EXT Racing Shox Storia V3-S User manual

USER MANUAL
MANUALE UTENTE
MTB
UTV&SSV ATV

3
TABLE OF CONTENTS
INDICE
INTRODUCTION 4
SAFETY PRECAUTIONS 5
WARRANTY 6
FEATURES 8
TECHNOLOGIES 9
HYDRAULIC SETUP 11
SAG 13
SHOCK INSTALLATION GUIDE 14
SETTING UP YOUR SHOCK 15
SETTING TIPS 18
SERVICE & MAINTENANCE 19
RACE CHART 38
SHOCK MONITOR 40
INTRODUZIONE 22
MISURE DI SICUREZZA 23
GARANZIA 24
CARATTERISTICHE 26
TECNOLOGIA 27
SETUP IDRAULICO 29
SAG 31
INSTALLAZIONE SULLA BICI 32
REGOLARE L’AMMORTIZZATORE 33
SUGGERIMENTI PER IL SETUP 36
SERVIZIO E MANUTENZIONE 37
RACE CHART 38
SHOCK MONITOR 40

EXT WORLD
CONGRATULATIONS
EXT R&D DEPARTMENT
4
With over 55 years of collective experience, EXT Racing Shox is one of the most
successful European engineering company capable to meet all your need in the
field of automotive, two wheeler systems and vehicle dynamics. From F1 to Rally, GT/
Le Mans, WTCC/WTCR and motorbikes, off-road applications with special dedicated
projects for production cars. EXT is specialized in hydraulic damping systems and
has diversified in different industrial applications such as damping motion control,
seismic and defense. EXT is most well known for the development of shock absorbers
for extreme racing conditions. From the world of F1 to biomechanics the passion is
the same, a factor that has set us apart for the last 55 years.
Thank you for choosing EXT Racing Shox. All EXT products are designed, engineered,
machined, assembled, tested and developed by EXT staff in Italy. Every product has
gone through rigorous tests and is directly developed through racing. This owner
manual contains important information about your shock absorber.
Please read it carefully.
EXT Research & Development Department designed this shock absorber for
one reason: to create the best product in the bike industry, implement the most
sophisticated technologies, developing new ones by enclosing in a single shock
the essence of our experience within the racing sport. EXT is constantly innovating,
creating seemingly impossible products, into reality. With a strong focus on the
future, our goal is to be the innovators of tomorrow.
We bring to you the same technology we use in the UCI Downhill World Cup and in
the Enduro World Series during the last racing years. All our shocks are constantly
under improvements and we develop an exclusive hydraulic damping specification for
yourbike and your riding style.
We always test our products on the Dyno Bench to be sure every detail is perfectly
checked to allow you to get the maximum performance.
We strongly believe in innovation, developing new technologies to reach a new
level of absolute performance while assuming the maximum safety. Innovation is
our aim and strength.

SAFETY PRECAUTIONS
NOTE
SAFETY SYMBOLS
YOUR SAFETY IS
INVOLVED
IMPORTANT
INFORMATIONS
WARNINGS
5
The Storia V3-S contains pressurized gas. Do not open, service or modify this
product without proper education and proper tools. This product is developed and
designed for the bike industry and must be installed on related vehicles, including
pedal-assisted motorized cycles that produce a maximum of 250 watts of power.
DO NOT USE this shock on throttle-equipped motorized cycle or any vehicle
carrying more than one rider. Any such unauthorized use may result in failure of
the suspension, which may cause a crash and result in property damage, SERIOUS
INJURY OR DEATH, and void warranty.
Read and ensure you understand
the information in this manual and
other technical documents related to
this product before using this shock
absorber.
ExtremeBiomec Srl can not be held
responsible for any damage to the
shock absorber, bike, other property
or
injury to persons.
Always use EXT Racing Shox parts.
Use
of other parts or self built ones void
warranty and could cause a structural
failure.
In this manual, instructions and important
informations concerning safety or
technical documents is distingushed by
the following symbols.
If the shock absorber function is
irregular, or if you notice any leakage,
stop riding immediately and return
the product to an MTB authorized EXT
service center.
The product warranty shall only
apply if product has been operated
and maintained in accordance with
recommendations in this manual.
An improperly installed rear shock
can be extremely dangerous. We
recommended to have it installed by a
qualified bike mechanic.
Before disassembly or service always
remove gas pressure.
EXT SuperLight Springs are calculated
to the minimum length for the stroke
required. Spring must be used without
preload or max 2mm preload. Keep in
mind that one complete spring turn is
equal to 1mm preload.

WARRANTY
LIMITED TWO (2) YEARS WARRANTY
WARRANTY EXCLUSION
DAMAGE
DISCLAIMER
6
Extreme Biomec Srl, owner of EXT Racing Shox, an Italian limited-liability company
based in Viale del lavoro 66/68, 36021 Barbarano Mossano, Vicenza, Italy, applies
the following limited warranty conditions to all products.
EXT guarantees their damper systems are free from origin defects for the
period of two (2) years from date of purchase, according to 99/44/EC
decree.
Invoice, documents of transport or receipt are proof of warranty start date, and
it’s mandatory they are presented to EXT for every warranty service required.
In case of a warranty claim, the purchaser can return the product to EXT or to
an authorized dealer, presenting the requested proof of purchase within 2 year
period of warranty cover, and specifying the nature of the shock absorber
failure and warranty claim.
This warranty does not cover defects like: crash damage, alterations, neglect,
improper use, abuse, incorrect use, improper assembly, improper service,
improper fixings, use of non EXT spare parts, modifications not allowed unless
specifically authorised by EXT in written form.
This warranty does not cover parts subject to wear like hydraulic seals, o-ring
seals, sliding bushing, oil, dust seals and oil seals.
This warranty will be immediately voided in case of removal or tampering of
serial numbers or they identifying marks.
Original EXT spare parts have a warranty period of six (6) months.
Extreme Biomec srl WILL NOT ASSUME RESPONSIBILITY FOR DAMAGES TO
PERSON OR THINGS RESULTING FROM PRODUCT USE.
In some countries this clause is not accepted; this limitation could be not
applied to your country.
This warranty contract is the one and only way for customers to raise a claim
on product. No EXT dealer, agent, distributor or employee can modify, extend
or amplify this warranty.

FEATURES
8
– 4 way adjustable (LSC-HSC-LSR-Lok proprietary system)
-- High flow Ø29 mm main piston
-- Ø24 mm valve piston
-- Ø14 mm chromemoly shaft to increase strength
-- Self-proved Lok Technology - Progressive opening and silent working
-- New and more silent check valve with low inertia to increase sensitivity and improve
control
-- Negative spring to avoid harsh top-out and improve bike platform stability
-- Factory tuned HBC technology, improved in terms of efficiency
-- Very low reservoir pressure for maximum sensitivity (55 PSI)
-- Thinner bottom-out bumper for maximum stroke wheel travel in all conditions
-- New high viscosity index oil for longer consistent riding in all situations
-- Redesigned rebound knob for an even easier spring swap
-- New rebound and compression adjustment to increase (+50%) tuning range
-- Chromoly shaft with low-friction coating
-- Spring thrust bearings for improved spring load conditions
-- Reservoir with large volume bladder design
-- Improved tube protector
-- Metric measure (Standard or Trunnion mount)
1-LOK
2- BL - (4mm allen key)
Low speed Compression
3- BH - (12mm spanner)
High Speed Compression
4- R - REBOUND
5- PRELOAD
max 2 turns
The grub screw only needs to be tightened in the
groove gently
6- SPRING THRUST BEARING
Always remember to correctly install it when
changing spring on your shock.
2
3
4
5
6
1

TECHNOLOGIES
HYDRAULIC BOTTOM-OUT CONTROL (HBC)
LOK 2.0
9
EXT Racing Shox introduced this feature in a World Rally Car in 1994. The
Hydraulic Bottom-Out system make the compression progressive and
thanks to this it is possible to ride with a softer spring for a better and
improved traction. The HBC system controls only the last 15% of the stroke.
So you can rely on a very plush feeling and a great support on the last
millimeters of your bike’s rear travel. More than 50% of dedicated hydraulic
force exclusively to control the bottom-out. Thanks to this we are able to
use a smaller bumper and you can count on every millimeter of your travel.
A 2-Way lock-out system improved to avoid any kind of bobbing while you
pedal on any kind of surface. Completely customizable, the LOK system
has a blow-off valve that prevents any kind of damage if you forget the
LOK lever before a downhill ride. It is made up of a completely independent
valve system that controls the oil
flow in a separate chamber. The
force developed to prevent any kind
of bobbing can be chosen by the
rider and adjusted according to his
preferences. The 2.0 Version offers a
greater support and is quieter than
the previous version.
On the graph it is shown how HBC
controls the last part of the stroke. The
peak on the right side is the strength
achieved by the shock when the HBC
is full closed.
FORCE
LOCK ON
F
O
R
C
ELOCK OFF
VELOCITY
REBOUND
HBC
LAST 15% OF THE STROKE
DISPLACEMENT

ULTRA LOW FRICTION COATING
HIGH TURBULENT FLOW
NEGATIVE SPRING
THE SOUND OF TECHNOLOGY
10
Most of the sliding parts that compose EXT shock are developed with Ultra- Low
friction technology. The shaft is treated to increase life, strength, and reduce friction.
Sliding bushes are in carbografite, the seals are custommade and developed to not
fade and keep consistency in the control of damping forces.
Gas pockets (aeration) and vapour cavitation (“bubbles” or “voids”), which form in the
hydraulic fluid due to severe operating conditions are common problems observed
in hydraulic shock absorbers. These problems negatively affect bike handling and
comfort. To avoid these issues and reduce hysteresis at lowest value we use a new
generation valves with a special design that produce a turbulent flow.
With this innovative design damping force remains independent from viscosity
changes and temperature. Aeration is minimal and the cavitation issues are mostly
eliminated.
We have introduced an additional spring on Storia V3-S to increase rear wheel
rebound control on last mm of the damper and avoid harsh top out feeling.
The negative spring during our tests has shown an increased platform stability and
more sensitivity on first few millimeters of damper travel.
EXT Racing Shox are not the quietest shocks on the market. To build a high
performance shock absorber, we need to put parts inside that are working
and moving together with other ones to create restrictions to oil flow, and
these can produce sounds as the valves open and close. Don’t worry about
this, it is normal and it means that your shock works correctly.