• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

2008 TE250 - Leaking marzocchi fork at the lower adjuster

M

millenium7

Husqvarna
AA Class
Those damn marzocchi forks..... #1 purpose in life is to leak....
Anyone know the procedure for getting to the lower portion of the fork? it looks like oil is leaking from the adjustment screw but I can't be 100% sure

Does this fork require any special tools to strip it down and replace the seals? And is there a kit with all the o-rings and seals for the lower fork portion?
A video would be ideal but can only find one for the upper portion, not the lower portion
 
Well....the seals, wipers and bushings are all in the top section of the fork. You remove the fork cap from the fork, then from the damper rod. Once that's done, the top will separate from the bottom slider. You just need to make sure that the seal retainer clip is removed from its groove. You can easily access the bottom compression adjuster assembly, once the lower part of the fork is separated from the top.
 
The only special tool you might need is a fork seal driver, some people cut pvc pipe in half for a cheap driver. It’s also better to set oil by height but you can do it by volume.
 
Nah its definitely leaking from the lower section of the forks. I've already replaced the fork and dust seals and that area is clean, yet the garage floor is covered in oil after the bike sits for a while. I'm pretty sure its leaking from the bottom adjuster itself, so my guess is a split o-ring around the adjustment screw

Found this post https://www.cafehusky.com/threads/08-wr250-forks-breakdown.33048/

Still a bit confused but I 'think' if I just compress the spring slightly it should hold the lower valve and can then be undone via a normal 21mm socket and impact driver at the bottom?
Then once I get the lower adjustment assembly out I have to strip that down
 
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