Ip Fegv S4901

1501 Pomona Rd, Corona, CA 92880 • 951.279.6655 • fax 951.279.7171 • www.racetech.
com
GOLD VALVE CARTRIDGE EMULATOR INSTRUCTIONS

H-D V-Rod – FEGV S4901
<IP FEGV S4901.doc> FEGV S4901 P Thede  6-28-16 2 pgs
TOOLS REQUIRED - Long Allen Socket (10 mm), air impact, 5/16" (8 mm) drill and drill motor, tape measure
(metric/inch), tubing cutter, Fork Fluid.
Please read the instructions completely before proceeding. If you have questions please call Race Tech. If
you are unfamiliar with this process, stop and have a qualified mechanic assist you.
DISASSEMBLY AND PREPARATION
1 Remove the forks and completely disassemble them. When
removing the fork cap use caution as the stock springs are
preloaded heavily and the cap can be released with a lot of
force. For stubborn damping rod bolts (on the bottom of the fork),
hit the head of the damping rod bolt with a drift and hammer to jar
the threads loose. An air impact and a long Allen socket also Cap Height
Preload
helps.
2 Drill the existing Compression Holes larger and add additional
holes. No matter how many compression holes come stock, you Spacer
must end up with six 5/16 inch (8 mm) holes (3 sets of 2 holes) Length
with
(see Figure 1). When drilling new holes, space them lengthwise at
7/16" (10 mm) increments. Each set of two holes must be
perpendicular to the last set (figure 1). After drilling, chamfer and
deburr the compression holes, inside and out. Do not modify the
rebound holes.
EMULATOR VALVING SETUP Spring
Length
3 The compression damping is controlled by the Emulator Valve Spring
setup. Double-check this setting. Set up the Emulator Valve Spring with
(1 ½) turns of preload. This is done by first loosening the lock nut on the
bottom of the Emulator and backing off the Allen bolt (counter clockwise)
until there is no tension on the spring. From there turn the Allen bolt in
(clockwise) (1 ½) revolutions and tighten the lock nut. Emulator
4 Begin reassembling the forks according to your manual. Remember to Aluminum
install the Top-out Spring and bottom-out cone. Consult the Adapter
manufacturers specs for damping rod bolt torque. Damping Rod
Top-out Spring
CUT THE PRELOAD SPACERS Rebound

Holes
5 Spring preload is the amount the spring is compressed when it is
installed with the forks fully extended. Do this step with no fork fluid.
(See figure 1) Extend the fork all the way. Install the Aluminum
Adapter and the Emulator by dropping them down the fork tube. The
Emulator must sit on top of the Adapter with the Emulator Valve Spring
facing up. Visually check to make sure the Emulator is sitting squarely 7/16
on top of the Adapter.
Install the spring. Place both spring washers on top of the spring (6) 5/16”
Enlarged
temporarily. Rest the Fork Cap on top of the Spacer. Measure the Compression
distance between the top of the fork tube and the bottom of the sealing Holes
lip on the Fork Cap (the point that touches the top of the tube when the
cap is tightened). This is a direct measurement of Preload. Cut spacers
to provide 2 3/8” (60 mm) of preload. Figure 1
Cut the spacers with a tubing cutter (available at hardware stores). Washers must be installed on both ends of
the spacer. The spacer must not rest on the spring or the cap directly. Double-check your preload by stacking
the spring, spacer, washers and cap and measuring the distance from the sealing lip on the cap to the top of the
fork tube (see Figure 1).
OIL LEVEL SETUP
6 Remove the fork spring and install fork fluid. Use the recommended oil viscosity and level. Bleed the air
bubbles out of the fork by pumping them up and down. The oil level is measured from the top of the fork tube
down to the top of the oil with the fork completely collapsed and the fork spring out. Be sure to set the oil level
with the Emulator installed.
7 Finish reassembly by installing the spring. We highly recommend the Race Tech FRSP S4435P20 fork springs.
They work very well with Emulators. Install the springs with the close coils up at the top, then the first spring
washer, the spacer and the second spring washer. Re-check the spring preload. This will indicate whether the
Emulator is seated properly. Install the fork caps and, with the forks off the bike, push on them, checking for any
unusual drag or bind that would indicate an improperly seated Emulator. Install the forks back on the bike. Align
the forks on the axle for minimum bind. Torque all the bolts including the brake calipers, pump up the brakes and
enjoy!
TUNING NOTES
Most riders will use the standard settings, however if you would like to experiment with a different "feel", here are
some guidelines. To adjust the Gold Valve Emulator you must remove it from the fork leg (you don't have to remove
the forks from the bike in some cases). Remove the springs using a twisting motion to avoid oil drips. To remove
the Emulator, use a parts grabber or a 1/16" (1.5 mm) welding rod with 1/4" (6 mm) of both ends bent over 90
degrees into an "L" shape. Push the end into the Emulator slot and turn it 90 degrees to hook the Emulator. Before
installation, be sure the jam nut on the Emulator is tight.
TUNING VARIABLES
VARIABLE Standard Optional Primary Effect
Valve Spring Preload* 1 ½ Turns 0 to 5 Turns Overall firmness, controlling a mushy feel and
the speed the front end dives under braking
Oil Viscosity** 20 wt 30 wt Use oil viscosity to set rebound, this affects
traction and stability
Oil Level 130 mm / 5.1” 120 to 150 mm Affects bottoming resistance
Valve Spring Rate 40 lbs/in 26 or 64 lbs/in Overall firmness and the ride on square shaped
bumps
Fork Spring Preload 2 3/8” / 60 mm 1.5 to 3” Lowers or raises ride height
* Measured from zero preload (no tension) on the Valve Spring. To find zero preload back off on the adjuster bolt until
the spring is loose then tighten it until the spring just touches. More Preload gives more compression damping and
a firmer ride.
Use oil viscosity to set the amount of rebound damping, then adjust the compression with the Emulator settings. The
Emulator does not affect rebound, however oil viscosity does. The primary compression adjustment is the amount of
Emulator Valve Spring Preload. Increasing Valve Spring Preload makes the fork stiffer. The effect of all the
variables overlap giving extreme tuning flexibility. If you use heavier viscosity oil, back off on the Emulator Valve
Spring Preload to compensate for the increased compression damping this causes.
TERMS
Spring Rate - The spring stiffness measured in kg/mm or lbs/in. This is not Preload.
Spring Free Length - The length of the spring when it is not installed.
Spring Set Length - The installed length of the spring with the forks fully extended.
Spring Preload - Amount the spring is compressed from it's Free Length to install it. It is not the length of the spacer.
Free Length minus Set Length equals Preload.

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1501 Pomona Rd, Corona, CA 92880 • 951.279.6655 • fax 951.279.7171 • www.racetech.

GOLD VALVE CARTRIDGE EMULATOR INSTRUCTIONS

manufacturers specs for damping rod bolt torque. Damping Rod

CUT THE PRELOAD SPACERS Rebound

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