Fork part identification (not on parts list???)

[elgallo73]

Folks,

I am having difficulty identifying the following part:





I have checked the parts diagram for a 2011 Monster 696 yet cannot locate this item.  It screws into the fork securing the spring in the lower portion of the tube.

Any expert here who knows what it is?  I need to order a replacement yet I cannot order one if I do now know the part number nor the nomenclature.  I'm not surprised it is not on the parts list given the "frankenbike" nature of the Monster series...

[stopintime]

Part # 17 on page 24 ?

[elgallo73]

Which catalog are you using (could be my lucky day!)?

Part #17 (349.1.237.1A, "Complete Pumping Element", $39.99) on page 24 of the catalog on Ducati Omaha's site which I might add, is the wrong catalog (shows Showa forks instead of the Marzocchi's which are standard on the 2011 696).

Part #17 (349.2.099.1A, "Stanchion Tube", $437.99) is for the entire assembly, which of course I don't need.  Additionally, the part in the photo above is NOT shown in that diagram, nor would it be a part of the stanchion tube.

The part above screws into the fork tube, securing the spring in the lower half.  

[stopintime]

Hmmm...

I was looking at '11 696 EU and at page 87 (sorry, not 24) I see part number #17 34912371a, which I thought might be it - even though it's hard to see if it's the same as in your picture.

If that's a Showa fork - maybe you have a Showa fork?? (that would be a surprise!)

In the US catalog, we're back to a typical Marzocchi lay out....  complete unit 34920991a.
I don't know if your picture shows a part of that complete unit (so, we're back to square one I guess)

[elgallo73]

Just checked, the Euro parts catalog shows what appears to be the Showa forks.  It is definitely not part #17, but could be part #20 (349.1.238.1A, Bushing).  I HOPE that is the part and it would appear to be the one, from the diagram.

The part shown is threaded, yet I am missing the spring which is shown in the diagram, maybe not necessary???

[stopintime]

You need to confirm, but doesn't it lok like a valve?

If it is and you have a Marzocchi - it's not supposed to be loose?

How did it happen - fell apart when you opened the fork?

Sorry for all the question marks    just trying to use logic (since I'm no expert)

[elgallo73]

I am replacing the stock springs on my Marzocchi's with Racetech linear springs.  Disassembly seemed straight forward enough, read as much as I could.  This part had me stumped initially as this is my first time taking apart a set of street bike forks (last time I did this was on a YZ 80 in the early 80's, much easier!!!).

I managed to damage the bushing/whatever while attempting to unscrew it from the fork.  The part is typically (and was) tight.  There are (6) holes that are 6mm in diameter with a 10mm hole through which the pumping element rod goes through.

I'm no expert here, either, but it appears that to POSSIBLY be a valve but I am on the fence with this as there is another valve still bolted in the fork via the cap screw on the bottom.

It would APPEAR that these forks are a sort of "hodge podge" of parts.  I base this on the differences between the diagrams listed for the Euro 696, US 696, and the Showa equipped 2009-2010 696 Monsters.

For example, my forks do not look EXACTLY like the diagram listed for what SHOULD be on my bike, but when looking at (3) different diagrams (EURO/US/Pre-2011), I can piece my forks together from the set (hope this makes sense).

I am going to order part number 349.1.238.1A (listed as a bushing) and HOPE TO GOD that it fits, unless someone else here recognizes it and maybe has a spare...

[elgallo73]

Update:

Ordered part number 349.1.238.1A and it dropped right in!  Even better, this part appears to be made of stainless steel vice the original aluminum.

The received part differs from the the installed item in that there are (4) large orifices compared to the (6) small orifices on the original and a larger hole for the rod which secures to the top cap (total area for oil to pass appears to be the same).  In addition, instead of (6) side holes for tightening, the nut is "castellated".  Forgot to take a pic but hope this is relatively descriptive.  This IS the part listed as being installed on my 2011 696 but differs from what was INSTALLED, your mileage may vary...

Notes: this is my first time delving into street bike fork internals (probably a good thing they were relatively simple Marzocchi's) so there was a learning curve.  True to the "parts bin special" manner in which the Monster's are assembled, my forks differed from the parts list.  I could be wrong, but it seems to me that many of the parts for the Marzocchi's are interchangeable.  Racetech springs and some fork oil transformed the stock forks, cheap and effective upgrade for the front suspension...

There was no fork oil height specification in the workshop or owner's manual, only called for 500cc of 7.5wt fork oil.  I received varying recommendations for oil height so I just went ahead with 500cc's of ISO 46 hydraulic oil (~15wt) per fork.  Worked fine, This is very preliminary but on the way to work the forks worked like a champ and provide a much better ride than the original progressive springs.  Rider sag is about 25% (I know, probably a bit tight for street use) of the total travel and I may remove a shim on my next service to give a bit more.

If you do this, be careful with the fork caps, I buggered one up and am still looking for a replacement.  Removing the springs is not as bad as one might think, when the forks are off the bike with the top caps removed, I found it very easy.  I used GSXR 750 fork seals/wipers.  I cannot remember the starting year but anything after 2000 up to 2005 will work (got it from the OEM part alternatives thread).  Much cheaper than OEM...  1.5" PVC pipe cut to about 3" and split in two halves with a hose clamp works as an EXCELLENT and CHEAP seal driver!

Granted they are not Ohlins or similar, but being married and on a budget the mod fits the bill nicely!