First, let me start off by saying that I have searched the forums and found detailed instructions and points to be aware of on installing Racetech or any other springs in forks. Great and helpful contributions by knowledgeable members!!!
I am embarking on installing Ohlins valves and Racetech springs on my 2007 919 forks.
1. What are the steps in replacing stock valves with Ohlins valves?
Start with RMB's post: 07 919 fork respring & revalve
2. Does the Shim stack that comes with Ohlins valves need to be modified in any way?
FPK105 has extra washers. I did not need to use all of them.
3. Is there a bottom out preventer valve (pardon my newbie language) or something like that on the damping rod that causes a problem? I have seen it on videos of some other bikes but couldn't find a video for a 919. If there is one how to get around it? Is there anything else to be special handled?
There is a oil lock piece which is not screwed on. It should ideally slide off. In my case it got stuck in the fork bottom after removing the cartridge bolt. I push it from bottom with a screw driver.
4. What are the torque specs for triple tree and pinch bolts?
Follow the Service manual as torques may or may not differ by different years.
5. Is red loctite or blue loctite to be used anywhere?
Per FPK105 instructions Loctite 243 on cartridge bolt and compression and rebound valves.
6. I weight 185 pounds w/o gear. What is the recommended oil height with Ohlins valves and 0.9 Kg racetech springs?
I used Oil height 140 mm as suggested by RMB. I did not have the oil level tool so I went slowly and kept measuring the height. Make sure there is no air trapped.
7. For the 2007 919 and my weight what should be the recommended preload and spacer length?
Following RMB's suggestions I used 91 mm of spacer for 15 mm of preload. My calculation was also in the neighborhood.
8. Can the stock spacer be used or does the tubing that came with racetech spring need to be cut?
Use tubing that racetech provides in the kit.
From RMB: A small pipe and tubing cutter is ideal for the work unless you have access to a lathe with a parting tool.
9. Are any special tools needed other than cartridge holder that looks like an H?
Tool that looks like an H is Race Tech Cartridge Fork Holding Tool for Twin Chamber Forks - TFHP 01. I used this and on occasion a wire to the damper rod to prevent it from falling down the tube.
A video would be a great.
I have really searched but if this information is already been posted somewhere please point me to it.
Sorry for the long post and many questions.
Thanks for the help!!!