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Racetech G2R Gold Valve Installation

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Old 03-12-2012, 09:46 AM
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Location: Morristown, Tennessee
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Default Racetech G2R Gold Valve Installation

See the link below for the removal of the front forks and how to disassemble the fork to remove the damper.

https://cbrforum.com/forum/how-103/c...lation-120001/

Now you should have the damper removed from the fork. The stock compression valve (pic 1) is located in the bottom of the fork. Press on the valve body with your thumb and is should move about half an inch up in the damper. Now you will see a clip ring (pic 2) just above the bottom of the damper. Using a pick or small screwdriver remove this clip. Next I had to use a piece of 220 grit sandpaper to remove a small lip just below the clip ring you just removed. The valve assembly would not come out without removing this lip on my bike. Once this lip is smooth re-install the bolt from the bottom of the fork and use it to pull out the stock compression valve (pic 3).

Next you will need a good digital caliper to take measurements of the stock valve assembly and to measure the washers that come with the gold valves. First measure the entire stock valve assembly and record the measurement. Mine was about 51.69mm. Now you need to loosen the allen screw holding the stock valve assembly together. Place the lower part of the valve in a vise with soft jaws so you don't damage it and loosen the bolt. As you remove the bolt turn it upside down to keep all the stock parts on the bolt. This way you keep it together so you can place them on a small screwdriver to keep the order correct. (pic 4) You will use a few of the stock parts with the gold valve kit.

Here is the stock order just in case you get things mixed up. (Pic 4)
1. Bolt (R) R= use with gold valve
2. Cupped Washer (R)
3. Spring (looks like a bent washer)
4. sleeve (R)
5. Check plate (R)
6. Valve
7. .12x17mm washer
8. .10x13mm
9. .10x16mm
10. .10x16mm
11. .10x15mm
12. .10-.11x15mm
13. .10-.11x15mm
14. .22x8mm
15. .55x11mm(R)
16. Base (R)

Now you will need to use the access code that is printed on the instructions from racetech to get the recommended valve stack for your weight and riding style. This will determine which washers will be used with your gold valve. There will be a Restrictor Valving stack and Compression Valving stack. My recommendation was the 00.09 restrictor valving and c34 compression valving. You will have to use your digital caliper to measure out the correct washers for your recommended valving stack. These measurements are very small and you have to very precise with your measurements. The washers do not come in individual labeled bags but are mixed together in a few bags. This makes no sense to me since it would be much easier if they came in their own bag and labeled so you didn't have to measurement all of them to sort them into their respective stacks. Once you have measured and sorted all of the washer you are ready to begin the install.

Here is the order of assembly:
1. Bolt (stock)
2. Cupped Washer (stock)
3. Sleeve (stock)
4. Spring
5. Check Plate (stock)
6. Gold Valve with recessed side facing the sleeve and o-ring installed
7. Restrictor Valving stack (00.09 = (2) .15x9mm & (2) .10x9mm
8. Compression Valving stack (c34 = (4) .15x17, .10x15, .10x13, .10x12, .10x11, .10x10, .10x9)
9. Base plate ( 1 of the thick washers from racetech kit)
10. Washer (Last washer from stock valving)
11. Stock base (this is part the bolt is screwed into) Needs loctite

Using one thick base plate from kit and the last stock washer my overall height was within .05mm of the stock height. The gold valve is thinner than the stock valve so you must compensate for this difference.

Once you are sure you have this assembled correctly you are ready to attach it to the base using loctite on the threads and tightening the bolt to 30 in-lbs. After you tighten the bolt there should be no movement. If the gold valve is loose or if you are to move any of the parts it is not correct. Loosen the bolt and re-check everything then try again. Once you are sure its correct and tight check the overall length to make sure its all as close as possible to the stock valve height.

You are ready to re-install the valve assembly into the damper. Push the valve into the damper and re-install the clip ring. You are finished installing the gold valve.

Follow the instructions in the thread at the top of the page on how to put your forks together, fill with fluid, bleed the fork and re-install on your bike.
 
Attached Thumbnails Racetech G2R Gold Valve Installation-cimg3152.jpg   Racetech G2R Gold Valve Installation-cimg3153.jpg   Racetech G2R Gold Valve Installation-cimg3154.jpg   Racetech G2R Gold Valve Installation-cimg3157.jpg   Racetech G2R Gold Valve Installation-cimg3161.jpg  

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