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Thread: Base valves stuck

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    Default Base valves stuck

    Sent 4cs forks for a revalve. Their base valves installed.(19mm socket) They are in there sooo tight I cannot get them to budge. Tried a little heat on fork lugs,breaker bar, battery impact gun, hit breaker bar with mallet. Nothing. Called shop and apparently they install these with air impact gun. WTF! He stated something about the WP service manual.? This is ALUMINUM. Why the hell would you use an impact gun? Iíve watched a bunch of videos on 4cs forks and as far as I can find, torque on valves is 40Nm,or 29.5ftlb. Any suspension tuners out there want to chime in on this? Would like to get some feedback before I go trashing this particular shop.

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  3. #2
    Lifetime Team KTMTalk Layton's Avatar
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    Default Re: Base valves stuck

    Good 6 point socket with the end ground flat. Most sockets are tapered on the flats and that reduces the contact area on that thin aluminum base valve.

    Then maybe use an air impact if all else fails. Good luck!

  4. #3

    Default Re: Base valves stuck

    I had a set that was like that with thread locker, had to use impact. They also get a bit corroded, and the insert wants to spin, so sometimes an impact is your only choice.
    1999 300 MXC
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    Default Re: Base valves stuck

    I use the same method as Layton. A 6-point (very important detail) socket ground to have no taper. Stick the axle thru the fork lug, put your weight on the axle to compress the fork, then coax it softly with an air impact gun - use only enough force to break it loose.
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    Default Re: Base valves stuck

    Thanks for the replies. Layton, why would a suspension shop ever use an impact to install these? Am I out of line saying that this is ridiculous? Thanks.

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    Default Re: Base valves stuck

    They were not being careful just rammed them in with there impact. Like the others sad grind the radius off your socket use a 6 point socket, heat and go slow, another trick before you do it take your socket put it on the nut make sure itís flat and give it a couple hits with a steel hammer not real hard but solid hits it shocks the nut sound weird but it well help. Itís the same thing a hammer impact driver dose.

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    Default Re: Base valves stuck

    I would take it to the shop and tell them to remove it. If you strip or gall the threads-you are liabl$. If they do it-itís on them. Then, tell them to torque it with a torque wrench, so you can remove in the future.

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    KTMTalk Member wfopete's Avatar
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    Default Re: Base valves stuck

    Indeed, a little heat and some gentle taps to break the threads free helps but be prepared to get new BVs. I had this problem and broke the BV cap right off. It happens.
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    Default Re: Base valves stuck

    Quote Originally Posted by ridenazi View Post
    Thanks for the replies. Layton, why would a suspension shop ever use an impact to install these? Am I out of line saying that this is ridiculous? Thanks.
    There is no way to hold the insert, it starts to spin when you tighten it down. The "impact" will allow it to tighten.
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  11. #10
    KTMTalk Member wfopete's Avatar
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    Default Re: Base valves stuck

    Quote Originally Posted by RodC View Post
    There is no way to hold the insert, it starts to spin when you tighten it down. The "impact" will allow it to tighten.
    Well there is. A tie down to compress the forks a few inches will secure the cartridge in place and allow you to torque to spec.
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