1993 Rocky Mountain Thunderbolt

My next step would be to put a socket end over it to protect the valve and use a hammer to tap it..tap it harder then give it a big wack if it's not moved.
Crimping might stop it as iirc that might have crimped against the cap.
 
hmmm… but if i do that, it might lodge the air cap even tighter in the stanchion, and i may never get it out? catch 22, eh? :?
 
okay took to chance and just went with it. tapped it in with a socket, and popped it out by pumping it up. it was very nerve racking to say the least. first side i ended up tapping it in further than i needed. pulled off the ring and started pumping… nadda.

so decided to give the other side a try. this time i tapped it in much more gently and only as much as needed. started pumping, and could see it creep up little by little, then… POP!!! gawd that startled me. really wasn't expecting the result to be so fast, like a popping a cork out of a champagne bottle, but instead of a soft piece of cork, a hard piece of aluminum!!! i could have seriously injured myself if it had hit me in the face i think. thank goodness it was securely fastened to the fork pump hose! :p

went back to the first leg determined to pop it out as well. so just kept pumping till it came out. but this side had no warning as it didn't creep up like the first, just straight to the pop.

well, gonna call it a night and do the actually servicing another day. :)

thanks Ben (FC) for all your advise! ;)
 

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yes that's a spring in there. is there not supposed to be one??? there's one on each side.

gotta check over the exploded diagram and service manual today to familiarize myself with the rest of the re-build.
 
found some answers. a common mod to the fork was to put springs into them:

http://forums.mtbr.com/vintage-retro-cl ... 72430.html

I should add, the hot setup was to get a coil spring that fits (from their other forks of that era) then run way less air pressure. Made it feel like a short travel bomber.
I had one of these three years ago. I was able to fix the air leak by replacing the top-cap o-rings (greased up well), and I slipped in a pair of springs for an 80mm Bomber. They slid right in with about 1mm of preload. With the springs, a 190 lb person only needs to run about 28 psi in each leg. I sold the bike to a freind who's still ridng that fork with no problems.
 
> hmm… there's no mention or illustration of the springs in the manual

Right. In the past there were tuning kits available, I think in 3 different strengths (some where coloured: yellow, red, green - can somebody confirm?, some where black) - some with plastik caps on the upper and lower end of the forks to better fit the spring in the stanchion tubes, some without.

From my point of view they make sense, if the rider is >100kg, because you can't use high preasures in the old Marzocchi forks without damaging the seals.
 
so i'm only about 140lbs (~64kg), so i'm thinking of taking out the springs as i don't think i'll need them. plus it'll save me some weight. thoughts?
 
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