Marzocchi Z2 seal change -Help Needed

[dyna-ti]

My SS build has hit a snag.My Z2's have sprung a leak at the seals,so i suppose its time for new ones[seals].Problem is i dont have much to spend.

Im not into paying £45 for LBS service and shop prices[£20-£25] for the seals.
The z2's are a basic fork and it shouldnt be that difficult.i have about 5 manuals to look at
I've serviced them before ,doing oil change, clean etc but never the seals.

CRC have the seal setting tool and the protector/remover thingy which adds up to £25 plus the seals[Z2=30mm]@£15=£40
Thats better but im a bit skint after the Ti-glide parts/service/build palaver :roll:
Anybody able to lend me the tools
Be returned clean and sent recorded
If any of the 10UTB crowd have them, i could get them off you there.

 

[FluffyChicken]

About to do the same with mine (bushing and seal)

Going to use screwdriver and socket set/drainpipe method. Oh and a freezer

http://www.enduroforkseals.com/id3.html
http://www.enduroforkseals.com/id27.html
seem good.

 

[dyna-ti]

Still needing ,

 

[dyna-ti]

Threw caution to the winds and inspired by Big Eck's 'a 20 minute job'.It had to be done,no 2 ways about that

The top dust seals were really stubborn and with the screwdriver bending under the strain ,popped out.The first one came out with such force that its somewhere in the room but i cant find it
Then removed both spring clips
Ive wrapped the screwdriver with duct tape to protect the lower edge,the end is under the oil seal and above the washer,but its not coming out even when i apply pretty much all me strength :? .The screwdriver bending quite alarmingly.
these seals arent so much as shifting a mil. Ive also tried working the tip around to see if one bit is easier,but to no avail


Any clues :?
Or are these things normally super tight?? and just take a while to give,and when it does it will go suddenly ,like the dust seals did

Or is it welded on through years of use :shock:
Though it looks in ok condition :?

 

[FluffyChicken]

I do not know, I only know the theory and will be doing mine at the weekend, finger crossed. I have tried to take the dust seals off, but well, they are not budging yet, and I've not put as much force through as you have.

Have you -
Tried putting some of the fork oil on to them soften them up.

Cooling them down (in freezer to contract the inner seal) and/or heating the leg top area up with a hair drier (to expand the surroundings not the seal).

Prayed to the RetroGods ?

I'll be following this one for hints 'n' tips

 

[dyna-ti]

I do not know I only know the theory and will be doing mine at the weekend, finger crossed. I have tried to take the dust seals of but well, they are not budging yet, and I've not put as much force through as you have.

Have you
Tried putting some of the fork oil on to them soften them up.

Cooling them down (in freezer to contract the inner seal) and/or heating the leg top area up with a hair drier (to expand the surroundings not the seal).

Prayed to the RetroGods ?

I'll be following this one fit hints 'n' tips

thanks for the quick answer fluffy.It could be a spell in the freezer/hairdryer will help break the lock up.
I've upped to a large screwdriver well wrapped.ill tease at it :?
Cheers again

 

[drystonepaul]

I've done successfully done this job a couple of times using a socket set, tyre levers, a ring spanner, a bit of old inner tube, a screwdriver and a kettle.

Patience helps too.

 

[dyna-ti]

I've done successfully done this job a couple of times using a socket set, tyre levers, a ring spanner, a bit of old inner tube, a screwdriver and a kettle.

Patience helps too.

Now explain how you used all that
I take it you poured boiling water over it :?

After putting it in the freezer for 2 hours then warming the seals up with a hairdryer.But to no avail
I'm stumped I had maximum power on a screwdriver with a 1/2" shaft.Sod all,nowt,not even a smidgen


Once im pee'd off then its out with a knife and ill cut the f'ers out :x

 

[dyna-ti]

Wipes sweat from brow and breathes a deep[some might say premature]sigh of relief.

The buggers are out.

Lots of hot air was used to remove them some of it even came from the hairdryer.
And i think ive bent the big screwdriver :shock:

If thats what they're like coming out,then heaven knows what they'll be like going in.
But theyre out and thats the main thing