Ok so there arent any how to's on this so I thought I would post up, cant post in the how to section so mods do your thing please
Alright, first things first, tool list, these are a must, theres others but these are some that you may not have that you need. Also make sure you keep everything very clean, remove any foreign objects and debris. If you have a German Shepard like me this proves to be a bit more difficult!
Traxxion dynamics cartridge fork tool kit
inch pound torque wrench, not the harbor freight one, you need to be exact
Ok, first thing is to disassemble the forks, Garth did a great how to on fork seal replacement so here is a link to that. Follow his steps then come back here.
First, drain out the old oil
2nd, raise your sword and shout "by the powers of greyskull" and compress the spring, or get a friend to help, its much easier and not as painful, trust me
Remove the fork cap and decompress the spring, remove the spriing.
Next unscrew the #8 allen bolt at the bottom of the fork, you may have to stop the inards from spinning, I did this with a long screwdriver
Also, its a pain to break that bolt loose so putting the allen in a vice works very well
Remove the cartridge from the fork tube
Now unscrew the compression valve out from the bottom of the cartridge and the rebound valve out from the top. I used a vice, heat and a pipe wrench, Im sure theres a better way but this worked very well for me
Close up of the stock compression valve
Close up of the stock rebound valve
Now both valves have the ends peened so you will have to file these off
Peening filed off
Now lets rebuild the compression valve. When you order the compression valves from Race Tech via 303 cycle(thanks again) it comes with an access code. Go onto race techs site and enter that code with your info into their valving size chart, there it will tell you what valve stack and restrictor stack you should choose, Measure out the valve stacking with the digital caliper, this is a critical step to get right but very easy, I bought this caliper for 10 bucks at harbor freight
Now lay out the valves in order of how they are going to go. Stock is on the left, race tech is on the right
Race tech will provide you with a chart so you dont get confused with where things go.
Now assemble the stack, locktight the nut and torque to exactly 30 in lbs, no more, no less
Now for the rebound valve, same as the compression, lay it out in order and reassemble according to the race tech chart. Stock is on the left, race tech on the right
Now assemble the valve and torque nut to 30 in lbs exactly, no more, no less
Remember to put the teflon ring on the rebound valve and the rubber o ring on the compression, blue lock tight the threads on both ends and put the cartridge back together
Now you are probably putting in new springs with these valves as well, this is a part that differs from rider to rider depending on size. If youre going with a lighter spring rate you may need to shim the spring, race tech will provide these shims. The chart race tech gives you tells you the new oil to use, the level it should be set at and even gives you suggested compression, rebound, static and sag settings. Even if you dont like their settings its a decent platform to work off of. With some patience and the right tools this is a job I think anyone can do. Just remember to clean everything very well!!!!
Now just reassemble and install!! And enjoy!!