took out (520 + a spillage + 370)

Seems to work. If anyone catches this thread and knows I did it wrong, please let me know

(I was a bit wary of just dumping in 725 ml per leg because I didnt know how much oil was still trapped inside, and the manual also seemed to indicate that there's a cartridge inside the fork that is filled and drained differently so that could be holding oil too.. Maybe 725 ml was the volume inside the cartridge plus the volume inside the fork..)

I wish I had gotten this post out sooner... check out the link in this thread:
http://www.cafehusky.com/threads/marzocchi-fork-bleed-dirtbike-magazine.3171/

I found it very helpful.

When doing forks, it's not the amount of oil rather the height. More oil (high in fork) more bottoming resistant the fork will have. I never understand why the manuel calls out oil amount other than knowing how much to buy. Shoot for 120-125mm unless you ride very easy.