217 Lorain Place

Los Gatos, California 95032

408.406.2089
www.smartperformanceinc.com
www.spi-racing.com

SMART Performance/SPI-Racing KYB Mid-Valve Modification Kit – aka “Dell Taco”

PROTOTYPE RELEASE
06 to 09 YZ125/250/250F/450F – 09 CRF450R – 07-09 KX450F
(portions of this kit can be suited to the 06 KX450F)

What is it?
The SPI-Racing KYB Mid-Valve modification kit replaces the design and function of the factory configuration by using a series of shims, spacers and
springs to incorporate a completely different approach to the behavior of the valve based on rod speed.

Why is this needed?

The factory configuration has two primary faults: 1. The design allows pressures within the cartridge generated from low and mid speed movements
to be vented too easily and too soon. This causes the fork to blow-through or over oscillate which delivers too much force into the spring, which
slows forward momentum generating a ride that feels harsh and nervous. 2. The second fault is that the factory design locks pressures within the
cartridge during high speed hits, which causes a dramatic spike in the damping curve thereby transmitting too much force or energy back into the
chassis and rider. This also scrubs forward momentum and can lead to instabilities or potentially the loss of control. Both factors can also contribute
to early rider fatigue (including arm pump) and excessive internal damage to the body.

How?
The SMART Performance/SPI-Racing Mid-Valve kit incorporates the principle of what we call “hydraulic crossover”. This means that the mid-valve
configuration has various stages of functionality, which in turn generates the required resistance based on the amount of energy coming into the bike
from the strike or hit into the wheel. Each stage passes onto the next stage when the energy overcomes the prior stage. To achieve this, the shims,
often configured in a multi stage stack, are held up against the face of the piston to manage low and mid-speed strikes. When forces overcome the
shim stack, the stack meets up with a limit plate which in turn begins to initiate the high speed blow-off circuit, controlled by a new spring. The low
and mid-speed properties are controlled by the shim stack and the initiation or timing into the blow-off circuit is controlled by the rate of the new
spring and the pre-load placed on the spring. The kit also contains the parts to modify the base valve assembly allowing for better control of high
speed rod movements and improve rebound performance.

Compromises and Concerns?

The installation of the kit is more difficult to install and tune than a factory design, and requires a new way of thinking when tuning and setting up a
bike to the particular needs of a rider. The pre-load on the blow-off spring is very sensitive to performance, and precise calculations have to be made
in order to best control cause and effect. For this reason, the kit should be installed by someone with advanced mechanical skills and a good working
knowledge of suspension design.

Contents of kit
1. Available on line – Excel spreadsheet to calculate blow-off pre-load. See www.spi-racing.com or email info@smartperformanceinc.com.
2. This instruction sheet.
3. Sample valve configuration sheet.

BAG ONE BAG TWO (base valve parts)

1. Two new blow-off springs (#175) 1. 2 – 14x.30x6mm shims/washers
2. 4 – 11x1.43x6mm spacers/washers 2. 2 – 11x1.43x6mm spacers/washers
3. 2 – 14x.30x6mm shims/washer
4. 2 – 8x4.3x6mm collar/spacers

BAG THREE (extra tuning shims) BAG FOUR BAG FIVE

1. 2 – 14x.11x8mm shims 1. 4 – 16x.20x12 shims/pre-load rings 1. 2 – 16x.30x12 shims/pre-load rings
2. 2 – 16x.11x8mm shims
3. 4 – 11x.25x8mm shims/washers

SMART Performance Inc. KYB Mid-Valve Instruction Sheet 500-100-XXXXXX-XX Rev 1.0
Tools required
1. Basic KYB disassembly tools for top cartridge, inner base assembly, rod holder and tools to remove base adjustor bolt and jam nut.
2. Grinder to remove peen on mid-valve stem.
3. M6x1.0 die to clean up or regenerate threads on mid-valve stem.
4. M6x1.0 tap to clean up or regenerate threads on mid-valve nut.
5. Torque wrench capable of setting of 48 inch-pounds.
6. Dial calipers or the means to precisely measure shims to .01mm thickness.
7. Microsoft Excel 2003 or newer.

CAUTIONARY NOTES
1. Item number 4 in BAG ONE, the 4.3 collar, as well as the collars that came with the bike (the 5.3) has an outer surface that is polished. If
this surface is not polished, the shims will bind when required to lift. Not all collars are created equal. If there are any imperfections on the
collar, (such as machine tooling marks or grooves) polish them out or replace the collars.
2. Double check all shim thicknesses and sizes before installing. Yes, sometimes we make mistakes, and sometimes things can get a little
mixed up when building the stack. Always layout the entire mid and rebound stacks, recording and noting the build, before assembly
begins. Place shims onto the stems one shim at a time. With this design, 1/10th of 1mm can make a difference. There is no room for error.
3. The notch in the mid-stem stem between the main body of the stem and the threaded section may allow for the top few shims in the
rebound stack to move off-center when using the 5.3 collar in the mid-valve build. Do your best to center and hold these shims while
assembling and torquing the stack and nut.
4. Do not clamp or hold the rod in a manner that will cause damage to the rod. Always protect the rod. Never expect the clamping forces on
the rod to keep the rod from spinning while torquing the stem nut. Use a 19mm open end wrench to hold the stem while tightening.
5. Sometimes the mid-valve stem needs to be replaced, usually from something that KYB did or did not do. For this reason, we stock them.

General Instructions - Mid-Valve

1. Remove the cartridge from the fork. Remove the base valve assembly and then remove the rod from the cartridge. If you don’t know how
to do this, we would recommend that you seek assistance from someone that reads that and says, “yea…piece of cake”.
2. Remove most of the material from the tip of the mid-valve rebound stem that is pressed against the nut and remove the nut. That said, you
can often forgo this step and just unscrew the nut, (damn the torpedoes…full speed ahead!). This can actually help preserve a bit more
material but you risk damaging the nut, the stem…and your dignity. Unless you have a good feel on how to do this, take the safe route.
3. Depending on the “status” of the stem, either remove the components of the rebound stack, piston and mid-valve, or run a die on the stem
and then remove the contents of the stem. Take your time and layout and note each part with respects to when it came off. Imagine how
you would work if you were working in total darkness, and then do that…but with the lights on. Don’t just pull off parts and zip-tie them.
4. Create a master plan for what build you want to create, using the Excel spreadsheet or using previous build sheets provided by us.
5. Then assemble the back components piece by piece. See the long string of step-by-step photos on our website if you need to.
6. When you arrive to the last few shims or washers near the tip of the stem, just before the nut goes on, make a judgment about how much
room you have for the nut and how much stem you have left. Then add or remove shims or washers accordingly. Ideally, finish with the
14x.30x6 shim included with the kit. Or, conclude with at least one 10 or 11mm x .25 or .30 x 6mm shim.
7. Apply one tiny drop of high strength thread locking compound, install the nut, then torque to 48 inch-pounds. Let set for 20 to 30 minutes.
8. See our alternative KYB cartridge bleed procedure for the best method to install and bleed the cartridge.
Base Valve
1. Remove the nut and all the contents on the stem. Again, take your time.
2. If you have two aluminum washers, (towards the bottom) discard one. If you have one aluminum washer you then have a bleed stack, and
are faced with the decision to keep it, alter it, or remove it. If you remove it, you need to run a spacer under the aluminum washer.
3. Directly on top of the aluminum washer, place the 11x1.43x6mm washer (bag 2). Then remove all shims at the bottom of the stack that are
thicker than .11mm. Then add your stack back onto the stem, then install the piston and collar.
4. Then install the check plate spring but use the 14x.30x6 shim (bag 2) instead of the factory KYB cup washer. Apply some thread lock
compound and torque to 48 inch-pounds.
Tricks
1. The 4.3 and 5.3 collars can be cleaned and coated in DYKEM or other inks to measure the movement or lift of the limit plate, which in turn
will tell you how much high speed blow-off is occurring after testing and breakdown.
2. You can use fine tip locking pliers (such as a Vice-Grip design) to clamp and hold the rebound/mid-valve piston down against the 4.3 or 5.3
collar, (holding back the pressure of the blow-off spring) in order to ease assembly of the rebound stack.

Need Help?
For general questions and tuning issues you can reach us at info@smartperformanceinc.com. For emergencies or moments of total confusion, you
can reach us at 408-406-2089. You can also get much needed help and advice at the suspension forum at www.ThumperTalk.com.

Other products and procedures for KYB forks and shocks.

y 215.VM2.K5 Vibration Cancellation Liquid y KYB EPNP (dual spring) Inner Chamber Spring Set y Anti cavitation flow plates – coming soon!
y Alternative procedure for assembling and bleeding the upper cartridge. y Alternative “dry-build” procedure for the KYB shock.

SMART Performance Inc. KYB Mid-Valve Instruction Sheet 500-100-XXXXXX-XX Rev 1.0
SMART Performance Inc. KYB Mid-Valve Instruction Sheet 500-100-XXXXXX-XX Rev 1.0
 SMART Performance/SPI-Racing KYB Mid-Valve Modification Kit

SMART Performance/SPI‐Racing KYB Mid‐Valve Modification Kit ‐ SAMPLE BUILD CONFIGURATIONS
LIGHT DUTY ‐ SINGLE STAGE MEDIUM DUTY ‐ SINGLE STAGE HEAVY DUTY ‐ SINGLE STAGE
BASE MID‐VALVE BASE MID‐VALVE BASE MID‐VALVE

OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID

1 32 0.11 6 1 20 0.11 8 1 32 0.11 6 1 20 0.11 8 1 32 0.11 6 1 20 0.11 8

2 32 0.11 6 2 20 0.11 8 2 32 0.11 6 2 20 0.11 8 2 32 0.11 6 2 20 0.11 8
3 32 0.11 6 3 16 0.11 8 3 32 0.11 6 3 20 0.11 8 3 32 0.11 6 3 20 0.11 8
4 32 0.11 6 4 14 0.11 8 4 32 0.11 6 4 16 0.11 8 4 32 0.11 6 4 17/16 0.11 8
5 32 0.11 6 5 11 0.25 8 5 32 0.11 6 5 14 0.11 8 5 32 0.11 6 5 16 0.11 8
6 32 0.11 6 6 11 0.25 8 6 32 0.11 6 6 11 0.25 8 6 32 0.11 6 6 14 0.11 8
7 32 0.11 6 7 17 0.30 8 7 32 0.11 6 7 11 0.25 8 7 32 0.11 6 7 14 0.11 8
8 32 0.11 6 8 8 4.30 6 8 32 0.11 6 8 17 0.30 8 8 32 0.11 6 8 11 0.25 8
9 32 0.11 6 9 SPRING ‐ #175 9 32 0.11 6 9 8 4.30 6 9 32 0.11 6 9 11 0.25 8
10 30 0.11 6 10 11 1.43 6 10 32 0.11 6 10 SPRING ‐ #175 10 32 0.11 6 10 17 0.30 8
11 28 0.11 6 11 11 1.43 6 11 32 0.11 6 11 11 1.43 6 11 32 0.11 6 11 8 4.30 6
12 26 0.11 6 12 16 0.20 12 12 32 0.11 6 12 11 1.43 6 12 32 0.11 6 12 SPRING ‐ #175
13 24 0.11 6 13 16 0.20 12 13 30 0.11 6 13 16 0.20 12 13 32 0.11 6 13 11 1.43 6
14 22 0.11 6 14 14 28 0.11 6 14 14 32 0.11 6 14 11 1.43 6
15 20 0.11 6 15 15 26 0.11 6 15 15 30 0.11 6 15

16 18 0.11 6 16 16 24 0.11 6 16 16 28 0.11 6 16

17 16 0.11 6 17 17 22 0.11 6 17 17 26 0.11 6 17

18 11 1.43 6 18 18 20 0.11 6 18 18 24 0.11 6 18

19 20 1.60 6 19 19 18 0.11 6 19 19 22 0.11 6 19

20 11 0.25/.30 6 20 20 16 0.11 6 20 20 20 0.11 6 20

21 21 11 1.43 6 21 18 0.11 6
22 22 20 1.60 6 22 16 0.11 6
23 23 11 0.25/.30 6 23 11 1.43 6
24 24 24 20 1.60 6
25 25 25 11 0.25/.30 6
26 26 26

AVAILABLE LIFT =  1.36 AVAILABLE LIFT =  1.15 AVAILABLE LIFT =  1.13

PRE‐LOAD ON SPRING =  0.94 PRE‐LOAD ON SPRING =  1.15 PRE‐LOAD ON SPRING =  1.17

LIGHT DUTY ‐ TWO STAGE MEDIUM DUTY ‐ TWO STAGE HEAVY DUTY ‐ TWO STAGE

BASE MID‐VALVE BASE MID‐VALVE BASE MID‐VALVE
OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID OD Thickness ID

1 32 0.11 6 1 20 0.11 8 1 32 0.11 6 1 20 0.11 8 1 32 0.11 6 1 20 0.11 8

2 32 0.11 6 2 16 0.11 8 2 32 0.11 6 2 16 0.11 8 2 32 0.11 6 2 16 0.11 8
3 32 0.11 6 3 14 0.11 8 3 32 0.11 6 3 14 0.11 8 3 32 0.11 6 3 14 0.11 8
4 32 0.11 6 4 20 0.11 8 4 32 0.11 6 4 20 0.11 8 4 32 0.11 6 4 20 0.11 8
5 32 0.11 6 5 16/17 0.11 8 5 32 0.11 6 5 16/17 0.11 8 5 32 0.11 6 5 20 0.11 8
6 16 0.11 6 6 11 0.25 8 6 32 0.11 6 6 14 0.11 8 6 32 0.11 6 6 16/17 0.11 8
7 32 0.11 6 7 11 0.25 8 7 16 0.11 6 7 11 0.25 8 7 16 0.11 6 7 14 0.11 8
8 32 0.11 6 8 17 0.30 8 8 32 0.11 6 8 11 0.25 8 8 32 0.11 6 8 11 0.25 8
9 32 0.11 6 9 SPRING ‐ #175 9 32 0.11 6 9 17 0.30 8 9 32 0.11 6 9 11 0.25 8
10 32 0.11 6 10 8 5.30 6 10 32 0.11 6 10 SPRING ‐ #175 10 32 0.11 6 10 17 0.30 8
11 32 0.11 6 11 11 1.43 6 11 32 0.11 6 11 8 4.30 6 11 32 0.11 6 11 SPRING ‐ #175
12 30 0.11 6 12 11 1.43 6 12 32 0.11 6 12 11 1.43 6 12 32 0.11 6 12 8 4.30 6
13 28 0.11 6 13 16 0.30 12 13 30 0.11 6 13 11 1.43 6 13 32 0.11 6 13 11 1.43 6
14 26 0.11 6 14 16 0.20 12 14 28 0.11 6 14 16 0.30 12 14 32 0.11 6 14 11 1.43 6
15 24 0.11 6 15 16 0.20 12 15 26 0.11 6 15 15 30 0.11 6 15

16 22 0.11 6 16 16 24 0.11 6 16 16 28 0.11 6 16

17 20 0.11 6 17 17 22 0.11 6 17 17 26 0.11 6 17

18 18 0.11 6 18 18 20 0.11 6 18 18 24 0.11 6 18

19 11 1.43 6 19 19 18 0.11 6 19 19 22 0.11 6 19

20 20 1.60 6 20 20 11 1.43 6 20 20 20 0.11 6 20

21 11 0.25/.30 6 21 20 1.60 6 21 18 0.11 6

22 22 11 0.25/.30 6 22 11 1.43 6
23 23 23 20 1.60 6
24 24 24 11 0.25/.30 6
25 25 25

26 26 26

AVAILABLE LIFT =  1.95 AVAILABLE LIFT =  1.24 AVAILABLE LIFT =  1.13

PRE‐LOAD ON SPRING =  0.35 PRE‐LOAD ON SPRING =  1.06 PRE‐LOAD ON SPRING =  1.17

SMART Performance Inc. KYB Mid-Valve Instruction Sheet 500-100-XXXXXX-XX Rev 1.0