YSS Europe b.v. PD Fork Valve Assembly Instruction

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:: PD Fork Valve Assembly Instruction

Tools required
	1)	Drill motor and 6 or 8 mm drill.
	2)	Allen Socket 8, 10, 12 or 14 mm.
	3)	Tape measure.
	4)	Tubing cutter.
	5)	YSS Fork oil.

Recommended
	1)	Choose correct fork spring for your motorbike. Consult YSS service center or www.yss-australia.com or www.yss-europe.com or www.yss.co.th
	2)	Check the proper fit before installation

Instruction

		Note: All these steps should be done by a suspension mechanic.
	1)	Take off the fork from the motorbike.
	2)	Disassembly the fork (don�t remove the seal)
	3)	Take the fork spring and damping rod out.
	4)	Place YSS PD Valve on the top of damping rod.
	5)	Put the step on YSS PD Valve into the large hole and must cover it completely (as shown in Picture 1).
	6)	The inner diameter of fork spring must be at least 3-4 mm larger than the PD Valve plate (less than 3 mm. can use with some model of PD Valve which having side flow space).
	7)	Drill the compression hole and addition as the sizes of damping rod are following: 4 holes of 6 mm. (1/4 inch) for 175 4 holes of 8 mm. (5/16 inch) for 235 6 holes of 8 mm. (5/16 inch) for 265 and bigger and the distance between the holes must be at least 10 mm. apart (as shown in Picture 2).
	8)	Chamfer and deburr in and out of the compression holes.
	9)	Check the YSS PD valve (spring rate 7 Nm for 175, 235, 265, 290 and 12 Nm for 310, 335, 360, 425 with 2 turns of valve spring preload).
	10)	Tighten the jam nut of YSS PD Valve.
	11)	Assembly the forks as your manual or do the reverse of reassembling.
	12)	Drop YSS PD Valve down the tube to sit on the damping rod with the PD Valve spring facing up.
	13)	Insert the fork spring into the inner tube on the top of YSS PD Valve.
	14)	Ad the fork spring spacer (cut them for 14-17 mm. same as the thickness of PD Valve, more or less depend on the fork spring preload requirement).
	15)	Install the fork fluid by removing the fork spring and PD Valve, use the oil viscosity as recommended by YSS manual or manufacturer. (10W for standard or 15, 20 and 30W for optional).
	16)	Pump the fork for bleeding.
	17)	Install YSS PD Valve and check the oil level.
	18)	Install the spring and spacer.
	19)	Re-check the spring preload.
	20)	Install the fork cap and push on them.
	21)	Tighten all bolts.
	22)	Assembly the forks back to the motorbike completely.

Tuning option

Tuning	Standard	Optional	Advantage
Oil Viscosity ⁽¹⁾	10W	15W, 20W, 30W	More or less rebound depend on viscosity to make stability
Valve Spring Preload ⁽²⁾	2 Turns ⁽³⁾	0 to 7	Overall firmness, controlling the speed of front end dives under braking
Valve Spring rate	7 N for 175, 235, 265, 290 12 N for 310, 335, 360, 425	12 N 7 N	Overall firmness and smooth ride on square shaped bumps

(1)

Use oil viscosity to set the amount of rebound damping, then adjust the compression with the PD-Valve settings. The PD Valve does not affect rebound, however oil viscosity does. The primary compression adjustment is the amount of preload on Valve Spring.

(2)

Measured from no tension on the Valve Spring.

(3)

2 turns of Valve Spring Preload for lighter riders.

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