[Modifying stock cartridge on '99 V11 Sport?]

Success!  The damping is much better, and the adjuster screw has a greater effect on the range.  I used 5w, but in the future, the fork could easily be tuned with a more viscous oil to suit different conditions.  I made a modification gallery with some pics:

 

https://www.v11lemans.com/forums/index.php?app=gallery&album=268

[Modifying stock cartridge on '99 V11 Sport?]

There were two different Marzocchi forks on the early Sport (1999-2001), on one: the axle is nutted; and the other: the axle threads into the left fork leg.

 

These are all 43mm USD, as I recall. (there will be another part number in the system for the black finish on the 2001 Rosso Mandello.

 

@Drewteague, can you confirm the build date (left headstock tag, month-year), 9th/10th VIN characters, and the fork type (nutted or screwed in)?

 

(I've never heard of a 1999 Sport in the US. So, it may have a couple other features that might inform your suspension set-up.)

It's a '99 by VIN, build date 3/2000.  The front axle has a nut, and does not thread into the fork leg.

[Modifying stock cartridge on '99 V11 Sport?]

Awesome info, everyone!  Thanks for all the links.  Good to know my intuition was on point.  My customer lent his bike to a friend who claimed it suddenly lost damping, but it seems it was always like that.  I'll confer once again with the bike owner to clarify his goal (eg. more damping altogether, more progressive damping, etc) to make a plan around hole location/size and fork oil weight.  I'll post the results when I have them.

[Modifying stock cartridge on '99 V11 Sport?]

Hey, everyone!  I'm a tech doing a light track day build on a customer's '99 V11 Sport.  He complained of no compression damping in the front.  I dismantled the left fork, and found nothing excessively worn or broken.  I did notice, however, that the cylinder of the cartridge is drilled three times.  This allows all the oil to puke out the sides, eliminating most of the damping until the ring passes the last hole, about 3/4 of the way through the entire stroke.  This corresponds to the reaction I get from the fork leg compressing it manually, off-bike.  Everything I've found indicates that this is the stock setup, and that it hasn't been mangled by someone in a past life.  

 

Now, Has anyone plugged or filled any or all of these holes in order to increase overall damping, directing more or all of the oil through the adjustable valve, thereby increasing the range of adjustability?  I'd definitely be running 5w if I ended up modding it in this fashion.