Reducing Travel on 2002 DJ1's

[RCOH]

I am looking at buying some 2nd Hand 2002 Marz DJ1 forks. Currently they are set at 130mm travel. I know they can come in either 80, 110 or 130mm settings. I would like them in 80mm setting.

My question is: Can you reduce the travel just by rearranging internal components (spacers, springs, etc) OR do you have to buy a travel reduction kit/send it somewhere to change travel settings. If anyone knows how much it would cost (approx) to get the kit/reduce the travel, it would be much appreciated.

Thanks.

[tommo_nip]

if they are anything like the 04 ones then yes you can just change springs and spacers, not sure if you would still be able to buy the 02 springs so maybe custom made, and just finding the lenght and getting the right amount of spacers in there.

[Carlin]

I'm not sure if the 02 internals are simmilar to the 00 internals, but it was possible for me to get the positive springs on my Z1s cut sown and add some extra negative springs (this can also be done with spacers) to make them three inches of travel. No guarantees of what this will do to your spring rate though.

Or this may be the go for about $50au=postage:

http://www.chainreactioncycles.com//Models.aspx?ModelID=2463

Or mabye this one for ~$60au:

http://www.chainreactioncycles.com//Models.aspx?ModelID=522

Rik will probably be able to tell you more ;)

[Juls]

If they are 2001 or 2002,

they are probably the Cryofit 30mm leg Crown,
and probably almost identical to my Z1 Wedges.

There is a known issue of those crowns causing the legs to snap
after a long period of use and stress.
and I should know cause I plowed my head into the ground because of it.

http://forums.farkin.net/showthread.php?t=25289

My suggestion is to steer clear of them if they are showing signs of bushing wear or are leaking from the seals, as this will indicate alot of wear and tear and possibly stressed uppers.

I believe the DJ had slightly different legs than the Z1, but I could be wrong there, they could just have made the DJ legs the same as the Z1 that year. (And thats what they mean by new DJ legs on there site)

Either way, definatly don't do anything to crazy on these forks, and especially no bad landings. Even more so if they are on a dually.

If you notice the 2004 DJ's have STEEL uppers, and 32mm legs and steel crown. There is a reason for that!

Anyway .
as for reducing the travel
you simply dismantle them totally, and put in however bigger spacers you want under the pistons, you will have to find something the right size or buy genuine ones, you will also need to get new springs,
however it might be cheaper to get the springs changed length at a spring shop if your not planning on changing back.

you will need some 7.5 wt fork oil too, can get at the motorbike shop for around $20 a bottle (for enough for about 5 rebuilds)

Kind regards
Juls

[RCOH]

Thanks for help guys. Keep it coming.

Juls, it says on the marz website that 02 dj used same staunchion thickness as 02 JrT's & SuperT's. I think it is marginally thicker than on other forks, but thanks for the heads up anyway. I saw your little 'accident'...pretty nasty. I also had 2002 Z1 wedges (came stock on 02 Atomik) * I bent the forks, making head angle steeper by about 2 degrees!!!

[Juls]

Yeh I think it's more to do with how they mounted to stanchion to the Crown, than the actual leg thickness. That causes the snappage.

looking at my Z1 legs, they are at least 2.5mm wall thickness.

which I reckon is pretty thick.

I can't see them using thinner legs on the Z1 over the JR T and Super.

I think they mean they are just thicker than the MXR and Atom and other X/C and trail forks.

I'm not saying you'll break em..
I'm just saying be careful it could happen on a bad landing.
and anything can happen if you break the forks.. ANYTHING including death!

They don't recall the DJ though, so thats a good sign.
I would still try to get some 2004's if you can, they go for around $300-400 Second hand.

regards
Juls