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.

HYDRAULIC SETUP
LOW SPEED COMPRESSION (BL)
HIGH SPEED COMPRESSION (BH)
REBOUND (R)
11
This can sometimes be a mine field. Where to start? Track surfaces change
continuosly, wet or dry, steep or flat and the list can go on. Take note of your setup
riding on a trail you know well, so you can concentrate on shock tuning; make
adjustments one by one.
Low speed compression acts on any compression
where the shock’s stanchion move at a slow rate or
speed, totally independent from how slow or fast
the wheels are moving. LSC manages all changes of
the bike stance due to weight translation where low
shaft velocity is involved (i.e. berms, compressions,
g-outs, pedaling). You can obtain a very consistent
grip and feedback when you find the correct setup.
High speed compression helps your bike to skip
across obstacles before it is transmitted to you. A
high speed compression event is characterized by
a high shaft velocity impact (i.e. high speed hitting
rocks, roots, braking bumps, flat landing). At lower
bike speed, HSC is involved in square edges bumps
hitting. Suggestion is to start in the middle and
move in direction where bike becomes faster or
more comfortable or more stable.
This is responsible for your feeling of control while
riding but also for your comfort giving the bike the
ability to glue wheels to the ground. Start by having
a controlled rebound feeling and move from this
point until you find the correct setup. You should
feel your bike like it sticks to the ground, goes
through corners consistently by not getting pushed
out of it. Keep in mind that if rebound is too fast
your ride could be uncomfortable and nervous. If it’s too slow, your shock will not
have enough time to recover the full stroke through the bumps. For the initial set-
ting whilst riding in the car-park you can push as far into the travel as possible and
then keep your legs and arms stiff so that you don’t absorb the rebound stroke.
Observe the rebound stroke and then set the rebound so that the shock reco-
vers past the SAG point and then settles back down to the SAG point. If it simply
recovers to the sag point it will most likely be too fast. Your preferred rebound will
probably be within one or two clicks of initial setting.
F
O
R
C
E
FULL CLOSE
MIDDLE
FULL OPEN
VELOCITY
FULL CLOSE
MIDDLE
FULL OPEN
F
O
R
C
E
VELOCITY
VELOCITY
FULL CLOSE
MIDDLE
FULL OPEN

12
Remember always to use the correct type of tire with the correct pressure.
It is a good idea to do some tire pressure testing. You’ll be surprised how much
grip you can get when your tires and shock are correctly set. Remember that the
tyre is an almost undamped linear air spring that also affects steering.
If rebound adjustment is close to the end of clicks we suggest you to ask for a
specification change. Make sure to fill correctly the form you can find on EXT
Mountain Bike Customer Area on EXT official website; then send it to your
nearest Service Point or at EXT headquarters.
Always check that your bike’s pivot are in good order and run smoothly. This can
affect the initial setting up of your shock if there is excessive stiffness on them.
Take note of your setup for any kind of trail or weather condition.
Take one adjustment at time.
If your weight is more rearward it can be a good idea to set up your fork softer.
This will help you in flat turns off camber turns and allow you to ride easily.
Rebound damping control is related to spring rate used. Higher
spring rates require more (slower) rebound damping.
If you’re a FLAT PEDAL rider
your weight distribution is
usually slightly more rearward.
So with this in mind your
initial setup will require less
high speed compression and
a slower rebound adjustment.
If you’re a CLIP PEDAL rider
your weight is generally more
centered on the bike. So you
may need a firm setting in
compression. Also, you may
set your rebound faster.

TRAIL RIDE ENDURO DOWNHILL
SAG
SPRING RATE
13
SAG is the amount that your suspension settles under your own weight when you’re
in the riding position. Setting sag is a key element of your setup because, if the sag
isn’t properly set, it alters the bike’s ride characteristics by changing the geometry
and handling not in a good way.
Choosing correct spring rate is really important to setup correctly your EXT shock.
There is not a unique formula because the rate could be affected by your riding style.
For a starting point please follow this formula:
This value is expressed in Newton / millimeters (N/mm). The whole bike industry
uses pound instead Newton. To convert N/mm to LBS/in please multiply for 5,71.
Always remember:
SAG = 0,25 (25%), 0,3 (30%), 0,35 (35%)
C1 value is your backward weight on the bike. For example a 0,7 value is equal to a
70% of your weight backward etc.
EXT SPRING MAX PRELOAD IS EQUAL TO 2 COMPLETE TURNS.
NEVER EXCEED THIS PRELOAD.
SHOCK LENGTH - (STROKE x DESIRED SAG) = SHOCK SAGGED LENGTH
RATE (K) N/mm = RIDER WEIGHT(Kg) x 9,81 x (BIKE .TRAVEL/SHOCK STROKE) x C1
SHOCK STROKE x SAG
i.e.: 200mm - (57mm x 0,3) =183mm
Always remember: 0,25 (25%), 0,3 (30%), 0,35 (35%)
30% 35%
25%

SHOCK INSTALLATION ON BIKE
14
1. Move up the spring adjustable plate and make sure that rebound adjustment is
fully closed
2. Insert the spring on the shock
3. Insert the spring thrust bearing under the spring, it must seat between the spring
and the lower plate.
4. Insert the lower spring plate and locate the circlip on dedicated housing
5. Make sure that the circlip is fully seated
6. Move the adjustable spring plate near the spring without preloading it
7. Mount the damper on your bike
8. Lift your bike from the saddle and let the rear wheel fully extend the damper
9. From this position preload the spring with adjustable spring plate (max 2mm)
10. Use a flat head screwdriver to tighten lock grub screw
11
664 - 54 - 5
2 - 32 - 3
7788
991010
To remove the shock or the spring follow the instructions in reverse order.
Always pay attention the correct fitment of the Spring Thrust Bearings and the circlip.
The installation process is equal to the one of e-Storia.

15
When you purchase a full custom EXT product your shock is built following accurately
your bike rear suspension kinematic, your weight and riding style. With this in mind
you can move through adjustments to find your perfect setting.
First of all have a look at your correct SAG. You can find a complete guide in this
manual (pg. 14).
SETTING UP YOUR SHOCK
Incorrect spring rate may produce a fork angle that is too steep or too flat.
This may give a tendency for over-or understeering, which could seriously affect the
handling characteristic of the bike.
Clicks are counted from full closed position. The reason is “full hard” is always
an absolute position. “Full soft” will vary depending on tolerances.
Normally the 1first click and/or detent is counted as “zero” position. Just remember
that full clockwise configuration is “full hard” for all adjusters.
COMPRESSION ADJUSTER
LOW SPEED COMPRESSION - BL
HIGH SPEED COMPRESSION - BH
Low speed compression is located on the upper part of the
compression valve.
You can adjust it via using a 4mm allen key.
To adjust follow this directions:
1. Turn the valve completely clockwise (ZERO POSITION)
2. Start to turn counter clockwise until you find the correct setup. Every different
position is signaled by a click.
High speed compression is just below the Low speed
compression adjuster. You can modify it using a 12mm
spanner.
Don’t use excessive strength on the adjuster. This could damage your shock seriously.

REBOUND ADJUSTER - R
Rebound adjuster is located on the lower part of the shock in
opposition to the compression valve. You can adjust rebound
with this knob.
To adjust follow this directions:
1. Turn the valve completely clockwise (ZERO POSITION)
2. Start to turn counter clockwise until you find the correct
setup. Every different position is signaled by a click.
16
LOK
SPRING PRELOAD
SPRING TRUST BEARING
The 2 way lock out on Storia V3-S is studied to optimize
pedal performance. The adjuster is located just near the
compression adjuster.
LOK is activated by turning lever clockwise.
Not force the lever past it’s stop point.
You can preload your spring
(max 2mm = 2 complete spring turns) by turning the
spring preload plate. First don’t forget to unscrew the
grub. Once you finished don’t forget to lock the grub in
one of the grooves present on the shock body.
Storia V3-S features a special spring trust bearing that sits
between the spring and the collars, it’s installation is really
important for the correct functioning of the shock. Don’t
loose it and alwas remember to correctly install it.
It’s absence may cause failure of the shock or spring and
result in a crash, property damage, serious injury or death.
The Spring Thrust Bearing might thigtly fit your spring,
so if you feel a small resistance installing the spring on
the thurst bearing don’t worry it is a normal behaviour.
However in case of doubts fell free to contact Ext or
your local dealer for further assistance.

17
Never change the factory pressure inside the piggyback reservoir. This could
compromise your shock seriously and may result in damage to your bike and/or
SERIOUS INJURY OR DEATH. If you have any issue with your shock pressure contact
your nearest Service Point or EXT headquarters.
Keep safety, stability and comfort as your piority when setting the shock. This will
allow you to ride safer with more confidence and use less energy.
PRESSURE
BUMP STOP
EXT shock absorbers work with very low reservoir pressure. This gives the shock the
ability to have a very high degree of bump force sensitivity and a very low break away
or actuation force. Even at this low pressure the shock does not blow through its
travel or suffer from hysteresis even at the shaft speed of 2 m/s.
EXT Technologies allow to use very thin bump stop. In this way you can use the full
travel of your bike. There are also plastic spacers present to avoid a fast wear of the
bump stop.
Spring preload must not exceed 2 complete spring turns. Failure to comply with
these instructions may result in the destruction of the spring on the shock and
void warranty of suspension product and/or spring. Failure of the spring may
result in damage to your bike and/or SERIOUS INJURY OR DEATH.

18
SETTING TIPS
REBOUND
LOW SPEED
COMPRESSION
HIGH SPEED
COMPRESSION
Increase rebound
damping
Increase compression
damping
If the bike feels: unstable, loose,
bouncy
If the bike feels: hard, nervous,
low traction
If you feel the shock: soft, spongy
or the bike feels unstable whengoing
into a corner
If the bike feels: soft, low, is
bottoming
If the bike feels: harsh, hard
If you feel that the bike feels hard
and has poor traction
Decrease rebound
damping
Decrease compression
damping
Close
Open
CHANGE HYDRAULIC SPECIFICATION
EXT SUPERLIGHT SPRING
EXT Racing Shox is able to build mountain bike shocks with a full custom hydraulic
specification. Sometimes it could happen that your ride or your weight are subject to
changes. It is possible to do a re-tuning of your shock absorber via EXT official service
point or via EXT headquarters. Please visit our Mountain Bike Customer Area on EXT
official website for further information.
Your shock absorber is sold with 2 different EXT SuperLight V2 Springs. If you for
example have a 300 lbs/in spring and a 325 lbs/in spring, and you use normally
the second one, you can choose to ride the other one in a wet day. This will give you
more sag and more control. You can adjust your dynamic ride height via Low Speed
compression.
EXT SuperLight Springs are available with 25 lbs/ins increment.

19
To preserve maximum performance of your EXT shock absorber you have to follow
accurately this indication:
1. Before every ride check your shock visually
2. Inspect shaft and be sure there are no leaks
3. Check bump stop condition
4. Check and inspect bushings every 15 hours riding and replace them if necessary
5. Check seals every 15 hours riding
6. Clean your shock well after the ride and don’t wash it with high pressure jet wash
SERVICE & MAINTENANCE
RACE CONDITION
NOT RACE CONDITION
To ensure maximum performance we suggest a complete service after 50 hours
riding (ca. 6 months).
We suggest a service once a year or after 100 hours riding.
A complete service includes: oil change, seals, DU bushings, bump rubber and o-rings.
Only EXT or EXT Service Points can perform this operation.
ALWAYS USE ONLY EXT RACING SHOX SPARE PARTS AND SEVICE KITS
NOT FOLLOWING SUGGESTED SERVICE WILL VOID WARRANTY