Marzocchi front fork

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probably over tightened the pinch bolts - you need to pry the pinch bolt clamp open again (if in fact you did over tighten it, you've closed the clamp tighter on to the axle, making it near impossible to remove)

As I wrote earlier, I did not overtighten it.
 
Well, I always watch the torque and still it happens. The clamping bolts should clamp around the axle and hold it, right? Look where the outher clamping bolt is situated. This is situated, there were the nut on the axle falls in the fork. If the outher diam. of the round part of the nut is 1 mm smaller, than the hole it goes in, then the clamping bolt is not clamping anything there. Only pulling the 2 halfs together, without clamping!
So the saw cut in the fork is not parallel anymore. Just check on your own bike:) I am curious how this looks like.

This what you are seeing on yours? Difficult to see from pic, but the two halves are touching. Looks to clamp well on the other side.
 

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This what you are seeing on yours? Difficult to see from pic, but the two halves are touching. Looks to clamp well on the other side.

Correct, this is what is happening. Because the cilindrical part of the nut is 1 mm smaller in diam. than the hole it fits in. So even if you use the right torque, it will make a plastic deformation to the fork. The wrench will click after the material of the fork has deformed that much, that it will give the desired resitance, or maybe touch on the outside the nut. Again, without clamping in the right way!
I have made a nut with the same diam. as the hole in the fork and now it is clamping parallel.
 

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Just another pic. which shows clearly that the axle is being supported on a very narrow area. On the outside there is no support at all with the original nut.
 

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Anybody new with these problems, who has had any feedback from a Duc dealer for example?
 

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