Shock Gold Valve Installation

VALVING INSTRUCTIONS - SHOWA BFRC
BALANCE FREE REAR CUSHION

These instructions cover installation of the Shock Gold Valve onto the shaft for BFRC type of shocks. These shocks are a twin tube design and have a solid piston on the shock shaft. To get to this point in the installation see the â–ºBFRC shock rebuild instructions ClickHere.

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.

Click on the images to enlarge.

Shortcuts:

 > SHAFT DISASSEMBLY
 > VALVING

CAUTION:  IF YOU ARE UNFAMILIAR WITH REBUILDING AND REVALVING SHOCKS, 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
- Torque wrench (SnapOn Digital Torque Wrench shown)
- Metric calipers and micrometer
TMVJ 065 Vise Jaws mounted on a Vise - suggested
TSCP 01 - Clip Tool
 
Supplies 
Contact Cleaner - or other good, clean solvent
Loctite - Hi-Strength (included in the Gold Valve Kit)
USSG 01 - Ultra Slick Seal Grease


 

 
SD1 - Once the Valving Assembly has been removed from the shock remove the valving shaft nut. Unlike standard Showa shocks the nut is not peened on. Simply unscrew the nut.
 
Save and re-use the stock nut.
V1- VALVING - VALVING STACK TYPES - SINGLE OR TWO STAGE

You will either be building a Single Stage or a Two Stage Stack (or possibly a combination of both). The difference is the Crossover. The Crossover is a smaller diameter shim between the Lo-Speed and the Hi-Speed Stacks. Look for this shim in the valving stack listed in the DVS. If it is not there it is a single stage stack.

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

 


Click to enlarge

V2- IDENTIFY THE 3 AND 6 PORT SIDES OF THE PISTONS
 
 
The 3 port side is on the left - this side faces up
 
The 6 port side is on the right - this side faces down

V3- Rebound Assembly
 
Assembly order:
 Cupped Washer (cup facing up)
 Check Sleeve (new - provided in kit)
 Check Spring Wave Washer (use stock)
 Check Plate (16 id x34 od x.50 thick - provided)
 Gold Valve - 3 Port Side up, 6 Port Side down (rebound and compression Gold Valves are identical and the 3 port side faces up on both - critical)
 

 
For Two Stage the total Rebound valving stack is made up of a:
 
Hi-Speed Rebound Stack
Rebound Crossover and a
Lo-Speed Rebound Stack

Note: The DVS Custom Setup Sheet displays individual shims and does not label Hi-Speed, Crossover, and Lo-Speed.

 (this is only an example - not your setting)
               
The Total Valving Stack starting from the Gold Valve piston face:
(4) .20x34 - Lo-Speed Stack
(1) .15x22 - Crossover (notice the smaller diameter)
(1) .25x34 - Hi-Speed Stack
(1) .30x32
(1) .30x30
(1) .30x28
(1) .30x26
(1) .30x24
(1) .30x22
(1) .30x20
 
Install the rebound valving stack in the order that it is listed, starting with the largest diameter shim of the Lo-Speed Rebound Stack, then the Crossover, then the largest diameter shim of the Hi-Speed Rebound Stack tapering down to the smallest.

 V4- Make sure the Rebound Valving Stack Height is correct. Critical!!
 
This step is here to insure the Bleed Base Plate is aligned with the feed holes in the shaft.
 
If needed, height adjustment is done with Spacing Shims added just below the Bleed Base Plate.
 
Spacing Shims must be larger in diameter than the smallest shim in the stack. 
 

V5- Compression Assembly
 
Note: If Spacing Shims are required to achieve the correct Total Valving Stack Height they will be placed directly on top of the Bleed Base Plate. (see the next step)
 
For Two Stage the total Compression valving stack is made up of a:
 
Hi-Speed Compression Stack
Compression Crossover and a
Lo-Speed Compression Stack

Note: The DVS Custom Setup Sheet displays individual shims and does not label Hi-Speed, Crossover, and Lo-Speed.

 (this is only an example - not your setting)
               
The Total Valving Stack starting from the Gold Valve piston face:
(4) .20x34 - Lo-Speed Stack
(1) .15x22 - Crossover (notice the smaller diameter)
(1) .25x34 - Hi-Speed Stack
(1) .30x32
(1) .30x30
(1) .30x28
(1) .30x26
(1) .30x24
(1) .30x22
(1) .30x20
 
Install the compression valving stack in the REVERSE order that it is listed, starting with the smallest diameter shim of the Hi-Speed Compression Stack tapering up to the largest, then the Compression Crossover, then the Lo-Speed Compression Stack. 
 
Install the Compression Gold Valve (3 Port side up, 6 Port side down).
 
 Check Sleeve (new - provided in kit)
 Check Plate (16 id x34 od x.50 thick - provided)
 Check Spring Wave Washer (use stock)
 Cupped Washer (cup facing down)
 


 

V6-  Make sure the Total Valving Stack Height is correct. Critical!!
 
This step is here to insure you don't "run out of thread" onto the straight, non-threaded, portion of the shaft when tightening the Nut.
 
If needed, height adjustment is done with Spacing Shims added just above the Bleed Base Plate below the Comression Valving Stack.
 
Spacing Shims must be larger in diameter than the smallest shim in the stack. 
 
Click images to enlarge.
 

 

 

 

V7- Re-use the stock nut. 
 
Clean everything completely. Use Hi-Strength Loctite (included) on the shaft nut.
 
Make sure the Check Plates move freely before you tighten the Nut. Install and torque the shaft nut to the proper setting (see the DVS) using a torque wrench. This is critical!

V8- Single Stage Compression and Rebound

Examples on conventional shocks (but you get the idea). 

V9- Two Stage Compression and Rebound
 

Notice the gap in the valving stack where the Crossover is. The Crossover Gap should be clearly visible.

 

V10- Visually check your work.
 
Hold the completed valving assembly up to the light and look for any irregularities. Make sure the shims are laying flat on the piston surface. On two stage stacks check that the Crossover Gap is clearly visible.
 
If there are any problems, disassemble the stack and look for dirt, bent shims, or any other causes. Reassemble and inspect again.
 
You might be thinking that this looks like either a very tiny shock shaft or a fork compression valve. Well, you're right, it's a very tiny shock shaft. You get the idea.

 

V11- 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. Piston upside down, Compression and Rebound Stacks reversed on location or installed upside down.
 
Please call Tech Support if this occurs and you can't figure it out.

 

V12- Return to the main Rebuild instructions to complete the reassembly.