Bicycle Mechanics - Marzocchi Marathon-Clueless!!

If someone could help me with this problem...I have an 2002 Marzocchi Marathon S/Doppio Air, blah, blah. Anyway, I took my bike apart, including forks, to paint, and overhaul. The forks have been awesome! Now, a new bushing kit was installed, by a certified mechanic, in fact, he's the local fork guru. Anyway, the damn things won't hold oil. The oil leaks from the seals. I just went out, and the forks totally compressed, and never came back up. Of course, Marzocchi is not available for tech support, even to a shop. He's stumped, I took them apart agin, everything looks danmage free. Could the new seals be rejects? Any ideas out there? I want to ride!

Occasionally seals need to "wear in" but I am not sure that is the case here. It sounds more like the inner diameter of the seal is more than the outer diameter of your stanchions. Some brands will have replacement seals of different dimensions, so I would look at whether or not they are available for Marzo. If they are, then you need a set of a tighter diameter fit. If not, then see about comparing another new set for measurements, something he can do.

Thanks for the tip. That's the only thing that makes sense to me as well.

2002 you say.. I betcha he put the 32mm seals into the fork instead of the required 30mm seals. That would cause some leaking!!!

Again...thank you! I'll be bringing this up to my mechanic on Monday. Well, at least my bike looks extra sweet with the new paint, and forks too...but, I gotta' ride!

I have heard bad things about Marzocchi tech support but they have always treated this consumer great. Obviously shipping cost would be involved but why not just send to them and have them check it out and repair it?

I, too, have been hearing only negative about Marzocchi support, including tech., which is a shame, since i LOVE their forks. A mechanic today, told me he sent his off, only to be charged $150 for some parts, and repair. I'm trying to do everything before I have to go that route. If they don't answer their phones, how would I find out the progress/length of time to have my forks back, and my budget is a bit tight right now. But, it may come to that.