How much fork oil in an 06 Pro? manual says 290 but this seems too much in the rebound side as when the leg is pushed right down (before I put the cap back on) it runs over!!

And less than this came out !!!

The manual gives a level value of 180mm is this with spring in, leg pushed in, damper rod up??? etc.

Its the 250 with ally forks.

Ian

Lo m8 i have a 03 250 pro i phoned gasgas up and they told me 300cc

grade 5 if they are the same hope this helps

Ikb, you didn't empty it fully in the first place. That is why it runs over when collapsing the fork after refilling

It was full empty as I had removed the adjuster to get all of the oil out. But when I set it at the 180mm level there was no rebound damping!!

After an hour or so messing about I stripped the rebound leg down taking the inner cartridge apart I then filled the catridge with oil and then reassemled and filled to a level of 180mm and everything is fine.

The cartridge on a Marzzochi fork is sealed at the top and bottom with only small holes to let the oil in, I think it may fill itself after much bouncing up and down but then the level would need checking again!

See what I mean now! look at this bulletin from Trialspartsusa.com Marzocchi 2006

If you ever empty all of the oil out you must remove the cartridge, take the end cap and piston out and refil to above the small hole with the damper rod fully extended (it needs to be upside down for this) then refit the piston spring and end cap. you will also spray some oil around the workshop as well!!!