Suspension Revalving Guide

When to Consider Revalving

Signs You Need a Revalve

• Correct spring rate but poor performance
• Harsh initial stroke despite proper sag
• Bottoming with clickers fully adjusted
• Unable to find comfortable damping setting
• Bike feels unbalanced front to rear
• Arm pump or fatigue from harshness

Stock Valving Limitations

WP XACT stock valving is designed for average riders (160-180lbs) on mixed terrain. Utah hard enduro demands:

• Softer initial stroke for rock compliance
• Progressive mid-stroke support
• Bottom-out resistance for big drops
• Better low-speed damping control

Understanding Valving Basics

Compression Valving

Controls how fast suspension compresses:

• Low-speed: Rock gardens, technical sections
• Mid-speed: Jump faces, acceleration bumps
• High-speed: Big hits, square edges

Rebound Valving

Controls how fast suspension extends:

• Too fast: Bike bucks and kicks
• Too slow: Packs down, harsh feel
• Just right: Follows terrain smoothly

Shim Stack Basics

Thin metal discs that flex to control oil flow:

• Diameter affects when valve opens
• Thickness affects stiffness
• Quantity affects progression
• Order creates damping curve

Utah Hard Enduro Valving Specs

Fork Valving (WP XACT 48mm)

Compression Stack - Soft Initial

Base Valve:
24 x 0.10
22 x 0.10
20 x 0.10
20 x 0.10
18 x 0.10
16 x 0.10 (2)
14 x 0.10
12 x 0.20
10 x 0.30

Rebound Stack - Controlled

Mid Valve:
20 x 0.10
18 x 0.10
16 x 0.10 (2)
14 x 0.10 (2)
12 x 0.15
11 x 0.20
10 x 0.30

Shock Valving (WP XACT PDS)

Compression Stack - Progressive

Main Piston:
40 x 0.20
38 x 0.15
36 x 0.10
34 x 0.10 (2)
32 x 0.10
30 x 0.10
13 x 0.20
11 x 0.30

Rebound Stack - Balanced

Rebound Piston:
30 x 0.10
28 x 0.10
26 x 0.10 (2)
24 x 0.10
22 x 0.10
13 x 0.20
11 x 0.30

Specific Terrain Valving Modifications

Rock Gardens Special

• Add 18 x 0.10 face shim (compression)
• Reduce high-speed stack thickness
• Soften rebound 10% overall
• Float modification on base valve

Sand Wash Performance

• Stiffen mid-speed compression
• Add 22 x 0.15 to mid-stack
• Increase rebound damping
• Maintain stock high-speed

Technical Climb Setup

• Progressive compression curve
• Crossover at 26mm diameter
• Slower rebound for traction
• Increased low-speed support

DIY Revalve Process

Tools Required

• Suspension vise
• Shim kit (6-40mm, 0.10-0.30)
• Dial calipers
• Clean workspace
• New seals/oil
• Torque wrench
• Pin spanner

Fork Revalve Steps

1. Disassembly
   • Remove from bike
   • Drain oil completely
   • Remove cartridge assembly
   • Separate compression/rebound
2. Shim Stack Access
   • Remove base valve nut
   • Document existing stack
   • Clean all components
   • Inspect for wear
3. Modification
   • Build new stack per spec
   • Maintain total stack height
   • Check free movement
   • Reassemble carefully
4. Testing
   • Bench test compression
   • Check full stroke
   • Verify no binding
   • Set oil level precisely

Shock Revalve Steps

1. Preparation
   • Remove spring
   • Discharge nitrogen
   • Measure shaft travel
   • Note oil condition
2. Disassembly
   • Remove shaft assembly
   • Access piston stacks
   • Document configuration
   • Clean thoroughly
3. Revalving
   • Modify per terrain needs
   • Check shim flatness
   • Proper stack order
   • Correct preload
4. Reassembly
   • New seals mandatory
   • Proper oil fill
   • Bleed completely
   • Charge to 145 PSI

Valving Recipes by Rider Type

Lightweight Rider (<160lbs)

• Reduce face shim diameter
• Softer low-speed compression
• Lighter rebound control
• Maintain high-speed safety

Heavyweight Rider (>200lbs)

• Increase initial support
• Progressive mid-stroke
• Firmer rebound control
• Enhanced bottoming resistance

Aggressive Rider

• Stiffer overall valving
• Quick rebound return
• High-speed emphasis
• Maximum support

Technical Rider

• Soft initial compliance
• Progressive support
• Controlled rebound
• Balanced feel

Testing and Tuning

Break-In Period

• 2-3 hours minimum
• Varied terrain ideal
• Check for leaks
• Document feel

Clicker Starting Points

After revalve, start with:

• Compression: 12 clicks out
• Rebound: 14 clicks out
• Fine-tune from there

Test Loop Requirements

Create a loop with:

• Rock section
• High-speed section
• Technical climb
• Drop-offs
• Varied terrain

Common Revalve Mistakes

1. Over-valving - Too stiff everywhere
2. Mismatched damping - Front/rear imbalance
3. Wrong oil weight - Affects entire system
4. Poor assembly - Causes binding
5. Inadequate testing - Missing issues

Professional Revalve Service

Mountain Goat Sports offers:

• Custom valving consultation
• Dyno testing available
• Utah-specific setups
• Same-day service
• Ride testing included
• 30-day adjustment period

Pricing

• Fork revalve: $295
• Shock revalve: $295
• Complete bike: $550
• Includes all seals and oil

Maintenance After Revalve

Service Intervals

• Oil change: 20-30 hours
• Seal inspection: 40 hours
• Full service: 60-80 hours
• Nitrogen check: Monthly

Performance Indicators

Watch for:

• Increasing harshness
• Oil discoloration
• Clicker changes needed
• Unusual noises
• Leaking seals

Advanced Modifications

Checkpoint Cones

• Increases oil flow
• Reduces harshness
• Better small bump compliance
• Popular for technical riding

Gold Valve Conversion

• Replaces stock pistons
• Tunable ports
• More adjustment range
• Professional installation recommended

Bladder Conversion

• Eliminates ICS system
• More consistent damping
• Easier bleeding
• Reduced maintenance

Summary

Revalving transforms your KTM 300 XC-W or Husqvarna TE 300 for Utah’s demanding terrain. Whether DIY or professional, proper valving makes the difference between fighting your bike and flowing with the trail. Document your settings and don’t hesitate to fine-tune for specific riding areas.