KX500 RACE TECH SUSPENSION BUILD

[Sandblaster]

I have tried other suspension companies with varied results.
But I finally decided that I was going to do it myself.
After all, what's the big deal, piston, seals, some shims, oil, nitrogen, and your good to go right?
So, I ordered new bushings, seals, springs, and some Race Tech Gold Valve kits.
Since I don't race Supercross I bought the Type 1 Fork Gold Valve Kit.
Here is Race Tech's explanation of the Type 1 kit.

Race Tech's original bolt-on fork valving system for cartridge forks. Gold Valves commonly triple the flow area over stock pistons, putting valving control on the shim stack instead of the piston. This results in outstanding tuneability, improved control, traction, plushness and bottoming resistance.
Includes complete instructions, Gold Valve Pistons, Valving Charts, and Valving Shims. Most models also include the "Technical Edge Fork Maintenance and Gold Valve Installation Video".
Note: Standard Gold Valve Kits are Compression Kits. Kits that end in "C" include both Compression and Rebound Gold Valves.

We will start with the shock...
Here is the parts:

KX500 RACE TECH SHOCK REBUILD 2.JPG (115.33 KiB) Viewed 10648 times

[Sandblaster]

Before I opened the directions I started taking my shock apart.
I'm committed now so no going back

KX500 RACE TECH SHOCK REBUILD 1.JPG (33.44 KiB) Viewed 10647 times

Now, before you get started opening up all your packages, do yourself a huge favor and clean your work area.
The cleaner the better...
You don't want to contaminate your new parts with dirty old parts.
I disassembled everything and cleaned everything up really good.
Ready?
Get out your directions and read them...
As it turns out I consider these to be generic directions.
They try to cover a lot of different scenarios with the same directions.
While this is great for saving Race Tech time writing specific directions for each shock, it does cause some questions to be asked.
Yes, I called Race Tech a few times during the installation.
Now that I have done it and know what I'm looking for I shouldn't have to call them for the front forks unless something is missing from the directions.

Here is a few pics of another older kx500 shock mostly disassembled.

KX500 RACE TECH SHOCK REBUILD 3.JPG (149.05 KiB) Viewed 10647 times

The left side is the piston which will be replaced with the gold valve and shim stack.
The right side is replaced with a entirely new seal head.
No, I didn't use the Race Tech seal head.
I probably should have but I had this in stock and didn't want to have it go to waste

KX500 RACE TECH SHOCK REBUILD 4.JPG (114.28 KiB) Viewed 10647 times

Bladder pic.

KX500 RACE TECH SHOCK REBUILD 5.JPG (120.61 KiB) Viewed 10647 times

[Sandblaster]

As you can see, this shock was really dirty from sitting around in a box disassembled.
If it was going to be rebuilt it would have to be thoroughly cleaned.

So back to the goods...
Here is the first page of the directions..

kx500 race tech shock rebuild directions 1.JPG (207.27 KiB) Viewed 10642 times

I have highlighted two key pieces of information.
The first is your internet access code.

kx500 race tech shock rebuild directions 7.JPG (9.92 KiB) Viewed 10642 times

This code allows you to go online and download your shim stack charts.
These shim stack specs are extremely important and are based on the info you provide to Race Tech.
So please,,, please...please, be honest with yourself.
Make sure the info you provide is accurate.
If your not a Pro Supercross rider, don't say you are.
You will be way happier building your suspension based on your REAL riding level.
I'm setting mine up for desert racing so plush, smooth suspension action is what I want.
I want to pass guys over miles of whoops sitting on the seat and sipping some tea

This is the part I found funny...

kx500 race tech shock rebuild directions 8.JPG (21.65 KiB) Viewed 10642 times

So here I am, out a few hundred bucks in suspension parts, I've got my forks and shock off, my shock is disassembled, am I gonna stop now?
NO!

[Sandblaster]

Trying to figure out which of all these charts I'm suppose to use for the shim stacks..

kx500 race tech shock rebuild directions 5.JPG (216.2 KiB) Viewed 10638 times

kx500 race tech shock rebuild directions 6.JPG (130.54 KiB) Viewed 10638 times

[Sandblaster]

I read all the directions, I looked at all the spec sheets I downloaded from Race Tech with my Internet Access code.... nothing..
So, not wanting to admit defeat I called Race Tech.
They were busy and I had to leave a message.
So I figured that I might as well watch some Race Tech how to video's on You Tube.
There were a few surprises in the video's, nothing major.
About the time I finished watching the last video I received a return call from Race Tech.
After a little head scratching we figured out that all the shim stack info was not on my paperwork.
There must have been a computer glitch because when I downloaded the specs for the forks today, all the shim stack info was there.
So the Race Tech rep gave me the specs on the phone...
Finally, it all makes sense now

With the shim stack numbers and the aid of this diagram you simply stack the shims in the order they are shown on the chart.

kx500 race tech shock rebuild directions 9.JPG (30.59 KiB) Viewed 10638 times

[Sandblaster]

I'll post some more info on this after I go on a coast run.
There are some mile long whoop sections I want to go destroy...

[Sandblaster]

Here is another KX500 rear shock being built by Master Mechanic JT..

JT BUILDING A KX500 SHOCK WITH FULL RACE TECH VALVE.JPG (80.67 KiB) Viewed 10182 times

JT BUILDING A KX500 SHOCK WITH FULL RACE TECH VALVE DOUBLE CHECKING.JPG (91.2 KiB) Viewed 10182 times

[Sandblaster]

And JT stacking a valve on a 08 KX450F fork..

20150930_162931.jpg (293.6 KiB) Viewed 10178 times

[Sandblaster]

They look so nice and purdy when they are fresh..

RACETECH GOLD VALVE AND SHIM STACK KX500.JPG (45.77 KiB) Viewed 10174 times

[Sandblaster]

Being very picky....

RACETECH GOLD VALVE AND SHIM STACK KX500 2.JPG (63.56 KiB) Viewed 10171 times

JT has applied to be a hand model but so far no takers