COMPRESSION GOLD VALVE INSTALLATION

FMGV 2002C CRF250L
20mm DIRT SFF

Welcome to the wonderful world of Gold Valving. To obtain your personal Custom Suspension Settings:

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.

These are instructions for Compression Gold Valve Kits. For general fork rebuild procedure refer to the Fork Gold Valve Instruction List.

CAUTION: IF YOU ARE UNFAMILIAR WITH REBUILDING AND REVALVING FORKS, 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 Required

- In-lb torque wrench that accurately measures 0 to 50 in-lbs (0.58 kgf-m) (SnapOn Digital Torque Wrench shown)

- Hi-Strength Loctite (included)

- Metric calipers and micrometer

The CRF250L has Single Function Forks (SFF). This means that the left fork leg (as viewed sitting on the bike) contains the damping cartridge only, with no spring. The right leg contains a fork spring only, no damping.

Note: RT Fork Spring Kit for this bike retains the stock spring in the right leg and adds an additional spring to the left leg.

V1- Disassemble the left fork leg. Remove the compression assembly from the bottom of the cartridge. Push the assembly in enough to expose the circlip. Remove the circlip then the assembly.

Disassemble the Compression Valve Assembly. Clean everything.

V2- Start assebling by putting the Sleeve Washer, Check Spring, and the Check Plate on the Valving Bolt.

V3- The two sides of the Gold Valve are different. It is important to orient it properly. Place the Gold Valve on the shaft with the Recess going on to the bolt first.

The Recess is the circular pocket on the top face of the Gold Valve Piston.

V4- COMPRESSION BLEED HOLE

If your DVS Setup Sheet calls for a Compression Bleed Hole check to see if it is already pre-drilled in the piston. If it is not you will need to drill one.

Notice that the bleed hole is on the side of the piston with the recess and is drilled sideways. It connects the two sides of the piston and bypasses the valving stack. The exact location is not critical.

VALVING STACK TYPES - SINGLE OR TWO STAGE

V5- You will either be building a Single Stage or a Two Stage Stack. The difference is the Crossover. The Crossover is a smaller diameter shim between the Lo-Speed and the Hi-Speed Stacks.

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

V6- Two Stage Example

(Single Stage is exactly the same except there is no Crossover)

Put the valving on the shaft in the order listed, starting with the Lo-Speed Stack.

For Two Stage the total valving stack is made up of a:

Lo-Speed Stack

Crossover and a

Hi-Speed Stack

(this is only an example - not your setting)

The Total Valving Stack starting from the Gold Valve piston face:

(4) .15x17 - Lo- Speed Stack

(1) .10x11 - Crossover (notice the smaller diameter)

(1) .10x17 - Hi- Speed Stack

(1) .10x16

(1) .10x15

(1) .10x14

(1) .10x13

(1) .10x12

(1) .10x11

(1) .10x10

V7- Place the Base Plate (thick washer) on the shaft.

There are models that require 2 Base Plates.

Notice that the Valving Bolt is being held into the Recess. This keeps the Check Plate aligned during assembly.

V8- Make sure the Total Valving Stack Height is correct.

This step is here to insure you don't "run out of thread" when tightening the Valving Bolt. This height adjustment is done with Spacing Shims. If needed, they should be added just above the Base Plate. Spacing Shims must be larger in diameter than the smallest shim in the stack

The shims should be guided with the straight, non-threaded part of the shaft and should not be on the thread so the thread should be covered by the Base Plate.

When the valve stack is compressed during installation, the thread cannot extend below the Base Plate too.

V9- Use Loctite on the Compression Base thread...

V10- make sure the Base Plate is installed, then install the Valving Bolt and...

V11- tighten it to spec with a torque wrench.

CAUTION! The threads can be damaged without extreme care. You must use Loctite. The 6mm bolt must be torqued with a torque wrench to 30 in-lbs (2.5 ft-lbs or 0.35 kgf-m), NO MORE! Do not take this step lightly.

V12- Single Stage

V12- Two Stage

Notice the gap in the valving stack where the Crossover is. The crossover gap should be clearly visible upon inspection.

V13- Make sure the Check Plate is free and can move up and down against the Spring.

V14- Visually check your work.

Hold the Compression Stack up to the light and look for proper assembly. If there are any problems, disassemble the stack and look for burrs to surface and/or dirt in the valving. Reassemble and check again.

Make sure the o-ring is on the Gold Valve.

V15- 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. Please call Tech Support if this occurs and you can't figure it out.

V16- Return to the main instructions and continue with Rebound Valving and Assembly.