Kit
For 2016 KAWASAKI ZX10R

Owner’s Manual
Read this manual carefully before operating this BFRC® lite Kit.
No. T574200-OME1
The best technology and the highest
quality to meet every user’s needs.

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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 roadriding for a "rider seeking a difference". 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 controlledenvironment where there are technicians with special knowledge and skills. Make sure to change thespring at a dealership or store specializing in installation. If conducted by the customer, it is not coveredby 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 andproperty 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 specified 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 orserious injury".

CAUTION

The symbol represents a content that if mishandled, "it may cause injury orproperty 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 installation was improper, it may cause damage on the motorcycle and accident.
Please make sure that replacement is conducted in a dealership or controlledenvironment where there are technicians with special knowledge and skills.
If the product is installed on a modified motorcycle, it may cause function andperformance deterioration.
Install this product only on a motorcycle with genuine parts of its manufacturer.

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.
CAUTION

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 Service Manual provided by the motorcycle's manufacturer.

Caution when Using

WARNINGCAUTION

High-pressure nitrogen gas is filled in this product.
When disassembling and refilling nitrogen gas, the product may burst causing serious injury.
If exposed to flames and puncture a hole, this product may burst causing
serious injury.
Replacement and discarding must be done by a specified dealership.

There are recommended inspection items for this product to maintain its performance.
If not inspected and defects are ignored, it may cause function and performance deterioration.
When using, make sure to perform the recommended inspection items described in this manual.
Always use the oils specified by SHOWA.
When unspecified oils are used, it may cause function and performance deterioration.

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Contents
Overview........................................................................................................... 1

Product Features.........................................................................................................................1

List of Specification......................................................................................................................2
Recommended Inspection Items.................................................................................................2
Explanation of Icons Used in this Manual....................................................................................2

Installation Method of the Product (Replacement from Standard
Specification).................................................................................................... 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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Overview
Product Features
The BFRC® lite Kit is a rear cushion product that enabled to reduce the fluctuations 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, 9SpringPage 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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Overview
List of Specification
Assembly

Kit

STD

309 (312)/254 (253)309/254

Stroke (mm)55

55

Spring tuning (mm)

±5

―

160

175

Max. length/Min. length (mm)Spring length (mm)Length tuning
Filled gas pressure (Mpa)-1 to +3

―

1.0

1.0

SpringRate (N/mm)

ReboundspringRate (N/mm) -ST (mm)9191

100-10100-8

Oil

Type of oil

SS25

SS25

Tuningreference
position

Rebound side/Compressionside

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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Installation Method of the Product (Replacement from Standard Specification)
WARNING

Please make sure that installation is conducted in a dealership or controlledenvironment 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 manufacturer.
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 .

5.9-8.8 N.mTightening torque: 5.9 to 8.8 N·m

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Installation Method of the Product (Replacement from Standard Specification)
4. Remove the tandem step  on the left sideof the motorcycle, and pinch the stay  using 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 manualof 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 thateach 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 difficult, contact your nearest dealership that sells SHOWA products.

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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 theposition that stops lightly for
the Low side and High side.
It may cause internal damage.

Low[Note]
Spring set length L = 149 mm is the standard
position.
High: L < 149 mm
Low: L > 149 mm

L=149mm● Damping Force Tuning

Hard

Adjust the COM and REB on the plug bolt
COMP by turning with a hexagonal wrench (3mm).
COM: Compression side
REB: Rebound side
CAUTIONHigh

Do not force to turn from theposition that stops lightly for
the Soft side and Hard side.
It may cause internal damage.

Soft

Soft

Hard

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 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.

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Tuning Method
Available Option Parts
To widen the vehicle height tuning and setting change, a spring for replacement is available as the optional part. For purchasing, contact the specified dealership.
Rate (N/mm)

Specification

101

Hard

96

Medium hard

91

Medium (Installation part at factory shipping)86

Medium soft

81

Soft

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Replacement Method of the Spring
To replace the spring follow the bellow procedure.

WARNING Make sure the replacement is performed at a dealership or store specializing in installation. If performed by the customer, the warranty will be void.
 When assembling and disassembling the spring using a spring compressor, a large force is applied to the spring. The spring can detach and jumpout hitting human bodies causing injury. Use a fixing tool to make sure notto tilt and install it correctly.
 When using a spring compressor, make sure not to contact fingers andhands that can cause injury. Make sure to be cautious sufficiently.
 If a spring compressor is not available or person does not have required
skill, please contact the specified dealership.

Removing
1. Remove the BFRC® lite Kit from the motorcycle.
[Note]For the removing method of the rear cushion, refer to the service manual of the motorcycle manufacturer.
2. Using a spring compressor, compress thespring .

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Replacement Method of the Spring
3. Push down the spring seat stopper , andremove the stopper ring .

4. Remove the spring seat stopper  and thespring , and replace the spring.

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Replacement Method of the Spring
Installation
1. Attach the spring  and spring seat stopper  to the cushion sub COMP .

2. Attach to a spring compressor, and pushdown the spring seat stopper  until thegroove  is visible.
3. Attach the stopper ring  in the groove .

4. Check the spring seat stopper  is hookedon the stopper ring , and remove the
BFRC® lite Kit from the spring compressor.

WARNING

Attach the stopper ring to the whole circumference around the groove firmly.

5. Install the BFRC® lite Kit to the motorcycle.
For installation, refer to Installation Methodof the Product (Replacement from Standard Specification) (Page 3).

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Vehicle height adjusting with the lower metal
When the vehicle height tuning is necessary, adjust by changing the installation length of the lower
metal.
1. Loosen the lock nut  with a wrench.

2. Turn the lower metal  to change the installation length.

 The line of the screw part  of the lower
metal  is the reference line. When set
in the center of line , the whole lengthof the BFRC® lite Kit is the reference dimension.

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Vehicle height adjusting with the lower metal Turn the lower metal  clockwise topush the line  into the lower joint side
 for 1 mm, and the length is shortenedby 1 mm.

1mm

 Turn the lower metal  counterclockwise to extract the line  outward for
3 mm, and the length is extended by 3mm.
 Turn the lower metal  half to change
the whole length by 0.5 mm.

CAUTION

The lower metal  is designed not to be removed.
Do not force to turn or thepart breaks. When turning
the lower metal , use
your hand instead of awrench.

3mm

3. Fix the lower joint , and tighten the locknut  to the specified torque.
Tightening torque: 20 to 30 N·m
4. Install the BFRC® lite Kit to the motorcycle.
For installation, refer to Installation Methodof the Product (Replacement from Standard Specification) (Page 3).

20-30 N.m

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Troubleshooting
Symptom

Cause

The rear suspension is soft.

Inadequate damping force tuning.

Tune suspension.

The gas filling pressure is low.

Check at the dealership.

Setting of spring.

Replace spring.

Bent of the rod.

Check at the dealership.

Grease shortage of the cushion bearings.

Check at the dealership.

The rear suspension is hard.

Noise of the rear suspension.

Measures

The gas filling pressure is high.

Check at the dealership.

Damage.

Check at the dealership.

Abrasion of the cushion bearings.

Check at the dealership.

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Warranty

To Dealership
Please make sure a customer reads and agree with the warranty regulations, and enter information in
the box below.
If sold without filling out the information, the warranty shall not be effective.
The warranty shall not be applied to sensible symptoms (sound during adjusting, color tone changes
due to lighting, etc.) acknowledged as having no effect on the product functions.
The warranty shall not be applied to a product lacking a manufacturing engraved seal serving as thewarranty engraved seal.

Manufacturing engraved seal
Name
Customer

AddressPhone
E-mailDealership name

Purchased date
Year:

Month:Day:

Warranty period (From the purchased date)

6 months

AddressPhone
E-mail

If information is not filled in the box above, the warranty shall not be applied. Please make sure to fill it
all.
If information is not filled in the box above, please contact the dealership a product is purchased
promptly.
This warranty shall not be reissued. Please store in a safe place.

This document guarantees warranty application (free repair) on the contents specified in this document.

Manufacturer: SHOWA CORPORATION
1-14-1, Fujiwara-cho, Gyoda, Saitama 361-8506, Japan
http://www.showa1.com
Distributor: K-Tech Suspension Limited
Rawdon Business Park, Marquis Dr, Swadlincote, Derbyshire DE12 6EJ UK.
TEL +44 (0) 1283559000
http://www.ktechsuspension.com/

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Warranty regulations
1. If this product fails to operate properly during the specified warranty period as used under normal
condition following the cautions in the owner's manual, appended labels on the product, etc., pleasetake the product and this warranty to a dealership you purchased the product, present the warranty,
and request for warranty application.
2. The warranty shall not be applied in the following cases even in the specified warranty period.
 When the customer himself/herself changed the spring.
 Functional problems generated in the product's normal operation are not present.
Normal operation noise and some oil permeation on the oil seal itself (if there are no performanceissue).
 Change in riding comfort and feelings generated based on the product's characteristics.
 When the product is used for racing (includes circuit driving) Failure and damage due to improper usage, and invalid modification and repairs Failure and damage due to accident, fall, and drop.
 Failure and damage due to fire, salt, natural disaster like earthquake, and external factors.
 When the warranty is not presented.
 When the manufacturing engraved seal of this document does not match the product’s
manufacturing engraved seal.
 When required information on the warranty is missing or rewritten.
 Failure and damage due to installation to a model the product is not intended for.
 Failure and damage due to connected other devices.
 Failure caused from using parts, oil, etc. not specified by SHOWA.
 Replacement of consumable parts.
 Failure and damage due to the customer’s usage environment, maintenance and management
methods (scratches due to skipped stones, rust, color change, etc., from riding).
3. To have a repair service on this product, please request in the product unit condition.
Please note any cost to make it the product unit condition (cost for installation, removal, and otherlabor) is not covered by this warranty.
Also, on-site repair service shall not be provided on this product even during the specified warranty
period.
4. Please understand that warranty regulations are applied on the product unit only, not any otherdevices to be connected.
5. Please note that all inconvenience and losses (phone call fees, towing fees, replacement products,
loaner vehicles, compensation for absence from work, sales loss, etc.) caused from having awarranty repair shall not be covered under any circumstances.
6. Please note that our company is not liable for any loss and damage outside the manufacturer
warranty of your vehicle through installation of this product.

Balance Free Rear Cushion lite Kit
Owner’s Manual©SHOWA CORPORATION, June,
2016, All rights reserved.
Any reprinting or unauthorized use
without the written permission of
SHOWA CORPORATION is prohibited.
Printed in Japan

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