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BOZZA
TROUBLESHOOTING GUIDE
This section deals with some troubles, which can occur when using this fork. Possible causes are mentioned as well as
recommendations on how to possibly solve the problem. Always read the following table before performing any fork fixing.
TROUBLE
Oil leakage from the oil seal
Foot oil leakage
The fork is too soft under
any adjustment conditions
The fork is too hard
under any adjustment conditions
The fork has no reactions when
adjustment changes are made
Decreased leg stiffness
I.30
TELAIO, SOSPENSIONI E RUOTE
FRAME, SUSPENSIONS AND WHEELS
CHASSIS, SUSPENSIONS ET ROUES
RAHMEN, AUFHÄNGUNGEN UND RÄDER
BASTIDOR, SUSPENSIONES Y RUEDAS
Let's see what happens in each leg during REBOUND.
Spring rebound action pushes the stanchion downwards, thus causing an oil
need into the cartridge (see FIG. 4).
The compression of the oil volume into the chamber over the pumping
element (10) pushes the washers (B) at the pumping element piston bottom
to open. To change the fork damping now, the washer setting (B) can be
changed, as describe for the piston (4).
Apart from flowing through the above passage, the oil is pushed into the rod
(9) and can flow out of the chamber at the pumping element bottom through
the area outlined by the position of the conical pin (13). The size of this area
can be changed by turning the rebound screw adjuster (11). The chamber at
the pumping element bottom is also filled with the oil flowing through the
piston slots (4). The oil flow wins over the action of the return spring (21) and
lifts the washer (22), thus allowing the oil to flow from the outer chamber into
the body inner chamber. (6).
GENERAL RULES FOR A PROPER OVERHAULING
1. After a total disassembly, always use new seals during the reassembly
stage.
2. Always follow the sequence 1-2-1 when tightening two screws or nuts close
one to each other, i.e. always tighten the first screw (1) after tightening the
second screw (2).
3. Use non-inflammable and possibly biodegradable solvent when cleaning.
4. Always lubricate all parts in relative contact with fork oil before
reassembling.
5. Always grease the oil seal lips before reassembling.
6. Use only metric wrenches and not inch wrenches. Inch wrenches could
have sizes, which are similar to millimeter wrenches but could damage the
screws, thus being impossible to loosen them.
CAUSE
1. Oil seal wear
2. Scored stanchion tube
3. Dirty seal
1. Foot valve OR damaged
2. Loose foot valve
3. OR of the compression screw
1. Low oil level
2. Broken spring
3. Too low oil viscosity
1. Too high oil level
2. Too high oil viscosity
1. Inner rod pin blocked
2. Blocked compression
2. Oil with foreign bodies
3. Foreign bodies
occluding damper valves
Sliding bushing wear
DRAFT
REMEDIES
1. Change oil seal
2. Change the tube and the
oil seal
3. Clean or replace
1. Change the seal
2. Tighten the screw
3. Change the seal
adjuster damaged
1. Top up
2. Change the spring
3. Use a different oil viscosity
1. Restore the oil level
2. Use a different oil viscosity
1. Clean or change the rod
2. Disassemble and clean
screw adjuster
2. Clean and change oil
3. Disassemble and clean
Change sliding bushing
Part. N. 8000 A2925 (03-2004)
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