Hi there. I've got an 07 gasgas 280txt pro with the 40mm marzocci forks and I'm struggling to get the cartridge apart. I've got a pin spanner tool to turn the reboot cap but I can't seem to remove it. I can raise it enough to expose two hex nuts on the shift. 19mm and a thin 15mm nut, but I can't separate then. It feels like I'm going to break something. Any tips on how to disassemble? Thanks

Edited February 26, 20242 yr by geir58
Typo

Photo for reference

It should come apart easily.  I would use a thinner 15mm wrench.  Buy a cheap tool and grind it thinner.

Do you have the same problem with the other side?

Gentle heating always helps.

Lots of Marzocchi info here: https://www.ossa-efi.com/home/chassis/marzocchi-forks

Hmm I did grind the wrench. I could take some more off.  Haven't tried the other side. I'll give it a little heat to see if that helps

Also, The Hell Team's notes say 14mm thin wrench.  My thin wrenches are Imperial and one was a perfect fit.

That got it. It was just super tight for some reason, to the point where I felt like I was about to break it.

This query likely seeks guidance on disassembling the forks of a GasGas 280TXT Pro model from 2007. The person may be looking for step-by-step instructions, tips, or insights on safely and effectively dismantling the forks for maintenance, repair, or modification purposes.

Edited March 29, 20242 yr by smits

1 hour ago, smits said:

This query likely seeks guidance on disassembling the forks of a GasGas 280TXT Pro model from 2007. The person may be looking for step-by-step instructions, tips, or insights on safely and effectively dismantling the forks for maintenance, repair, or modification purposes.

The answer is to Google Marzocchi 40mm trial fork oil change You Tube or go to www.thehellteam.com  in Tech support.

4 hours ago, smits said:

This query likely seeks guidance on disassembling the forks of a GasGas 280TXT Pro model from 2007. The person may be looking for step-by-step instructions, tips, or insights on safely and effectively dismantling the forks for maintenance, repair, or modification purposes.

Get somebody to mentor you how to service forks the first time, from then on it will be easy, I know it does happen because I've taught a lot of people how to do it.  Once you've done one fork model the rest are close enough for it to be easy.  Changing the fork fluid is one of the more frequently over-looked service items, always drain the old oil into a clean clear glass container so you can inspect it for debris or water or pieces of fork slider coating etc.  I keep slider bushings and fork seals in stock so they are on hand when I need them.  I find the gap on replacement slide bushings needs to be carefully filed and shaped before installation to get the right stiction free fit, watch for that.