Fork Gold Valve Installation
VALVING AND ASSEMBLY INSTRUCTIONS - FMGV S282801C
SHOWA BFFC - BALANCE FREE FRONT CUSHION2016- ZX-10, 2017- GSX-R1000NOT DONE!!!!!!!!!!!!!! These instructions cover installation of the Fork Gold Valve onto the shaft for BFFC type of forks. These forks have a cartridge with a solid piston on the damping rod.
DVS Setup Sheet - If you haven't already, go to DVS Valving Search, insert your Access Code, and rider data and print your DVS Setup Sheet. Click on the images to enlarge. Shortcuts: > SHAFT DISASSEMBLY
> VALVING CAUTION: IF YOU ARE UNFAMILIAR WITH REBUILDING AND REVALVING SHOCKS, STOP!!! DO NOT PROCEED; SEEK OUT A QUALIFIED SUSPENSION TECHNICIAN.
NOTE: All measurements are metric (for inches divide by 25.4). The valving list starts at the piston face and goes towards the Base Plate. Valve specs are listed by (QUANTITY) THICKNESS x DIAMETER. A number in parentheses means quantity. If there is no number in parenthesis the quantity is one. Example: (2).15x30 means quantity two, 15 hundredths of a millimeter thick by 30 millimeters in diameter. |
| Tools
- Torque wrench (SnapOn Digital Torque Wrench shown) - TSCP 01 - Clip Tool - TFCA TF08 - Two Flat 8mm SocketXXXXXX Supplies Contact Cleaner - or other good, clean solvent Loctite - Hi-Strength (included in the Gold Valve Kit) USSG 01 - Ultra Slick Seal Grease USF-05 - Fork OilXXXXXX |
| SD1 - Once the Valving Assembly has been removed from the fork remove the Valving Bolt with the TFCA TF08 Two Flat Socket. Save and re-use the stock Valving Bolt. |
V1- VALVING - VALVING STACK TYPES - SINGLE OR TWO STAGE You will either be building a Single Stage or a Two Stage Stack (or possibly a combination of both). The difference is the Crossover. The Crossover is a smaller diameter shim between the Lo-Speed and the Hi-Speed Stacks. Look for this shim in the valving stack listed in the DVS. If it is not there it is a single stage stack. Note: The DVS Custom Setup Sheet displays individual shims and does not label Hi-Speed, Crossover, and Lo-Speed. This is for your information only. Also you will not use all the shims provided in the Gold Valve Kit. • Single Stage - made of:
Lo-Speed Stack
Hi-Speed Stack
There is NO Crossover
(it becomes one stack.) |  |  | • Two Stage - made of:
Lo-Speed Stack
Crossover
Hi-Speed Stack
The Crossover Gap is visible |  | 
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| V2- IDENTIFY THE 3 AND 6 PORT SIDES OF THE PISTONS
The 3 port side is on the left - this side faces up The 6 port side is on the right - this side faces down |
| V3- Rebound Assembly (bottom valve - installed on shaft first)
Assembly order: Stock Check Valve Assembly Spacing Shim (.30x14)
Clamp Shim (.30x10)
Bending Type Check Shims (2).15x24 Rebound Gold Valve - 3 Port Side up, 6 Port Side down (rebound and compression Gold Valves are identical and the 3 port side faces up on both - critical) 
Example: Note: The DVS Custom Setup Sheet displays individual shims and does not label Hi-Speed, Crossover, and Lo-Speed. (this is only an example - not your setting) The Total Valving Stack starting from the Gold Valve piston face: (4) .15x24 - Lo- Speed Stack (1) .10x12 - Crossover (notice the smaller diameter) (1) .20x24 - Hi- Speed Stack (1) .20x22 (1) .20x20 (1) .20x18 (1) .20x16 (1) .20x14 (1) .20x12 (1) .20x10 Install the rebound valving stack in the order that it is listed on the DVS, starting with the largest diameter shim of the Lo-Speed Rebound Stack, then the Crossover, then the largest diameter shim of the Hi-Speed Rebound Stack tapering down to the smallest. |
| V4- Make sure the Rebound Valving Stack Height is correct. Critical!! This step is here to insure the Bleed Base Plate is aligned with the feed holes in the shaft. This should be ok with the valving selected by the DVS. If it is not, double check everything. If needed, height adjustment is done with Spacing Shims added just below the Bleed Base Plate. Spacing Shims must be larger in diameter than the smallest shim in the stack. |
| V5- Compression Assembly (top valve - installed on shaft second) Note: If Spacing Shims are required to achieve the correct Total Valving Stack Height they will be placed directly on top of the Bleed Base Plate. (see the next step) Example: for Two Stage the total Compression valving stack is made up of a: Hi-Speed Compression Stack Compression Crossover and a Lo-Speed Compression Stack Note: The DVS Custom Setup Sheet displays individual shims and does not label Hi-Speed, Crossover, and Lo-Speed. (this is only an example - not your setting) The Total Valving Stack starting from the Gold Valve piston face: (4) .15x24 - Lo- Speed Stack (1) .10x12 - Crossover (notice the smaller diameter) (1) .20x24 - Hi- Speed Stack (1) .20x22 (1) .20x20 (1) .20x18 (1) .20x16 (1) .20x14 (1) .20x12 (1) .20x10 Install the compression valving stack in the REVERSE order that it is listed on the DVS, starting with the smallest diameter shim of the Hi-Speed Compression Stack tapering up to the largest, then the Compression Crossover, then the Lo-Speed Compression Stack. Install the Compression Gold Valve (3 Port side up, 6 Port side down). Stock Check Valve Assembly Bending Type Check Shims (2).15x24 Clamp Shim (.30x10) Spacing Shim (.30x14)
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| V6- Make sure the Total Valving Stack Height is correct. Critical!! This is an unusual design in that the valving stack is not tightened down with the valving bolt. It is tightened when the Valving Assembly is installed into the fork bottom. Therefore the most important thing about setting the Total Stack Height is making sure the Compression Base Plate floats with the two-flat bolt tight. This should be ok with the valving selected by the DVS. If it is not, double check everything. If needed, height adjustment is done with Spacing Shims added just above the Bleed Base Plate below the Comression Valving Stack. Spacing Shims must be larger in diameter than the smallest shim in the stack. |
| V7- Re-use the stock valving bolt. Clean everything completely. Install and torque the valving bolt to the proper setting (see the DVS) using a torque wrench. This is critical! |
V8- Single Stage Compression and Rebound Examples on conventional shocks (but you get the idea). | V9- Two Stage Compression and Rebound Notice the gap in the valving stack where the Crossover is. The Crossover Gap should be clearly visible. |
| V10- Visually check your work. Hold the completed valving assembly up to the light and look for any irregularities. Make sure the shims are laying flat on the piston surface. On two stage stacks check that the Crossover Gap is clearly visible. If there are any problems, disassemble the stack and look for dirt, bent shims, or any other causes. Reassemble and inspect again. You might be thinking that this looks like either a very tiny shock shaft or a fork compression valve. Well, you're right, it's a very tiny shock shaft. You get the idea. |
 | V11- Make sure the shims that go next to the Gold Valve completely cover the ports on both sides of the piston! If the ports are not covered there will not be enough damping. This could be caused by a number of reasons. Re-check everything. Please call Tech Support if you can't figure it out. |
1. ASSEMBLE FORK, INSTALL CARTRIDGE, INSTALL RESY, INSTALL VALVING ASSEMBLY
2. INSTALL SPRING AND SET OIL LEVEL – 230mm / 165cc???
3. INSTALL PRELOAD TUBE AND FORK CAP, TIGHTEN LOCK NUT, TIGHTEN FORK CAP INTO TUBE
4. INSTALL RESY BLEED TOOL TFRS B2738 ON TOP OF RESY PISTON AND INSTALL CIRCLIP
5. INSTALL VACUUM BLEEDER ADAPTER AND HOOK UP VACUUM MACHINE
6. PERFORM VACUUM BLEED PROCEDURE
7. REMOVE RESY BLEED TOOL
8. SET RESY PISTON HEIGHT 60MM TO EDGE OF PISTON FROM TOP OF RESY TUBE
9. INSTALL RESY CAP AND CIRCLIP
10. LAY FORK HORIZONTAL AND REMOVE BLEEDER ADAPTER
11. LOCK TITE AND INSTALL BLEED BOLT
12. CHARGE RESERVOIR WITH 75psi NITROGEN
13. CLEAN FORK AND INSTALL RACE TECH STICKERS
| V12- Return to the main Rebuild instructions to complete the reassembly.
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