Showa BFRC Lite User manual

Read this manual carefully before operating this BFRC®lite Kit.
The best technology and the highest
quality to meet every user’s needs.
No. T574200-OME1
Kit
For 2016 KAWASAKI ZX10R
Owner’s Manual
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Introduction
Thank you for purchasing the SHOWA Balance Free Rear Cushion lite Kit (referred to as "the BFRC®
lite Kit").
The BFRC®lite Kit is a suspension kit that provides the best performance and durability for public road
riding for a "rider seeking a di󰀨erence". It is designed with knowledge gained from the world's highest
motor sports, Moto GP, World Superbike Championship, Dakar, etc.
In 2015's World Superbike Championship, the winner of the world champion was riding the motorcycle
equipped with the BFRC®lite Kit and the Balance Free Front Fork (BFF).
Installation of the BFRC® lite Kit, handling, and tuning are described in this Owner's Manual.
Please read this manual carefully, and follow the described instructions.
Please note that installation, handling, and tuning should be conducted in a dealership or controlled
environment where there are technicians with special knowledge and skills. Make sure to change the
spring at a dealership or store specializing in installation. If conducted by the customer, it is not covered
by the warranty.
The warranty is appended at the end of this manual.
Please make sure to receive a warranty from a dealership where you purchased the product.
Handling this product properly
In this manual, items that need you to comply to prevent injuries on the user and other people and
property damage, in addition to the correct installation are shown with the following "Symbols". Please
understand what each "Symbol" means, and read this manual.
It is the safety warning symbol. This symbol is used to call your attention
when there is a danger for personal injury. Comply with the safety items spec-
ied after this symbol to prevent injury and accident that may cause death.
WARNING
The symbol represents a content that if mishandled, "it may cause death or
serious injury".
CAUTION The symbol represents a content that if mishandled, "it may cause injury or
property damage".
Note It describes points to pay attention, and focus when conducting service.
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Safety Caution
Caution When Installing
WARNING
Special knowledge is required to replace the rear cushion unit.
If someone without special knowledge performed installation, and the instal-
lation was improper, it may cause damage on the motorcycle and accident.
Please make sure that replacement is conducted in a dealership or controlled
environment where there are technicians with special knowledge and skills.
If the product is installed on a modied motorcycle, it may cause function and
performance deterioration.
Install this product only on a motorcycle with genuine parts of its manufacturer.
CAUTION
This product is a precision machine part.
Deformation and dent from a drop, hammer, and shock may cause function
and performance deterioration.
When handling and installing the product, do not drop, hammer, and apply shock.
If only one person handles the product, there may be a case that a motorcycle
and parts cannot be held by himself/herself.
Make sure 2 or more people work when removing and installing the product.
When installing to a motorcycle, comply with the items described in the Ser-
vice Manual provided by the motorcycle's manufacturer.
Caution when Using
WARNING
High-pressure nitrogen gas is lled in this product.
When disassembling and relling nitrogen gas, the product may burst caus-
ing serious injury.
If exposed to ames and puncture a hole, this product may burst causing
serious injury.
Replacement and discarding must be done by a specied dealership.
CAUTION
There are recommended inspection items for this product to maintain its per-
formance.
If not inspected and defects are ignored, it may cause function and perfor-
mance deterioration.
When using, make sure to perform the recommended inspection items de-
scribed in this manual.
Always use the oils specied by SHOWA.
When unspecied oils are used, it may cause function and performance de-
terioration.
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Contents
Overview .......................................................................................................... 1
Product Features ........................................................................................................................1
List of Specication.....................................................................................................................2
Recommended Inspection Items ................................................................................................2
Explanation of Icons Used in this Manual...................................................................................2
Installation Method of the Product (Replacement from Standard
Specication)................................................................................................... 3
Measuring Vehicle Height Before Replacing ..............................................................................3
Installation...................................................................................................................................3
Measuring Vehicle Height After Replacing..................................................................................4
Tuning Method................................................................................................. 5
Spring Preload Tuning and Damping Force................................................................................5
● Spring Preload Tuning.......................................................................................................5
● Damping Force Tuning......................................................................................................5
Available Option Parts ................................................................................................................6
Replacement Method of the Spring ............................................................... 7
Removing....................................................................................................................................7
Installation...................................................................................................................................9
Vehicle height adjusting with the lower metal............................................ 10
Troubleshooting ............................................................................................ 12
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1
Overview
Product Features
The BFRC® lite Kit is a rear cushion product that enabled to reduce the uctuations of pressure balance
to the utmost limit by making the piston, damping valve, and sub tank independent, and the damping
valve on the compression side and rebound side to the compact unit called the Plug Bolt COMP 
which is placed on the damper case.
No. Part Name Reference Page
Lower metal Page 3, 4, 9
Spring Page 4, 6, 8
Spring Adjuster COMP Page 5
Plug Bolt COMP Page 1, 5
Stay Page 3
Bolt M6 x 1.0 (2) Page 3
Bolt M8 x 1.25 (2) Page 3
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2
Overview
List of Specication
Kit STD
Assembly Max. length/Min. length (mm) 309 (312)/254 (253) 309/254
Stroke (mm) 55 55
Spring tuning (mm) ±5 ―
Spring length (mm) 160 175
Length tuning -1 to +3 ―
Filled gas pressure (Mpa) 1.0 1.0
Spring Rate (N/mm) 91 91
Rebound
spring
Rate (N/mm) -ST (mm) 100-10 100-8
Oil Type of oil SS25 SS25
Tuning
reference
position
Rebound side/Compression
side
Max -12 clicks/
Max -22 clicks
Max -2.25 rotations/
Max -1 rotation
Hydro spring tuning Min +22 clicks
(Total: 40 clicks)
―
Recommended Inspection Items
Before riding Semi-annually Annually
Operation check of the rear suspension
operation 
Oil leakage of the rear suspension 
Explanation of Icons Used in this Manual
In this manual, the following icon is displayed in illustrations for inspection and disassembling service
to proceed smoothly.
Icon Explanation
Specify the tightening torque.
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3
Installation Method of the Product (Replacement from Standard Specication)
WARNING
Please make sure that installation is conducted in a dealership or controlled
environment where there are technicians with special knowledge and skills.
When replacing the rear cushion, conduct tuning of the motorcycle posture with the following ways.
Measuring Vehicle Height Before Replacing
1. While placing a motorcycle on the ground, measure the distance from the axle shaft of the rear
wheel to the top frame, and record the value.
2. Measure above while a rider is on the motorcycle, and record the value.
3. Measure above by jacking up the motorcycle and the rear wheel is dropped completely, and record
the value.
Installation
1. Remove the standard rear cushion on the motorcycle.
[Note]
For the removing method of the rear cushion, refer to the service manual of the motorcycle manu-
facturer.
2. Install the BFRC® lite Kit to the motorcycle.
[Note]
Install the lower metal to face the forward direction of the motorcycle.
For the tightening torque of each bolt, refer to the service manual of the motorcycle manufacturer.
3. Install the stay  on the spring adjuster
COMP .
Install with M6 x 1.0 bolt .
Tightening torque: 5.9 to 8.8 N·m
5.9-8.8 N.m
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4
Installation Method of the Product (Replacement from Standard Specication)
4. Remove the tandem step on the left side
of the motorcycle, and pinch the stay us-
ing M8 x 1.25 bolt  with the tandem step
to install.
[Note]
For the tightening torque of the tandem step
installation bolt, refer to the service manual
of the motorcycle manufacturer.
Measuring Vehicle Height After Replacing
WARNING
After replacement, the caster angle of the front fork is changed from the
pre-replacement state. If ridden in this condition, it is very dangerous because
the motorcycle behavior may be unstable and the brake performance may
change. Before riding, make sure to tune the motorcycle posture.
Measure similarly before replacement, and adjust the lower metal installation position and the spring
preload to be the same value before replacement. (Refer to page 5.)
CAUTION
 When lowering the vehicle height, adjust within the compressed range that
each part of the motorcycle does not interfere with the BFRC® lite Kit.
 Conduct vehicle height tuning at installation with the spring preload.
 If tuning is di󰀩cult, contact your nearest dealership that sells SHOWA prod-
ucts.
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5
Tuning Method
Spring Preload Tuning and Damping Force
Perform spring preload tuning and damping force tuning of the BFRC® lite Kit following the procedure below.
CAUTION Always perform tuning in the position that a clicking feeling can be felt. When
tuned between clicking positions, it can cause shifted setting during riding.
● Spring Preload Tuning
Turn the tuning dial on the spring adjuster
COMP with your hand to adjust.
CAUTION
Do not force to turn from the
position that stops lightly for
the Low side and High side.
It may cause internal damage.
[Note]
Spring set length L = 149 mm is the standard
position.
High: L < 149 mm
Low: L > 149 mm
● Damping Force Tuning
Adjust the COM and REB on the plug bolt
COMP by turning with a hexagonal wrench (3
mm).
COM: Compression side
REB: Rebound side
CAUTION
Do not force to turn from the
position that stops lightly for
the Soft side and Hard side.
It may cause internal damage.
[Note]
The standard on the compression side is
22 clicks counterclockwise from the position
that is turned all the way on the Hard side.
The standard on the rebound side is 12
clicks counterclockwise from the position
that is turned all the way on the Hard side.
HighLow
L=149mm
Hard Soft
Soft Hard
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6
Tuning Method
Available Option Parts
To widen the vehicle height tuning and setting change, a spring for replacement is available as the op-
tional part. For purchasing, contact the specied dealership.
Rate (N/mm) Specication
101 Hard
96 Medium hard
91 Medium (Installation part at factory shipping)
86 Medium soft
81 Soft
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