2019- Sachs Fork Special Instructions
Block-off Sleeve Installation
FMGV 302302C
(with Links to Compression and Rebound
Gold Valve Installations) 

These are special instructions specific to the installation of the FMGV 302302C Gold Valve Kit for Sachs Forks common on Beta Motorcycles. General rebuild instructions are available in our Fork Video. Installation of the "block-off" sleeve converts the "compression-only" cartridge to a standard cartridge. The kit includes Compression Base Valves with Compression Adjusters and Low-speed Valves (LSV).

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. BE SURE TO SELECT YES LSV (Low Speed Valve).

In stock form these are Open-Chamber Coil Spring forks that create Rebound damping only on the left fork leg. The right leg is Compression only. 

Once this Kit is installed both forks will be identical. Both fork cap adjusters will be Rebound Adjusters. Compression Adjusters will be added on the bottom of both legs. 

See your DVS Setup Sheet for valving and setup recommendations.

Featured, and special thanks to Master Suspension Technician Wyatt Scott (he has very manly hands).

Click on images to enlarge.

Shortcuts:

 > COMPRESSION CARTRIDGE MODIFICATION
 > REBOUND VALVING
 > COMPRESSION VALVING
 > FORK SPRING PRELOAD SETUP
 

Cartridge Holding Tool - for Early Type

Block-off Sleeve Installation Tool (recess side towards sleeve)

 

Shaft Holding Tool

 
TOOLS and SUPPLIES REQUIRED
 
 
TMVJ 065 - Vise Jaws helps a lot!
Propane Torch - for early style seal head removal
Hi-Strength Loctite
Torque Wrench (accurate at 20-50 in-lbs)
Plastic Head Hammer
 
Included in kit:
TFSH 272 - Shaft Holding for seal head removal on early style cart
TFBS 27 - Block off sleeve installation tool
TFSH 1225 - Shaft Holding Tool

Shaft Holding Tool used on early model cartridges for seal head removal.

 
CM1- The holes near the top of the cartridge must be sealed off with the installation of the "block-off" sleeve. There are two types of cartridges:
 
1-Early model with integrated spring perch. This type must have the seal head removed to install the block-off sleeve. This requires disassembly of the cartridge using the shaft holding tool supplied in the kit.
 
Hold the Seal Head in the Shaft Holding tool in the vise. Place a #3 Philips Screwdriver or other close-fitting rod through the compression holes at the bottom of the cartridge tube and unscrew the seal head.
 
To loosen the existing threadlock. You may need to use some heat on the thread. Do not heat over 350º F.
 
Laying the cartridge horizontally on an anvil and tapping with a plastic mallet on the threaded area works well too.
 
2-Late model (around 2020 though there is some overlap) that has a separate spring perch retained with a circlip. The block-off tube can be installed without cartridge disassembly. 

CM2- This is a late model cartridge. The block-off sleeve can be installed with the cartridge assembled.
 
The ID of the Block-off Sleeve has a step on one end. This step goes on first to help start the installation.
 

This shows the block-off sleeve partially installed. Note the direction or the recess in the installation tool. On the later model cartridge tube with the wire circlip grooves install the sleeve to just clear the bottom groove.

CM3- Put the block-off sleeve into the installation tool in the recessed side. With the tool resting on the vise jaws and the vise loose, tap down on the end of the cartridge with a plastic hammer. Keep going until the feed holes are completely covered.
 

 

 

This is the completed rebound/mid-valve assembly. The Rebound Gold Valve is usually installed on the holder after the holder is on the damping rod.

CC2- Use the TFSH 1225 Shaft Holding Tool. Remove the stock rebound holder and Install the new one. It may help to use a propane torch to heat it at the thread for removal.
 
Re-use the stock Rebound Needle and Spring. Use Hi-Strength Loctite on the Rebound Holder Thread.

 
 

 
This is a Post Type Compression Assembly.
 
It has a LSV (Low Speed Valve) below the compression stack.
 
 
 

Stock left, RT right

FORK SPRING PRELOAD SETUP

 
FP1- Measure the "Free Length" of the spring.

 
FP2- Back out the Adjuster Screw on the fork cap and install the spring on the Cartridge. Measure the "Set Length" of the spring.
 
Preload = Free Length minus Set Length (this must be a positive number).
 
Check your DVS Setup Sheet for recommended Preload (it is usually between 3 and 5mm).

Note that in this image the Jam Nut is not tightened. It must be tightened before use.

FP3- If the Preload needs to be increased you can add Preload Washers at either end.

FP4- Complete the Fork Assembly.
 
Set the clickers. The adjusters on the bottom are Compression. The adjusters on the fork caps are Rebound.
 
Note: For additional horsepower install the stylish Race Tech sticker. (Thanks A.J. - you're a pro.)