Fork rebuild and re-valve

woods

Member
Joined
Mar 27, 2015
Messages
36
Location
Hollister, CA
So after 72,000 miles my fork decided to start leaking, I figured this would be a good time to rebuild it right with new springs and valving
I am swapping in a Penske shock at the same time since the biggest issue in the ST suspension is the shock.
I have done many different projects throughout the years but have never touched forks so hopefully this will be added to the list of good in the end.
I have done as much research that I could find and have started collecting some of the specialty tools needed but there isn't much information out there for the ST forks so I am hoping that the questions can be answered here.
I have decided to go with the Penske valving and will be on the lighter side with .90 springs
I did pick up the Race Tech Bible yesterday but have to take the time and read.

First question is I will need to buy a clamp to hold the damper rod assembly in my vise but can't find the correct size of clamp. I'm assuming it is a 20mm diameter but want to be sure.
Thanks for the help and bear with Me on the future questions.

Thanks, Ken
 

jrusell

Well-Known Member
Joined
Aug 23, 2017
Messages
460
Location
Dartmouth, Nova Scotia, Canada
So after 72,000 miles my fork decided to start leaking, I figured this would be a good time to rebuild it right with new springs and valving
I am swapping in a Penske shock at the same time since the biggest issue in the ST suspension is the shock.
I have done many different projects throughout the years but have never touched forks so hopefully this will be added to the list of good in the end.
I have done as much research that I could find and have started collecting some of the specialty tools needed but there isn't much information out there for the ST forks so I am hoping that the questions can be answered here.
I have decided to go with the Penske valving and will be on the lighter side with .90 springs
I did pick up the Race Tech Bible yesterday but have to take the time and read.

First question is I will need to buy a clamp to hold the damper rod assembly in my vise but can't find the correct size of clamp. I'm assuming it is a 20mm diameter but want to be sure.
Thanks for the help and bear with Me on the future questions.

Thanks, Ken
20mm is the piston/inside diameter.
24mm is what you need.
I used the race tech holder, but there are several other holders available.C779B73D-49C1-42DA-837F-B2E33DBA78AB_1_201_a.jpeg3C7D7FF5-FC5D-4E99-AE98-56B06A27158E.jpeg
 

jrusell

Well-Known Member
Joined
Aug 23, 2017
Messages
460
Location
Dartmouth, Nova Scotia, Canada
Did you have to remove the spring perch to get the rebound valve out or just the compression valve? I forget if theres a bumper on the damper rod.

What was your impression of the penske valveing?
There is a bottom out bumper on the damper rod so unfortunately you have to remove the top of the cartridge to access the rebound piston. Some heat around the top of the cartridge helps loosen the factory locktite.

Compression comes out easily after removing the circlip.
I used race tech pistons not Penske because of availability in my area. I was happy with result, but I did not use their recommended valving. If I was in the USA I would get Penske valves from Stoltec Moto.
 
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