1. Showa Fork Service Manual

'The best you've ridden is the best you know.' - Paul Thede -Race Tech is here to support you in doing quality suspension work.

This includes education like our Suspension Seminars as well as an extensive line of suspension tools. To find which tools are needed for specific models do a. Feel free to give us a call for more information. SHOCK BODY/RESERVOIR HOLDING TOOLS The Shock Body Holding Tool is ideal for clamping WP and Race Tech G3-S reservoirs. Can be sleeved to clamp any smaller tube including Fork Tubes, Shock Bodies etc.

Has four pinch bolts and can be used in a press for additional holding power. Machined from Billet Aluminum. TFSH 58 – TFSH 65 – DAMPING ROD HOLDING TOOL Some Damping Rods are difficult to remove because they spin. Making a special tool for each model can be a pain. This simple tool is a tapered aluminum rod.

With a tap of a hammer, the taper wedges into the ID of most Damping Rods, late model and vintage. You may be surprised by its holding power! Many forks come apart easily, but this inexpensive tool is great to have when you need it. TFDH 01 – RACE TECH SUSPENSION BIBLE (by Paul Thede) Based on Paul Thede’s wildly popular Race Tech Seminars taught around the world, this step-by-step guide shows anyone how to make their bike handle the way it should. IBSB 01 – VACUUM MASTER SHOCK FILLER The Vacuum Master Shock Bleeding Tool makes high-tech shock filling more affordable.

This machine not only saves time and increases efficiency, but it creates a 'perfect bleed'. The vacuum is so powerful it actually draws air out of the suspension fluid itself! TSVM 01 – FORK SPRING COMPRESSOR (foot-operated, wall mounted) The Foot-Operated Fork Spring Compressor is designed to work on most sport bikes and road racers with cartridge forks. It allows the spring to be compressed while the fork cap is removed from the rod. This design is wall mounted and really easy to use. TFSC 02 – Our H-D Adapter is recommended by Factory Harley-Davidson for the disassembly of their cartridge forks.

TFSC A01 – FORK SPRING COMPRESSOR (portable) Most street bikes with cartridges require a spring compressor. The factory unit is expensive and hard to use. This portable Fork Spring Compressor can be used on or off the bike on many models. TFSC 01 – FORK SEAL DRIVERS TFSD Series - Fork seal drivers. Split design. These are the standard of the industry. Item Code Diameter TFSD 31 30-31mm TFSD 33 33mm TFSD 35 35mm TFSD 37 36-37mm TFSD 39 38-39mm TFSD 41 40-41mm TFSD 43 42-43mm TFSD 46 45-46mm TFSD 48 47-48mm TFSD 50 49-50mm 24/32/41mm FORK CAP WRENCH This unique tool offers three different sizes to fit a variety of sport bikes.

TFCW 243241H - 41-43mm BIG PISTON FORK (BPF) FORK CAP WRENCH This BPF Fork Cap Wrench, along with the Cartridge Holding Tool TFCH 06 fit Showa BPF (Big Piston Forks). These tools are a 'must have' for maintenance of 09- GSX-R1000, 11- GSX-R600, H-D XR1200X, 09- ZX-6R and 11- ZX-10R. TFCW 4549 - SHOWA TWIN-CHAMBER FORK CAP WRENCH Fits 47 and 49mm Showa forks. Has 46 and 50mm octagons.

Removes compression valving assembly on most models too. TFCW 4650 - KYB TWIN-CHAMBER Fits 48mm KYB forks. Has 45 and 49mm octagons. TFCW 4549 - WP 48mm Fits 48mm WP forks that require a special pin spanner wrench (slots - no hex).

40mm pin spacing x 3.2mm pins TFCW 02 - WP 50mm DUAL-CHAMBER Fits KTM WP 48mm Dual Chamber forks that require a large 50mm hex. Also includes 29 spacing x 4.8mm Pin Spanner. TFCW 50H - NITROGEN GAUGE This Nitrogen Gauge does not require a wrench and easily reaches those recessed valve stems without an extension. It comes with a 1/4' flare nut quick coupling to work with the Quick Connect Hose (TSNH 48). Nitrogen Gauge - TSNG 02 NITROGEN REGULATOR This Nitrogen Regulator is excellent quality. It has output to 300 psi and comes with a 1/4' flare nut quick coupling to work with our Quick Connect Hose.

Nitrogen Regulator - TSNR 01 QUICK CONNECT NITROGEN HOSE The Quick Connect Nitrogen Hose has special 800 psi 'finger tight' 1/4' flare nut quick couplings. This simple assembly works perfectly with our Nitrogen Regulator and Gauge. Nitrogen Hose - TSNH 48 - WP SHOCK NITROGEN CHARGING TOOL The Race Tech WP Nitrogen Charging Tool works on all WP shocks with a reservoir.

This tool is quick and easy to use and a 'must have' if you work on a higher volume of WP shocks. TSNC 02 - NITROGEN NEEDLE This tool is designed for gas charged shocks with self-sealing type rubber valves. Used with Nitrogen Gauge - TSNN 01 Nitrogen Charging Needle TPNN 01 Replacement Needle SELF-SEALING NITROGEN CHARGING BOLT The Nitrogen Charging Bolt is a simple replacement of the standard WP Nitrogen Bolt and allows a shock to be pressurized with a standard Nitrogen Needle (TSNN 01). The OEM WP nitrogen filling system is pricey and cumbersome. These Nitrogen Charging Bolts can also be used to recharge some 'non-rebuildable' shocks. SPNV 0512 - SHOCK SPRING COMPRESSOR (screw type) This Shock Spring Compressor is strong, light-weight and easy to use.

It comes with 4 adapters (60, 66, 72, and 75mm) for different size spring collars and both an eyelet and clevis adapter. Invented by Jason Eldredge of Corporate Suspension in Utah, this one is so cool you’ll want to remove shock springs just for the fun of it. TSSC 02 – SHOCK SPRING COMPRESSOR (lever type) Provides quick removal and installation of most shock springs with spring rates up to 8 kg/mm. Features a Shaft Locking Device for safety. TSSC 01 – RESERVOIR CAP REMOVAL TOOL This tool threads onto the Schrader Valve located on the reservoir cap for easy removal. (Simply screw the tool on and gently pull the cap from the body.) TSCT 01 – CARTRIDGE HOLDING TOOLS TFCH Series - Holds cartridge during disassembly and assembly.

View for applications. Item Code Fits TFCH 01 Most KYB and Showa 20mm cartridges TFCH 03 Many KYB 46 & 48mm open chamber forks TFCH 04A Yamaha 06- R6, 09- R1 TFCH 06 BPF 41 & 43mm forks TFCH PS24050 WP KTM 65 Seal Head BIG PISTON FORK SEAL HEAD TOOL Designed to remove and install the seal head assembly from the inner fork tube in 41 and 43mm BPFs. It is reversable and has two hex sizes for the two sizes of forks. It allows changing fork springs without disassembling the valving stack.

TFCH 06 - SHOWA TAC and KYB Dual Chamber FORK CAP TOOL This is a dual-purpose tool for the Showa SFF Air TAC Fork. This tool allows you to remove the Fork Compression Valve Assembly from the top of the cartridge AND, by reversing it, remove the Base Bolt on the bottom of the fork. It also fits KYB Dual Chamber Compression Caps. TFCT 3602 - SHOCK CLIP TOOL Removes shock retaining clips without digging into the shock bodies.

Made of hardened tool steel. If you work on shocks you'll really like this one!

TSCP 01 - SEAL HEAD SETTING TOOLS Four sizes available. Mini's, Standard 40-50mm, Street and WP PDS 50mm shocks.

Allows the user to easily push shock seal heads into the bodies. Item Code Fits TSSS 01 40-50mm TSSS 01S 40-50mm Short TSSS 02 50mm WP TSSS 03 33-36mm SHOCK PRELOAD ADJUSTING TOOL Tired of chewing up your shock spring collars when you adjust preload?

Well we've got the tool for you! Can be used aggressively on preload adjusting collars with minimal damage. Many people chuckle at this one untill they try it. You'll like it.

TSPA 01 - WP PDS SHOCK NEEDLE T-HANDLE TOOLS TSPS T Series - This is the PRO version of the needle removal tool. If you are servicing a lot of WP PDS shocks these are the one to have. It is driven with a T-handle, holds the Needle, and is self-centering in the body. Item Code pin circle x pin diam TSPS T1524 15.0 x 2.4d TSPS T16530 16.5 x 2.4d TSPS T20 20.0 x 2.4d Note: It is ok for the pin diameter can be smaller than the hole it goes in to. WP PDS SHOCK NEEDLE TOOL The WP PDS Shock Needle Tool removes the Compression Needle from the shock body on early KTM WP PDS shocks. This is the most economical way to go (see TSPS T Series T-handle version) but only available for the early model. Required to install a SWCN 10 Telescopic Needle (15.0 pin spacing x 2.4d pins).

For later model PDS shocks see TSPS T Series Pin Spanners. TSPS 1524 - PIN SPANNERS RT Pin Spanners have a unique pin design with a reverse taper to keep them from popping out during assembly and disassembly. 2 pins - 4 sizes total: 4.0 / 4.5 and 5.0 / 5.5mm Item Code Fits TMPS 01 4.0 & 4.5 Pin Spanner TMPS 02 5.0 & 5.5 Pin Spanner TMPS P01P 4.0 & 4.5 Replacement Pins TMPS P02P 5.0 & 5.5 Replacement Pins We also offer other Pin Spanners specific to their applications. These include: TSPS Series - for WP PDS Compression Needles TFCH PS24050 - WP KTM 65 Fork Seal Heads TFCW PS38048 - WP 4CS Fork Caps TFCW 50H - WP 50mm Hex & 29 x 4.8 Pin Spanner Fork Caps SHOWA 50mm SHOCK PISTON RING TOOL Allows removal of the stock shock piston without damaging the piston band on late model Suzuki Showa shocks. The tool fills the circlip groove allowing the piston to slide past without damage. Fits 2010 -2011 RMZ250/450.

TSPR 50 – SAG MASTER Voted as Dirt Bike Magazine's 25 Best Tools Ever Invented, the Sag Master is a tool that makes measuring Static 'Race' Sag a snap because you read it directly. No more subtracting!

Also useful in determining proper spring rates and monitoring linkage and seal drag. Comes with instructions and, doubles as a tape measure!

TSSM 01 - T-HANDLE TOOL SET Excellent quality Chrome Vanadium, deep socket, 6 point tools. TTHS 02 - includes 8, 10, 12, 14 and 17mm - FORK BLEEDING TOOL Unique self-starting design easily threads onto the damping rod. Baffled so the oil runs down the rod eliminating the typical mess. Available as a set. (Works great with the TFSC 01 & 02 Spring Compressors for street applications).

TFBT 02S - PRO OIL-LEVEL TOOL Collapsible tube allows setting fork fluid levels with only two hands. Does not require a third hand!

TFOL 02 - GRADUATED CYLINDER Accuratly measures fork oil for filling Twin-Chamber forks. 500cc capacity TFGC 500 - CARTRIDGE ROD HOLDING TOOL The Cartridge Rod Holding Tool allows you to more easily service Showa Twin-Chamber as well as most street cartridge forks. The tool holds back the spring allowing you to get to the bottom nut or the fork cap on the cartridge rod. Plastic design keeps shafts from being marred. TFHP 01 - SHAFT HOLDING TOOLS Holds fork damping rods, cartridges, shock shafts, etc.

Unique design allows installation of dowels into the top of the vise jaws. The holding tools hang on the dowels instead of dropping on the ground when the vise is opened. Item code Fits TFSH 10 10,12,12.5,14mm TFSH 14 14,16,18mm TFSH 20 20,24,29mm TFSH 32 32,35mm TFSH S500 1/2' ALUMINUM VISE JAWS Race Tech Vise Jaws gently, yet firmly, hold fork tubes, fork legs and other round objects in a “V” down to a diameter of 12.5mm (½”). The “V” is offset and overhangs the edge of the standard vise jaw to provide clearance for large diameter tubes. Made to fit 4 to 6.5” Craftsman vises with removable jaws. These jaws have a bolt spacing of both 2.5 and 3 inches and fit other brands.

They can be drilled to fit other makes of vises as well. Pre-drilled for the pins supplied with Race Tech’s Shaft Holding Tools ( TFSH Series). TMVJ 065 - SHOCK SHAFT BUSHING DRIVER SET Used to install shock shaft bushings into seal heads. The set comes with 12.5, 14, 16, and 18mm drivers.

TSBD SET - SHOCK SEAL 'BULLET' Shock Seal Bullet Tools make installing seal heads onto shock shafts quick and safe. They eliminate the possibility of seal damage when installing the seal head onto the shaft.

This tool is a must for serious tuners. Item code Fits TSSB 125 12.5x10mm TSSB 14 14x12mm TSSB 16 16x12mm TSSB 18 18x16mm TSSB 1812 18x12mm YZ RESERVOIR CAP SETTING TOOL This tool is used to tap the bladder cap down to remove the snap ring on late model YZ's eliminating the possibility of damage to the Schrader Valve.

TSRC 01 - 17, 19, 22, 24 mm HEX AXLE TOOL This Axle tool, made of hardened tool steel, fits many sport and dirt bikes. TFHD 1724 - FORK TUBE DISASSEMBLY TOOL Remove and replace fork tubes from fork bottoms (AKA axle clamps, fork lugs, etc). TFTT 01 - DEBURRING TOOL Removes burrs resulting from grinding factory peening during Fork Gold Valve installation. TMBD 08 - COMPRESSION ADJUSTER SOCKETS Used to service shock compression adjusters. Item code Fits TSCA 01 YZ TSCA 19 19mm TSCA 21 21mm TSCA 24 24mm Note: The punch marks at the threads must be drilled 1 mm deep prior to removal.

FORK PRELOAD ADJUSTING SOCKETS Stop rounding off the edges of your adjusters. These sockets allow you to perform fork preload changes more easily. Specially designed for fork preload adjuster size and shape. TFPA 14 - TFPA 17 - FORK CLICKER ADJUSTER TOOL The Fork Compression Adjuster tool is basically a super-stubby screwdriver. It is designed to fit between the handlebar and the top of the fork tube. TFCA 01 - WP 4CS FORK CAP TOOL.

Showa Fork Service Manual

Functions and Roles Shock absorbers consists of spring which determine posture and cushioning buffer action and a damper which suppresses vibration. On 2-wheeled vehicles, shock absorbers are separated into the categories of the “front fork” and “rear cushion”. The front fork:. Front fork serves as rigidity component just like a frame. Vehicle specific rigidity given to present run out while braking and changing the direction of a wheel though handle operations. Maintain balance of vehicle frames stability and secures straight running stability as well as rotationality of the vehicle.

The front fork prevents excessive weight on the front wheel during drastic sudden applications the break, softens bumping when driving on rough road surfaces. The front fork maintains proper damping through traction with the road surface. Types of Shock Absorbers Upright telescopic type Free-valve type Construction is relatively simple, with stable performance. Applied widely from small scooters to large-sized cruiser types.

Cartridge type Constructed with high rigidity and stable damping force. Mainly applied to large-sized on-road models. Inverted telescopic type Big Piston Front Fork Constructed with enlarged piston to improve the responsiveness of damping force, thus demonstrate high performance. Applied to most current large-sized on-road models. S.F.F.（Separate Function front Fork） Constructed with pressure separation damper in one fork and spring in the other fork, this type of flont folk demonstrate high performance by deviding functions. Applied to motocross race models.

This front folk allow for both high damper performance as well as light weight construction. Cartridge type Demonstrates high rigidity and stable damping force through damper construction.Mainly applied to large-sized on-road models. Pressurized separation type By pressurizing the damper improved performance. Applied to motocross race model. SHOWA's Approach SHOWA develops its technology for stock motorcycles based upon feedback gathered from data for 2-wheeled vehicle road races and motocross races. Thanks to recent improvements in dynamic performance, the gripping power of the tires, improvements in the efficiency of the brake system, the increased control of sudden frontal subduction when breaking, as well as increased absorbency of road surface gaps along with a compatible riding comfort, SHOWA has been able to develop its Big Piston Front Forks for road models.

By striving to achieve further improvements to the rear cushion and in tire traction, we have also succeeded in installing the B.F.R. System in bikes for road racing as we aim for mass production. With the large diameter front forks used in off-road models, and with regard to the weight trends of highly rigidity, we have been able to achieve significant weight reductions in our S.F.F. Construction designed to enter the mass market. Through feedback from stock models utilizing performance and functional improvements cultivated from the limits of racing, SHOWA aims to provide shock absorbs that have achieved:. A high level of driving safety. Exceptional riding comfort.

Weight reductions Furthermore, in light of our anticipations for increased future sales expansion in the Asian market, and in order to be able to provide ever more attractive products for our users, we are opening a new R&D facility in Thailand that is to serve as our Asian base. We feel that have been able to prepare an extremely timely development system.