Marzocchi Forks '82 KTM 250

[glowride]

Is anybody familiar with these 40 mm Marzochhi forks found on an '82 KTM 250? The cap has an air assist valve in it, as they all do I believe, what I also have here is a knurled click adjustment knob with 4 positions and a red dot that tells me what position I'm in. There is a 5 mm square rod stock approx. 27" long welded to the bottom of adjuster in the cap which reaches to the damper top where it slides into a sguare hole (of course) and appears to spin damper to some sort of an adjustment. Is this an after market deal of some kind or a KTM thing from another year? Don't see anything about this in my Chassis Parts or Owner's Repair Manuals?
  So much for that situation, my other problem is that there appears to be a bushing on the bottom of the tube preventing it from exitng the leg, as I see in my Chassis Parts Manual, I have disassembled the allen head bolt from bottom of leg and removed damper unit. The tube will not come out of either leg in order to replace the fork seals. What is the trick to removing said tube from leg??

Thanx, MG

[Big Mac]

I have a set of 40mm forks that I was told came from an '82 250. They have the lug to hold the brake backing plate as opposed to a brake stay arm, and came with the dual-leading shoe setup.

They don't have any clicker or damping adjustment from the outside--just standard air caps. I haven't had the internals apart and not sure whether there is a square holed adjuster inside. May be that someone has put in later-year damper rod and internals in your forks?

[Britt Boyette]

Maybe Glowride has "Works forks". Could you post pictures of these forks? Maybe someone will remember something from back in the day.

I wonder if 40mm will fit a 76-77 MC5?

 Big Mac, email me at [email protected] so we can do some garage clean up.

Britt Boyette
1976 125 MC5

[glowride]

Big Mac, Not familiar with the lug style plate stays? I have never seen them on Marz or KTM. Britt I will grab a couple of photo's today while I have these disassembled and get them on here. Went to my local K dealer and they never saw anything like it and guessed that it has something to do with adjusting rebound and compression? They also advised to remove the retaining clip with pointed scribe or punch tool, heat up leg area at seal with a propane torch and simply yank apart. Bushings will slap against seal and tube should pop right out with the seal.
Al Buehner Suggested same.

Thnx, MG

[Big Mac]

May have been '83 250 that went to the dual-leading shoe and fork leg lug to hold brake plate in place in lieu of brake stay arm. Seemed like brakes went different directions on different models for a few years there. The 40MM Marz forks I have came with unpainted aluminum lower legs, think earlier were all painted red...but thought all the red legs were 38MM max.

[glowride]

WOW, got thru all that insert image stuff, Whew! Thanx to my wife, she's old enough to remember that ancient programing.
Anyway, here is what I have with these 40 mm Marz.
Thanx, MG

[glowride]

I just got to this today, been busy with my real job, kids, wife, life and the rest.
  I have removed the tubes from the legs using prior recommondations, worked out rather well. Now I can order new seals and bushings from Al Buehner and reassemble then paint.
  Britt if you can tell me what all this trickery on the caps and dampers does it would be greatly appriciated. If not maybe Mike Lenz might know wether this is KTM tech or some after market item from the 80's?

Thanx again guys, MG

[Big Mac]

May have been '83 250 that went to the dual-leading shoe and fork leg lug to hold brake plate in place in lieu of brake stay arm. Seemed like brakes went different directions on different models for a few years there. The 40MM Marz forks I have came with unpainted aluminum lower legs, think earlier were all painted red...but thought all the red legs were 38MM max.

[glowride]

WOW, got thru all that insert image stuff, Whew! Thanx to my wife, she's old enough to remember that ancient programing.
Anyway, here is what I have with these 40 mm Marz.
Thanx, MG

[glowride]

I just got to this today, been busy with my real job, kids, wife, life and the rest.
  I have removed the tubes from the legs using prior recommondations, worked out rather well. Now I can order new seals and bushings from Al Buehner and reassemble then paint.
  Britt if you can tell me what all this trickery on the caps and dampers does it would be greatly appriciated. If not maybe Mike Lenz might know wether this is KTM tech or some after market item from the 80's?

Thanx again guys, MG

[Mike Lenz]

KTM never had adjusters on the 40mm forks stock and I never have seen any that I can remember. Could be aftermarket or works.  Dont remember any aftermarket kits but... The lug forks were for the double leading shoe hub.  40 mm tubes are too long for a 76-77 mc-5 application. Could possibly work on a 78-80 as long as you used the swept back bar trees.  I have a set on an 81, with the longer steering stem.

[glowride]

Sorry about the image sizing on the bike photo! I've yet to figure out the system of doing this!
  I think I will take more photo's of these fork adjustment item's and send them to KTM along with frame and motor number's and see if they have anything in thier archive's of any such modification.
  Thanx again guy's, will let you all know if I find any further info on this deal!

Thanx, MG