FORK REBOUND and MID-VALVE
GOLD VALVE INSTALLATION
FRGV 200603
Dirt 20mm WP 4CS

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.

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

VR1- Unscrew the Hydro Stop (bottom-out) Needle with a T27 Torx bit.

VR2- Remove the Needle. There is a Check Valve inside the Bottom-out Needle. The Check Valve will be removed.
Removing the Check Valves converts both adjusters into Rebound Adjusters.

VR3-  The Check Valves (the small "bullet" shaped pieces in the middle) will be removed during installation. Shown is the stock direction of the Check Valves.
Note - Removing the Check Valves will make the valving identical between the two fork legs.

VR4- Measure the post height extension above the rebound stack.

VR5- Remove the rebound valving assembly.
VALVING STACK TYPES - SINGLE OR TWO STAGE

VR6- You will either be building a Single Stage or a Two Stage Stack for both the Mid-Valve and the Rebound Stacks. The difference is the Crossover. The Crossover is a smaller diameter shim between the Lo-Speed and the Hi-Speed Stacks.

Please note that the DVS might call for a Single Stage Mid-Valve Stack and a Two Stage Rebound Stack (or the other way around).

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

 

VR7- MID-VALVE STACK
The DVS calculates the entire stack with all the shims. Install the Mid-Valve Stack onto the Valving Shaft starting with the:

Check Spring
Mid-Valve Packing Stack
Hi-Speed Mid-Valve Stack
Mid-Valve Crossover (if it is a two stage Mid-Valve stack)
Lo-Speed Mid-Valve Stack

and
Sleeve Extender Shim(s) (6mm id x 8mm od shims) (if required)
Float is the amount the Mid-Valve stack moves before it has to bend.
Once the complete assembly is built, check the Float with a feeler gauge (step VR17). This may be off due to production tolerances on all of the parts in the assembly. Adjust the MV Packing Stack to create the correct Float.

 

VR8- REBOUND BLEED HOLE
If the DVS does not call for a Rebound Bleed Hole skip this step.
If your DVS Setup Sheet calls for a Rebound Bleed Hole check to see if there is one already pre-drilled in the piston. If one is called for, and there is no pre-drilled bleed hole, you will need to drill one.
Notice that the bleed hole is on the opposite 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.

VR9- Install the Rebound Gold Valve WITH THE RECESS IN THE GOLD VALVE FACING DOWN TOWARDS THE MID-VALVE.

VR10- REBOUND STACK
Install the rebound stack with the largest shim of the Lo-Speed Stack first against the piston face. Make sure the shims completely cover the ports.
If a two stage rebound stack is called for in the DVS, install the Rebound Crossover.
Install the Hi-Speed Rebound Stack in the order listed starting with the largest diameter shim and ending with the smallest diameter shim.

VR11- Two Stage Rebound Example

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

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

VR12- Measure the post extension beyond the rebound stack. The new measurement must be 10.3 to 10.7mm. CRITICAL!!
Adjust the Total Rebound Stack Thickness with Spacing Shims as needed to achieve this.
The Spacing Shims must all be larger in diameter than the smallest shim in the Rebound Stack.

VR13- Apply a small drop of Loctite onto the thread of the rebound valving shaft.

VR14- Do not install the Check Valves in either leg. Install the Hydro Stop Bottom-out Needle.

VR15- Torque the Needle to 30 in-lbs.

VR16- Install the rebound piston band. Curl it up tightly, then install it. You may find it helpful to use a bit of grease to hold it into the groove.

VR17- CHECK THE FLOAT
The most critical valving setup in the entire front fork is the FLOAT. Use a feeler gauge to measure the actual "float" of the mid-valve. The float is the amount the stack moves before it has to bend.
Insert the feeler gauge between the Gold Valve Piston face and the first shim. Make sure the feeler gauge goes all the way in to the surface of the inner sleeve.
This is the best way to check the float as there are always production tolerances that will throw the predicted float off of the calculated number.
Adjust the packing stack to get the correct float. THIS IS CRITICAL!
VR18- Single Stage Rebound and Single Stage Mid-Valve 

VR18- Two Stage Rebound
and Two Stage Mid-Valve

Notice the gaps in the valving stacks where both the Rebound and Mid-Valve Crossovers are. The crossover gap should be clearly visible upon inspection.

VR19- Check your work. Hold the Valve 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.

 

VR20- 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.

VR21- Continue with the Compression Gold Valve installation and Fork Assembly.
• 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