Cartridge forks are a popular choice for motorcycle enthusiasts due to their superior performance and adjustability. However, over time, the stock valving in cartridge forks may not provide the desired level of performance. Revalving cartridge forks can help improve the overall handling and response of your motorcycle.
Revalving cartridge forks involves replacing the stock valving with aftermarket options that better suit your riding style and preferences. This process requires some technical knowledge and the right tools, but with the following step-by-step guide, you can successfully revalve your cartridge forks and enhance your riding experience.
1. Disassemble the Forks: Start by removing the forks from your motorcycle and then disassembling them. This involves removing the spring, compression assembly, rebound assembly, and cartridges. Make sure to clean all the components thoroughly to remove any dirt or debris.
2. Evaluate the Existing Valving: Carefully inspect the stock valving to determine its characteristics and shortcomings. Look for signs of wear and damage that may affect its performance. Based on your evaluation, you can decide whether to modify the existing valving or replace it entirely.
3. Understand Your Riding Needs: Before selecting new valving options, it’s important to assess your riding style and needs. Consider factors such as your weight, skill level, and terrain preferences. This will help you choose the right valving setup that provides optimal performance.
4. Select Aftermarket Valving: Research different aftermarket valving options that are compatible with your cartridge forks. Look for reputable manufacturers and read reviews from other riders to make an informed decision. It’s recommended to consult with suspension experts or experienced riders for guidance.
5. Install the New Valving: Follow the manufacturer’s instructions to install the new valving components. Take your time and be meticulous during this step to ensure proper installation. Make sure to use the correct tools and techniques as recommended by the manufacturer.
6. Reassemble the Forks: Once the new valving is in place, reassemble the forks in the reverse order of disassembly. Make sure to tighten all the components to the specified torque settings. Inspect the forks for any leaks or abnormalities before reattaching them to your motorcycle.
Revalving cartridge forks can significantly enhance your motorcycle’s suspension and handling characteristics. However, it’s crucial to follow proper procedures and take your time during the process. If you’re unsure about any step, it’s best to seek professional assistance to ensure a safe and effective revalving job.
Understanding Cartridge Forks Revalving
Cartridge forks are a type of suspension system commonly found on modern motorcycles. Unlike traditional damper rod forks, cartridge forks use a separate damping mechanism that is housed inside the fork tube. This allows for more precise tuning and adjustment of the suspension to suit the rider’s preferences and the specific riding conditions.
Components of a Cartridge Fork
A cartridge fork consists of several key components, including:
- Outer fork tube: The outer fork tube provides the structural support for the fork assembly.
- Innter fork tube: The inner fork tube houses the cartridge assembly and allows for the movement of the fork stanchion.
- Cartridge assembly: The cartridge assembly contains the damping components, such as pistons, shims, and valves, that control the flow of oil within the fork.
- Fork stanchion: The fork stanchion attaches the front wheel to the motorcycle’s frame and provides the vertical movement of the suspension.
Why Revalving Cartridge Forks is Important
Revalving cartridge forks is a process that involves modifying the damping characteristics of the fork to better suit a rider’s needs. This can include adjusting compression and rebound damping, as well as modifying the overall damping curve. By revalving cartridge forks, riders can improve the handling, stability, and comfort of their motorcycles.
Some common reasons for revalving cartridge forks include:
- Adjusting to different riding conditions: Revalving can help optimize the suspension for different types of terrain, such as on-road or off-road riding.
- Customizing to rider preferences: Riders have different preferences when it comes to suspension feel, and revalving can fine-tune the fork to match those preferences.
- Correcting factory settings: The stock damping settings on cartridge forks may not be ideal for every rider, and revalving can correct any shortcomings in the stock setup.
The Revalving Process
Revalving cartridge forks involves disassembling the fork, modifying or replacing the damping components, and then reassembling the fork with the new settings. It is a complex process best performed by experienced suspension technicians.
Here are the basic steps involved in the revalving process:
- Remove the fork from the motorcycle.
- Drain the fork oil and remove the cartridge assembly from the fork tube.
- Disassemble the cartridge assembly and inspect the damping components.
- Modify or replace the damping components as needed.
- Reassemble the cartridge assembly and reinstall it into the fork tube.
- Refill the fork with the appropriate amount and weight of fork oil.
- Bleed and adjust the fork to the desired settings.
- Reinstall the fork onto the motorcycle.
After revalving cartridge forks, it is important to test and fine-tune the suspension settings to ensure optimal performance. This may involve making further adjustments to the compression and rebound damping, as well as setting the correct sag.
Overall, revalving cartridge forks can significantly enhance the performance of a motorcycle’s suspension system, providing a smoother and more controlled riding experience. It is a worthwhile investment for riders looking to improve the handling and comfort of their motorcycles.
Gather Necessary Tools
Before you begin revalving the cartridge forks on your motorcycle, it’s important to gather all the necessary tools. Having everything ready and organized will make the process smoother and more efficient. Here is a list of the tools you will need:
- Socket wrench set
- Allen wrench set
- Torque wrench
- Fork oil
- Fork oil level gauge
- Fork seal driver
- Shop rags
- Plastic container for drained oil
- Spring compressor
- Fork cap removal tool
- Fork oil syringe
- Seal pick
Make sure all the tools are in good condition and functioning properly. It’s also a good idea to have some extra shop rags on hand in case of any spills or leaks. Once you have all the necessary tools, you can proceed with revalving your cartridge forks.
Disassembly of Cartridge Forks
Step 1: Begin by removing the front fork assembly from the motorcycle’s front end. This typically involves loosening the top fork cap, removing the front wheel, and loosening the pinch bolts.
Step 2: Once the front fork assembly is removed, you will need to remove the fork cap using a specialized fork cap wrench.
Step 3: With the fork cap removed, you can then drain the oil from the fork tube. Place a drain pan underneath the fork tube to catch the oil as it drains out.
Step 4: Next, remove the cartridge assembly from the fork tube. This may require the use of a cartridge holding tool or a specialized fork disassembly tool.
Step 5: Once the cartridge assembly is removed, you can disassemble it further by removing the cartridge internals. This often involves removing snap rings, circlips, and springs.
Step 6: Clean all the components thoroughly with solvent and inspect them for any signs of wear or damage. Replace any worn or damaged parts as necessary.
Step 7: Reassemble the cartridge internals, making sure to follow the manufacturer’s instructions and torque specifications. Use a high-quality fork oil to lubricate the components during reassembly.
Step 8: Once the cartridge internals are reassembled, reinstall the cartridge assembly into the fork tube. Use a cartridge holding tool or a specialized fork reassembly tool to ensure a proper fit.
Step 9: Refill the fork tube with the appropriate amount of fork oil, as specified by the manufacturer. Use a fork oil level tool to measure the correct oil level.
Step 10: Reinstall the fork cap and tighten it to the manufacturer’s specifications using a fork cap wrench.
Step 11: Finally, reinstall the front fork assembly onto the motorcycle’s front end. This involves tightening the pinch bolts, installing the front wheel, and tightening the top fork cap.
Note: It is recommended to refer to the motorcycle’s service manual for detailed instructions and specifications specific to your make and model.
Inspecting Fork Components
Before revalving cartridge forks, it’s important to inspect all of the fork components to ensure they are in good condition. This will help identify any issues that may affect the performance of the forks.
Start by removing the fork from the motorcycle and disassembling it according to the manufacturer’s instructions. Once the fork is disassembled, visually inspect each component for any signs of wear, damage, or contamination. Pay close attention to the following:
| Component | Inspection |
|---|---|
| Outer Tube | Check for any dents, scratches, or other damage that may affect the integrity of the tube. Look for signs of pitting or corrosion. |
| Inner Tube | Inspect for any scratches or nicks that could cause oil leaks or affect the performance of the fork. Check the chrome plating for signs of peeling or flaking. |
| Bushings | Examine the bushings for any wear or damage. Look for signs of excessive play or uneven wear. |
| Seals | Check the fork seals for any signs of leakage or damage. Look for oil residue around the seals. |
| Damping Rod | Inspect the damping rod for any wear or pitting. Make sure it moves smoothly within the inner tube. |
| Valving | Take a close look at the valving components, such as shims and pistons. Look for any signs of wear or damage. |
| Spring | Inspect the spring for any signs of sagging or deformation. Check for any corrosion or damage. |
If any components are found to be damaged or worn out, they should be replaced before reassembling the fork. This will ensure that the fork operates smoothly and provides optimal performance.
Choosing the Right Valve Setting
When it comes to revalving cartridge forks, one of the most important factors to consider is choosing the right valve setting. The valve setting determines the amount of oil flow through the forks, which directly affects the damping characteristics and overall performance of the suspension.
There are several factors to consider when choosing the right valve setting for your specific needs:
Riding Style: Your riding style plays a significant role in determining the valve setting. Different valve settings are designed to cater to different riding styles, such as aggressive motocross, trail riding, or enduro racing. Understanding your riding style and the terrain you ride on will help you choose the optimal valve setting for your forks.
Weight: Your weight also plays a crucial role in determining the valve setting. Heavier riders require a stiffer valve setting to provide adequate damping and prevent bottoming out, while lighter riders may need a softer valve setting for improved comfort and responsiveness.
Terrain: The type of terrain you primarily ride on should also be taken into account. Riding on rough and rocky terrain requires a more aggressive valve setting to handle the increased forces and impacts, whereas smoother terrain may benefit from a softer valve setting for improved comfort and traction.
Suspension Setup: The overall suspension setup, including spring rates and sag settings, should be considered when choosing the valve setting. A well-balanced suspension setup will work in harmony with the chosen valve setting to provide optimal performance and control.
Professional Advice: When in doubt, seeking professional advice from a suspension specialist or reputable bike shop can be highly beneficial. They can assess your riding style, weight, and other relevant factors to recommend the ideal valve setting for your specific needs.
Remember, finding the right valve setting may require some trial and error to achieve the desired suspension performance. It’s important to experiment and fine-tune the valve setting to find the perfect balance between comfort, control, and responsiveness.
Revalving Process
The process of revalving cartridge forks involves several steps to ensure optimal performance and customization of your suspension. Here is a step-by-step guide on how to revalve cartridge forks:
| Step | Description |
|---|---|
| 1 | Remove the cartridge assembly from the fork tubes. |
| 2 | Disassemble the cartridge by removing the top cap, rebound adjuster, and compression adjuster. |
| 3 | Clean and inspect all parts for wear or damage. Replace any worn or damaged components. |
| 4 | Measure the existing shim stack and record the configuration. |
| 5 | Calculate the desired changes based on your riding preferences and the specific requirements of your bike. |
| 6 | Modify the shim stack by adding or removing shims to achieve the desired valving changes. |
| 7 | Reassemble the cartridge, making sure all parts are properly aligned and tightened to manufacturer specifications. |
| 8 | Reinstall the cartridge assembly into the fork tubes. |
| 9 | Check the fork oil level and adjust if necessary. |
| 10 | Test the revalved cartridge forks on the road or track, and make fine-tuning adjustments if needed. |
Following these steps will allow you to optimize the performance of your cartridge forks and tailor them to your specific riding style and preferences. It is recommended to consult a professional or refer to the manufacturer’s guidelines for detailed instructions and proper tools.
Reassembly and Testing
Once you have finished disassembling and cleaning the cartridge forks, it’s time to reassemble them and perform some testing to ensure everything is working properly.
Here are the steps to reassemble the cartridge forks:
- Start by lubricating all the necessary parts, including the seals, bushings, and O-rings. This will help reduce friction and improve the fork’s performance.
- Insert the rebound and compression dampers back into the fork leg, making sure they are properly aligned.
- Align the cartridge tube with the fork leg and insert it into place. You may need to use a rubber mallet or a soft-faced hammer to tap it in gently.
- Tighten the cartridge tube using the specified torque value provided by the manufacturer.
- Reinstall the fork springs and spacers according to the manufacturer’s instructions.
- Finally, reinstall the fork cap and tighten it to the specified torque value.
Once the cartridge forks are reassembled, it’s important to perform some testing to make sure they are functioning correctly:
| Test | Procedure |
|---|---|
| Sag Setting | Set the sag to the manufacturer’s recommended value by adjusting the preload. |
| Compression and Rebound Damping | Adjust the compression and rebound damping settings to achieve the desired feel and performance. |
| Smoothness of Operation | Check for any excessive friction or sticking in the fork’s movement by compressing and rebounding it several times. Ensure that it moves smoothly. |
| Leak Test | Apply suspension fluid to the fork leg and check for any leaks or seepage. |
If you encounter any issues during the reassembly or testing process, consult the manufacturer’s instructions or seek professional assistance.
By following these steps and performing the necessary testing, you can successfully reassemble and test your cartridge forks to ensure optimal performance.
