I am just past midway in changing the oil in the 45mm Marzocchis on my Quota 1100. The rebound/recoil side went fine, and is reinstalled on the bike, but I am having trouble with the compression side.
I got the old oil dumped from the fork leg, and the spring and preload spacers replaced, and I refilled the tube with 635ml of 7.5 wt. That's where things went sideways. I can pump that tube till I am blue in the face, but get very little if any compression. The small diameter inner rod, (this is the inner rod that the adjustment screw on the top of the fork leg acts upon to set rate, and whose depth within the outer tube on the recoil side determines the rate of oil passage, thus recoil), on the compression side will not fully insert into the outer rod, sticking about 3/8 on an inch proud of it, and does not provide any adjustment of compression. On the recoil leg, the inner rod, when sitting flush at the top of the outer tube, is at maximum recoil setting. If I pull the inner rod out just a hair, is causes the rate of recoil to change. On the compression side it makes no difference and cannot be made to sit flush with the top of the outer tube.
Can anyone tell me in what way this rod on the compression side is different than the recoil side? Am I correct in thinking something in the bottom of the fork leg is stopping the rod from fully inserting and thus functioning correctly?
Sorry if this seems garbled, I am not great at explaining things. I am at a loss here, so any advice is fully appreciated!
JD