Kit
For 2016 KAWASAKI ZX10R

Owner’s Manual
Read this manual carefully before operating this BFF Kit.
No. T574100-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 Front Fork Kit (referred to as "the BFF Kit").
The BFF Kit is a suspension kit that provides the best performance and durability for public road riding
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 BFF and Balance Free Rear Cushion lite (BFRC® lite).
Installation of the BFF 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, dust seal, and oil seal at a dealership or store specializing in installation. If conducted by thecustomer, 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 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 front fork.
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 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....................................................................................3

Installation Method of the Product (Replacement from Standard
Specification).................................................................................................... 4

Measuring Vehicle Height Before Replacing...............................................................................4

Installation....................................................................................................................................4
Measuring Vehicle Height After Replacing...................................................................................5

Tuning Method.................................................................................................. 6

Spring Preload Tuning and Damping Force.................................................................................6● Spring Preload Tuning........................................................................................................6● Damping Force Tuning.......................................................................................................6
Available Option Parts.................................................................................................................7

Replacement Method of the Spring................................................................ 8

Removing.....................................................................................................................................8
Adjusting Oil Level of Operation Oil........................................................................................... 11

Installation..................................................................................................................................13

Replacement Method of the Dust Seal and Oil Seal................................... 15

Removing...................................................................................................................................15
Installation..................................................................................................................................17

Troubleshooting............................................................................................. 19

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Overview
Product Features
The BFF Kit is a front fork 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 valve on the compression
side and rebound side to the compact unit called the Plug Bolt COMP  which is placed on the axle holder.

No.







Part Name

Reference Page

Fork Bolt COMP

Page 7, 8

Outer tube

Page 4, 6, 8, 12, 14, 15, 17

SpringPage 6, 8, 10, 11, 13

Slide pipe

Page 15, 17, 19

Plug Bolt COMP

Page 1

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Overview
List of Specification
Kit

STD

745/615739/619

Stroke (mm)

130

120

Slide pipe (Outer diameter)
(mm)

43

43

Outer tube clamp (Diameter)
Upper (mm)5050Outer tube clamp (Diameter)
Under (mm)55

55

Outer tube length (mm)

486

480

Filled gas pressure (Mpa)

0.5

0.5

Axle hole (Inner diameter)32

32

SpringRate (N/mm)

10.25

11.25

ReboundspringRate (N/mm) -ST (mm)1.7-80

14-20

Operation
oilType of oil

SS47

SS47

Oil level (mm)

253

160

Tuningreference
position

Spring preload

Low + 10 clicks(Total: 30 clicks)

Low + 6 rotations(Total: 15 rotations)

Reboundside

Max -16 clicks

Max - 2.5 rotations

Compressionside

Max -25 clicks

Max - 3.5 rotations

AssemblyMax. length/Min. length (mm)Dampingforce

Recommended Inspection Items
BeforeridingSemi-annually

Annually

Operation check of the front fork suspension







Oil leakage of the front fork suspension







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Overview
Explanation of Icons Used in this Manual
In this manual, the following icons are displayed in illustrations for inspection and disassembling service
to proceed smoothly.
Icon

Explanation
Specify the tightening torque.
It shows the press fitting part. Press fit using an adequate adapter.
It shows a part to clamp. To prevent deformation of a part, always clamp on the specified part.
A location to apply Liquid O-Ring #400.
A location to apply molybdenum grease.
Replace with a new part.

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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 front fork, 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 front
wheel to the top bridge, 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 front wheel is dropped completely, and record
the value.

Installation
1. Remove the front fork on the motorcycle.
[Note]For the removing method of the front fork, refer to the service manual of the motorcycle manufacturer.
2. Install the BFF Kit to the motorcycle.
 Install the upper end of the outer tube in
the BFF Kit to be 7 mm projection dimension from the top bridge upper face.

STD
7mm

[Note]For the installation procedure and tightening
torque of each bolt, refer to the service manual of the motorcycle manufacturer.

Kit
7mm

4

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Installation Method of the Product (Replacement from Standard Specification)
3. Install the axle shaft.
 For installation of the axle shaft, referto the service manual of the motorcycle
manufacturer.
 Tighten the axle holder bolt  with thespecified torque after applying molybdenum grease on the screw part.
Tightening torque: 20 N·m

CAUTION

20 N.mTighten the axle holder
bolt  with the specified
torque after applying molybdenum grease.

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 spring preload to be the same value before replacement. (Refer to page 6.)

CAUTION When lowering the vehicle height, adjust within the range that each part ofthe motorcycle does not interfere with the BFF Kit in the most compressed
condition.
 Conduct vehicle height tuning with the spring preload, and do not change
the projection amount of the outer tube.
 If setting problem is not resolved, 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 BFF 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.
 Always tune evenly on the right and left front fork.

● Spring Preload Tuning

Attach a hexagonal wrench (6 mm) on thecenter of the fork bolt COMP to perform tuning.

[Note]
 The standard is 10 clicks clockwise fromthe position that is turned all the way on
the Low side.
 1 click changes 0.5 mm preload amount.

Low● Damping Force Tuning

Hard

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

CAUTION

High

Soft

Do not force to turn fromthe position that stops
lightly for the Soft sideand Hard side.
It may cause internal damage.

Soft

Hard

[Note]
 The standard on the compression side is
25 clicks counterclockwise from the position that is turned all the way on the Hardside.
 The standard on the rebound side is 16
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

11.25

Hard

10.75

Medium hard

10.25Standard

9.75

Medium soft

9.25

Soft

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Replacement Method of the Spring
Replace the spring with the following 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.

Removing
1. Remove the BFF Kit from the motorcycle.
[Note]For the removing method of the front fork, refer to the service manual of the motorcycle manufacturer.
2. Loosen the fork bolt COMP  to free fromthe outer tube .
 Clamp the partof outer tube , andloosen the fork bolt COMP  using atool.
[Note]
While the front fork is attached to the motorcycle, the fork bolt COMP  can be loosened. Refer to the service manual of the
motorcycle manufacturer.

3. Lower the outer tube  to the bottom.

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Replacement Method of the Spring
4. Remove the fork bolt COMP  and collar.
 Hook and fix a 17 mm wrench ⓐ on theacross flat part of the joint metal , andturn the fork bolt COMP  with a tool toremove the fork bolt COMP .

a

5. Attach the tool ⓑ to the joint metal .
 Use the one with a M12 x 1.25 female
screw is cut on the end of a round rod
with approx. 15 mm in diameter. The
length should be 200 mm or more.

b

b

a

a

6. Pull up the tool ⓑ to remove the wrench ⓐ,
and remove the tool ⓑ and slider .

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Replacement Method of the Spring
7. Remove the spring collar COMP  and thespring .
 Use a tool that the end of a wire is bent to
the hook shape, and hook it to remove.

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Replacement Method of the Spring
Adjusting Oil Level of Operation Oil[Note]
 Because a small amount of oil is attached on the removed parts, after disassembling, the oil facein the front fork is lower than the reference value.
 Whilst only the spring is in place, conduct an oil face adjusting.
1. Enter the spring .

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Replacement Method of the Spring
2. Fill operation oil.
3. Using an oil face adjustment tool, adjust theoperation oil face.
Specified oil: SHOWA SS47
Operation oil face height Ⓐ: 253 mm

CAUTION

 Conduct oil face adjustment while only the
spring  is in.
 Perform while the outertube  is lowered all
the way.

A

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Replacement Method of the Spring
Installation
1. Attach the tool ⓑ to the joint metal .

b

2. Attach the spring collar COMP  and theslider .

b

3. Pull up the tool ⓑ, and hook a 17 mm
wrench ⓐ on the across flat part of the joint
metal .

b

b

a

a

4. Remove the tool ⓑ.

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Replacement Method of the Spring
5. Install the collar  and fork bolt COMP
 to the joint metal  with the specified
torque.
 On the fork bolt COMP  and the outer diameter of O-ring , apply Liquid
O-Ring #400.

25-30 N.m

Tightening torque: 25 to 30 N·m

a6. Clamp the partof outer tube , andattach the fork bolt COMP  using a toolwith the specified torque.

30-40 N.m

Tightening torque: 30 to 40 N·m
CAUTION

Clamp not to damage ordeform the outer tube.

7. Install the BFF Kit to the motorcycle. For
installation, refer to Installation Method of
the Product (Replacement from Standard
Specification) (Page 4).

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Replacement Method of the Dust Seal and Oil Seal
Replace the dust seal and oil seal with the following 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.

CAUTIONBe cautious not to damage the parts.

Removing
For the removing of oil seals, see the removing procedure of the spring replacement method 1 to 7
(Page 8 to 10).
1. Discharge operation oil.
 Tilt the BFF Kit, and discharge oil.

2. Extract the outer tube  from the slide
pipe.
3. From the outer tube , remove the dust
seal , stopper ring , oil seal , and oilseal spacer .

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Replacement Method of the Dust Seal and Oil Seal
4. Remove the guide bush .
 Attach the tool ⓒ that removes the outer
race of bearings to the guide bush .
 Use an adequate shaft to strike the toolⓒ remove the guide bush .

c

c

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Replacement Method of the Dust Seal and Oil Seal
Installation
1. Attach the tool ⓓ for seal damage prevention to the slide pipe , and from the toolⓓ side, attach in the order of the dust seal
, stopper ring , and oil seal .
 Apply the Liquid O-Ring #400 overall inside the lip for the dust seal  and oilseal .

CAUTION

Apply a thin layer of theLiquid O-Ring #400 overall inside the dust seal .

d2. Attach the oil seal spacer  and guidebush .

3. Insert the slide pipe  to the outer tube .
4. Press fit the guide bush  and oil seal
spacer  to the outer tube  with the installer tool ⓔ.

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Replacement Method of the Dust Seal and Oil Seal
5. Press fit the oil seal  to strike the oil seal
spacer , and place the stopper ring  to
the groove  firmly.

e

6. Using the installation tool ⓕ, press fit the
dust seal  to adhere the end of the outertube .
For the following procedure, refer to Adjusting oil level of operation oil and Installationin the Replacement Method of the Spring(Page 11 to 14).

f

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Troubleshooting
Symptom

Cause

The suspension operation is
soft.

Inadequate damping force tuning.

Tune suspension.

The viscosity coefficient of theoperation oil is low.

Replace oil (SHOWA genuineoil).

The operation oil amount islow.

Adjust the oil amount.

Setting of spring.

Replace spring.

The gas filling pressure is low.

Check at the dealership.

Bent slide pipe.

Check at the dealership.

The viscosity coefficient of theoperation oil is high.

Replace oil (SHOWA genuineoil).

The operation oil amount ishigh.

Adjust the oil amount.

The suspension operation is
hard.

Noise in the front fork.

Measures

The gas filling pressure is high.

Check at the dealership.

Damage.

Check at the dealership.

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MEMO

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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:
AddressPhone
E-mailWarranty period (From the purchased date)

6 months

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 spring, dust seal, and oil seal are changed by the customer.
 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 Front Fork 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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