Installing the Race Tech Gold Valve Cartridge Emulator
While I'm a huge proponent of cartridge forks, I'd be the last guy to suggest you replace your cruiser's OEM damper rod fork with one. I've done it a time or two and trust me, it's expensive and time-consuming. In my opinion, a better idea is to convert your damper rod fork to one that mimics the actions of a cartridge type, which fortunately is relatively easy and inexpensive to do.
The Gold Valve Cartridge Emulator is a device developed by Race Tech founder Paul Thede, that allows a standard damper rod fork to imitate the action of a cartridge fork, hence the name. (see the side bar for a brief description).
Installing the Gold Valve requires little more than lightly modifying the OEM damper rod, then dropping the valve into place, a procedure that takes less time to do than it did to write the foregoing paragraphs.
Remove the fork cap and spring...
Remove the fork cap and spring (top). I usually break the cap bolt loose before I remove the tubes from the triple clamp; that way I'm not wrestling with them on the bench. If you plan to do it that way, release the upper clamp's pinch bolt-if it's tight it'll distort the fork tube threads and make removing the cap bolts difficult, and may even ruin the fork's internal threads.
Be careful, as the cap may...
Be careful, as the cap may be under a fair bit of tension. There are a lot of juicy parts in the forks, so it's going to get messy as well. A tip: rotating the spring as you remove it will keep most of the oil inside the fork. Invert the fork, dump out the remaining oil and then remove the damper if it's still attached, along with the lower leg, if it's still attached.
The wedge-like device is a...
The wedge-like device is a universal damper rod tool; it's inserted into the damper rod to prevent it from turning with the bolt (bottom). Clean all parts and lay them out in order. Now would also be the time to inspect the fork seal and replace it if need be. (note that these H-D forks incorporate their own cartridge that uh, emulates the Emulator.)
To work properly with the...
To work properly with the Gold Valve, your OEM damper rod needs at least six compression holes with a minimum diameter of 5/16th of an inch. In most cases that'll mean enlarging the stock holes, and quite possibly drilling some additional ones. In this instance the stock damper rod had six holes so all we had to do was make sure they were 5/16's of an inch.
If you're drilling new holes, locate them 7/16's of an inch above and below the centerline of the OEM holes. To avoid weakening the damper rod, drill the new holes at right angles to the existing ones. Be sure you clean and deburr them too.
In most instances the Gold...
In most instances the Gold Valve will sit directly on the damper rod; a spacer is provided in case it doesn't. Always check the fit while it's still on the bench.
Install the topping spring...
Install the topping spring onto the damper rod (the kit includes longer springs if you want to lower the bike) and insert the rod into the fork tube. Tighten it securely according the OEM service manual instructions.
Here's a worms eye view of...
Here's a worms eye view of the damper rod as it sits in the fork tube, without the Emulator.
Following the Race Tech instructions,...
Following the Race Tech instructions, check and adjust the Emulator spring preload. Remember, more spring preload equals stiffer compression damping. Then install the Emulator on top of the damper.
The Race Tech instructions...
The Race Tech instructions will walk you through the fork spring preload adjustment. Although it looks like an octopus is measuring this spacer, it can be done by one person.
Measure twice, cut once and...
Measure twice, cut once and use a tubing cutter to ensure square edges.