Technical – K Sport

Technical information

The damping setting and spring rate for this product is different from the vehicle’s original shock absorbers. Any shock absorbers can be disassembled completely to change the damping setting. Disassembling the shock absorber also offers a chance for inspection and service to the shock. However, disassembling of the shock absorbers can only be performed by K-Sport’s certified professional technicians.

For detailed information about disassembling service, wages, and time required, please contact your local K-Sport’s dealers.

Suspension

This document is not permitted to be copied in full or partly or to print out.

Removing and installation of relevant brake parts will require specialized technology, and installation of this product shall be performed by qualified professional technicians.

Warning!!

K-Sport will take no liability for any accident, damage or death caused by improper installation of this product or using parts not supplied by our company, or retrofitting this product without our permission.

Do not install this product in vehicles other than those models specified in user’s manual.

Caution!!

Before installing this product please read the installation instructions very carefully.

Before installing this product, ensure all necessary components are available.

Please ensure all K-Sport’s components on the shock body have been secured tightly.

Components that shall be truly secured are: nuts, nuts on eye, upper holder, bracket holder, bolts with horn adjuster (if supplied), and any other parts. Be sure to tighten bolts on upper holder and angular tube of bracket holder.

Warning!!

This product contains high-pressure gas inside. Do not attempt to disassemble this product or put it in the vicinity of fire to avoid the risk of serious explosion. Do not install this product if it is found having been disassembled before.

This product has been designed with reinforcements to be used in vehicles operating on terrain. In addition, this product cannot be modified for any reason.

Warning!!

If the upper holder has been turned with over-torque during removal or installation, the bolt in the shock may be loosened. In addition this may cause damage to the product. When installing this shock, do not overturn with too much torque unless it is absolutely necessary. However, if it must be turned with force, ensure that it is turned with low torque and be sure that the cylinder hasn’t been turned. K-Sport shall not take any liability for loosened bolts caused by over-turning.

When removing or tightening bolts on the upper holder, do not use any tool to clamp the cylinder at the top of the shock or clamp the shock body onto the place where there are treads to avoid scratching.

Do not bump with force and/or impact the shock body (e.g. dropping this product) If the cylinder has been scratched, the seal may be damaged and cause the shock to leak.

To increase the product durability and performance, the outer diameter usually is greater than that of the original shock absorber. Some shock absorbers do not contain boots due to space limitation for a boot. For the product without a boot, we suggest the surface of the cylinder be cleaned regularly and check the shock periodically to ensure the performance and increase the lifespan of the product.

Please note that dirt and small pebbles may damage the cylinder.

All K-Sport’s products are used for racing cars, vehicles operating on non-normal road conditions and also vehicles for demonstration purpose.

K-Sport’s products should not be used in vehicles operating on normal road conditions.

K-Sport will hold no liability for the ban of this product due to local regulations or laws.

Vehicles with this product running on normal highways may cause damage or violate local regulations.

The purchasers shall bear full liability for the component installation.

All components must be installed by certified professional technicians.

K-Sport will hold no liability for any damage or death caused directly or indirectly from this product.

K-Sport will hold no liability for any installation error, including errors due to inadvertence.

D is used as the retaining tab for brake lines or ABS wiring, you can take liberty to install the brake fluid line by changing the angle.

E is the spring rubber attached to the shock absorbers of the MacPherson type suspension. To avoid noise, this spring rubber must be fitted. The rubber should closely contact with the spring and the spring holder. It will be automatically engaged when the vehicle is lowered. Installation of this component is a must !

• Please ensure the lower bracket is tighten before driving.
• Please do not use the adjustment wrench to lock the lower bracket, the adjustment wrench is for adjust ride height. If the lower bracket is tighten by the adjustment wrench, the unusual noise will happen again after 7~20 days.
• Please use the screwdriver and hammer to knock the lower bracket at the following picture, and stick with the tape to avoid the unusual noise.

Installation

Warning!!

The operator shall install this product correctly and properly. Before installation, please read the instructions carefully.

• When installing this product, the operator shall wear gloves to avoid the risk of hand injury. The upper holder used in this shock must be K-Sport’s original component. This shock absorbers may not be compatible with the upper holder of other brands.

• K-Sport shall not take any liability for damage to the shock or accidents that are caused by connecting the upper holder of other brands with this shock.

• Be sure to observe local relevant vehicle regulations about usage of adjustable shock absorbers. (For example, height limit, headlight ground clearance limit)

• K-Sport shall hold no liability for any violation against local vehicle regulations or laws.

• According to the installation instructions, avoid uneven road surface and driving at low speed.

• Ensure that components of the product are not loosened or oil is not leaking.

• Tighten all components with specified torque periodically.

• When a suitable height is determined it shall be tested and calibrated on straight line.

• The vehicle should go to a specified workshop or a commissioned vehicle calibration center to adjust the calibration.

• Please raise the car and remove the OE brake caliper and the brake disc.

• Use emery paper to clean the brake disc mounting faces (pic A) or use a blade to remove rust and then make sure all faces of the brake disc mounting are clean.

• The antirust grease spreads over the brake disc when the product leaves the manufacturer. Please clean oil sludge on the surface of it for fear of permeating the grease into the brake pads, in order to avoid causing unusual noise and a peculiar smell.

• Afterwards, please fit the brake disc in the car and ensure the central point of the brake disc and that of the brake disc mounting match (pic B and pic C).

• The new caliper mounting bracket needs to be bolted to the location points on the OE caliper mounting bracket and then all bolts must be tightened by using recommended torques. Please note the length of the bolts and spec. for thread must be proper. (pic D).

• Bolt the brake caliper to the caliper mounting bracket.

• Measure the distance on all sides between the 2 brake pads and the brake disc.

• Due to the fact that location points on the OE caliper mounting bracket have tolerance, please check whether the brake disc is central in the caliper pathway. If not, realign the brake caliper and the brake disc to the optimum position by putting the washer that is 0.25mm between the caliper and the caliper mounting bracket, or between the caliper mounting bracket and the hub. (pic E and pic F). Please note that 2 washers at most can be stacked off one bolt and two bolts should be fit.

• The brake disc should be flush with the brake disc mounting before the measurement of the relative distances between the brake caliper, the brake disc and the caliper mounting bracket are taken.

• The bleed nipples must be located at the top of the brake caliper when it is fitted to the vehicle.

• Please note the washer should be put onto the banjos (pic G) and tightened when the brake hydraulic hose is connected.

• Connect the brake hydraulic hose to the vehicle and tighten it.

• The same car model made in different countries may require different specifications for the brake hydraulic hose joint. The technician should note if the brake hydraulic hose joint which is connected to the vehicle is either raised-type or concave-type for all car models (pic H). These two types of adapting joints are supplied with the kit so the technician is able to decide which type of the adapting joint is required. (pic. N)

• The method of fixing the brake hydraulic hose attached to the hub is not exactly the same as where the OE location has been provided. The tool bag has 2 pcs of 8-type iron strips and 2 pcs of long fixing strips. The technician is able to alter the angle that is required. Upon completion of fitting, close the indentation of the 8-type iron strips by using the particular tools. (pic. P)

• The U-type strips supplied in the tool bag are used to fix the brake hydraulic hose. The U-type strips are not applicable for all vehicles; therefore, the technician can decide to fit it or not depending on the application.

• No matter how the technician fixes the brake hydraulic hose by any means, the technician should verify the brake hydraulic hose will not be affected by the hub direction or the shock absorbers stroke.

• The initial temperature of the brake pads is 50°C and the highest is 800°C. It’s essential to get the vehicle driven for around 1 – 5 kilometers in either cold or snowy weather until the brake pads reach the standard temperature. This will bring the brake to its best performance.

Tighten Torgues Table
Part Num. Tightening Torque
D 68-70NM
G 25NM
J 58NM
K 14NM
M 14NM
L 17NM
Caution!!

If the component cannot be turned smoothly, add some lubricant. To prevent sticking of the spring holder, we suggest that the components be checked and serviced periodically.

Warning!!

After adjusting the height, make sure the spring holder has been tightened. If not, it could cause damage to the vehicle.

• After putting on tires, measure the distance from the tire center to the fender of the vehicle (as shown in illustration and make sure the distance meets the following data:

Warning!!

Data should be selected based on model and weight of the vehicle. Warning!!

• There is correlation between vehicle height and the spring rate.

• Ease of lowering vehicle varies depending on spring rates.

• The ground clearance of the vehicle will always be renewed after the spring is replaced.

• If the selected spring rate is smaller than the standard it is possible the spring holder may need to be adjusted.

Adjustment

Caution!!

To prevent sticking of the spring holder, we suggest that the components be checked and serviced periodically.

Warning!!

After adjusting the height, make sure the spring holder has been tightened. If not, it could cause damage to the vehicle.

• After putting on tires, measure the distance from the tire center to the fender of the vehicle (as shown in illustration and make sure the distance meets the following data:

Warning!!

>Data should be selected based on model and weight of the vehicle. Warning!!

• There is correlation between vehicle height and the spring rate.

• Ease of lowering vehicle varies depending on spring rates.

• The ground clearance of the vehicle will always be renewed after the spring is replaced.

• If the selected spring rate is smaller than the standard it is possible the spring holder may need to be adjusted.

• If the component cannot be turned smoothly, add some lubricant.

When K-sport damper leaves the factory, its dampening force is not preset in a specific position.

• Turn the supplied adjustment knob clockwise to increase dampening force.

• Turn the supplied adjustment knob counterclockwise to decrease dampening force.

Warning!!

• Do not turn the adjustment knob exceeding the limit.

• Turing the adjustment knob exceeding the limit may cause damage of the damping setting.

Standard Setting

Front: using the adjustment knob to turn it clockwise to the stiffest and then move backward for one turn.

Rear: using the adjustment knob to turn it clockwise to the stiffest and then move backward for two turns.

Warning!!

• When adjusting according to driving a specific vehicle (for example, on race track), it is possible to make an asymmetrical setting for the right and left dampers.

• If it is uneven longitudinally, adjust only the front or rear damper.

• In some vehicles, you may need to remove the interior components before making the adjustment.

• When adjusting the damper, you may wish to modify the interior equipment of the vehicle.

• When it is necessary to adjust the damper, you may need to drill holes in the interior of the vehicle.

  • Please read all instructions completely before installation and save this manual for future use.
  • It is highly recommended that the installation of this product be carried out by a licensed and/or experienced technician or mechanic.
  • Verify that all parts are included before installation of this product.
  • Verify that all components are tightened.
  • A & B Motorsports assumes no responsibility for damage, accidents, injuries or death resulting from installation, assembly, misuse, and/or modification of the product.
  • These products may not be legally used on public roadways depending on ride height regulations and coilover restrictions for each country or municipality, and A & B Motorsports takes no responsibility for any violations of traffic rules, laws or regulations. Insurance coverage may be affected by installation or use of these products.
  • Periodically clean the piston rod shaft as dirt and grit may cause scratching.
  • Inspect the shock absorbers regularly.
  • Because this system contains highly pressurized gas, do not expose it to flames to avoid an explosion.
  • Do not modify and/or disassemble the shock absorber system in any way. Doing so may damage this coilover system and will void the warranty.
  • Do not cut or modify the bump stop in any way. Doing so may damage this coilover system and will void the warranty.
  • The installer assumes all responsibilities and liability for proper installation of this product. Please read all instructions completely and understand them well.
  • Please refer to the manufacturer’s instructions for factory strut removal.
  • Do not re-use the piston rod top lock nut unless specified.
  • After the machining process, a special coating is applied to the shock body to prevent corrosion. This is not oil leakage.
    • Be very careful with the application of torque when using an impact wrench as improper torque application may cause the piston rod damage.
    • We offer two types of the lower mounts:
    • For the lower mount with the brake line bracket – attach the brake lines and ABS harnesses to it (Diagram 1).
    • For the lower mount without the brake line bracket – the brake line brackets are supplied in the tool kit.
    • The provided brake line brackets and O-rings are attached to the brake lines or ABS brake harnesses (Diagram 2).
    • k The brake line brackets can be adjusted or altered to make sure the brake lines are secured and fixed safely.
    • l Turn the wheels to their full lock to verify the brake lines are in the right position, and if the brake line brackets will clear the tire and brake lines.

Diagram 1

Diagram 2

  • Be sure all parts are installed and torqued to manufacturer’s specifications.
  • A wheel alignment is required after complete installation of your K SPORT Coilover system.
  • The ride height adjustment range may vary depending on the vehicle model, weight, engine size, wheel size and other related factors.
  • The vehicle’s minimum ride height is related to the spring rate.
  • Be sure to clean grit and dirt from the threaded shock body before adjusting ride height as the dirt or grit will cause the spring seat, locking ring or lower bracket to stick.
  • Replacing the wheel and lowering the jack may be required repeatedly to check ride height, so the desired ride height is reached.
  • Unless otherwise instructed, use the lower bracket (D) to adjust the vehicle ride height.
    HOW TO ADJUST RIDE HEIGHT
    n) FOR APPLICATIONS WITH ADJUSTABLE LOWER BRACKET (D) The correct spring preload needs to be checked before the Coilover kit is going to be installed in the vehicle. Do not attempt to adjust the vehicle ride height via the spring seat (A) and the spring seat locking ring (B). (Please refer to DIAGRAM 3).

Diagram 3

Do not attempt to adjust the vehicle ride height via the spring seat (A) and the spring seat locking ring (B).

  • ‚ The vehicle ride height is adjusted through the lower bracket (D). Thread the lower bracket (D) upwards to lower, and downwards to raise the vehicle’s ride height.ƒ Use the locking ring for the lower bracket (C) to tighten the lower bracket (D). It is highly recommended that a hammer or a mallet to be used (Please refer to DIAGRAM 4), or a torque wrench be attached to the wrench supplied with the kit to tighten the locking ring for the lower bracket (C). (Please refer to DIAGRAM 5, and the 70Nm-80Nm torque is recommended).

Diagram 5

Diagram 6

FOR APPLICATIONS WITHOUT ADJUSTABLE LOWER BRACKET
(D) (shock separate from spring)

Lowering the vehicle ride height:
shorten the distance (A) and distance (B)

Raising the vehicle ride height:
extend the distance (A) and distance (B)

It’s essential that BOTH distance (A) and distance (B) be adjusted when adjusting the vehicle ride height.
If you ONLY adjust the distance (A), the spring will be hung in the air or be compressed, this will cause shock noise or result in the vehicle being very bouncy. Doing so will damage the shock strut.

lease check the shock stroke after the desired vehicle ride height is reached. We highly recommend you to leave 2/3 of the shock stroke minimum outside of the shock body (multiply “shock stroke” by .667) for the normal operating safety range.

HOW TO ADJUST REAR SHOCK STROKE (for applications without adjustable lower bracket (d) or with shock separated from spring(non-coilover strut type))

※ Please skip this section if your K SPORT coilover system comes with the rear lower bracket (d).

1) If no upper mount is included with your K SPORT Coilover kit, mount the original equipment (O.E.) rear top mount to the K SPORT rear shock, and use the O.E. nut to secure the O.E top mount.

2) Adjust the Hi-Low Kit and spring to the desired vehicle ride height. Then install the rear shock to the vehicle. Adjust the rear shock via the lower base so that it will fit without compressing the spring. (some models do not come with the lower base) If no upper mount is included with your K SPORT Coilover kit, mount the original equipment (O.E.) rear top mount to the K SPORT rear shock, and use the O.E. nut to secure the O.E top mount.

Note: The desired vehicle ride height must be adjusted by the Hi-Low Kit and the spring first before the rear shock is installed in the vehicle. (The installation steps mentioned here must be in order).

3) Once installed, measure the shock stroke (chrome section), and record this number as “A”. In general, this number is 100mm ~ 140mm.

4) Replace the wheel and tire, and jack up the car on the stand then measure the distance between the fender and the tire shown in the picture, then record this number as “B”.

Note: In this step, the car must be off the ground with nothing obstructing normal operation of the shock.

5) Lower the vehicle to the ground and measure the distance between the fender and the tire, record this number as “C”. Subtract C from B and record that number as “D” (this is an amount that shock cylinder goes into the cartridge)

Note: For normal shock operation, D must approach or be equal to one third of A; also, D must be in range of 30mm ~ 50mm.

Example: If A = 10cm, B = 5cm and C

= 2cm then D (shock travel length) =

3cm (5cm – 2cm), and 3cm approaches to one third of A

(3.33cm), and it is also in the range of 3cm ~ 5cm. So in this example the shock travel length is in normal operating range.

6) After the rear shock stroke is adjusted correctly, you can start adjusting the damping setting (damping adjustment method may vary depending on the applications). According to our testing, we recommend you start at the softest setting (all the way counterclockwise) turn the adjustment knob to ‘H’ direction between 6 – 12 clicks, which is the most suitable setting for paved surface use.

Note: The recommended damping setting mentioned above is just for your reference. You can adjust the damping knob to any setting you desire.

Each damping adjustment setting from 0 – 33 is discrete even though changes may not be felt in the vehicle.

A) when the car is jacked up

A) when the car is on the ground

7) Easy Adjustment Method for Rear Shock Stroke in no- coilover strut type

Put the vehicle down the ground after the vehicle ride height you desire is adjusted. Release the handbrake. Measure the distance between the fender and the tire shown in the picture (B), it is about 30mm ~ 40mm.

  • when car is jacked up
  • when car is on the ground

Jack up the car off the ground, then measure the distance between the fender and the tire shown in the picture (A), the measurement is about 70mm ~ 80mm.

Once the shock stroke adjustment is incorrect, re-adjusting the lower base to get the correct shock length is required.

NOTE: If incorrect shock stroke occurs, this would cause damage to the shock and even oil leaks.

The vehicle ride height is adjusted by the Hi-Low Adjuster, and vehicle ride height adjustment has nothing to do with shock stroke.

  • K SPORT Coilover kits features 33 level of adjustable damping settings. The damping force is not preset.
  • Four adjustment knobs are supplied in the tool kit.
  • Insert the adjustment knobs into the top of the each coilover.
  • Do not turn the adjustment knob past the last setting. Doing so will damage the coilover system.
  • The damping setting of the front and rear coilovers can be at different settings; however, the damping setting of the left and right coilovers on the same axle should be the same to avoid uneven tire wear and incorrect handling balance.
  • It is recommended that the vehicle be driven at the standard damping setting for daily use.
  • Damping adjustment method may vary depending on the applications.
  • Some vehicle parts and/or interior panels or shock itself may have to be removed to adjust the damping force.
  • Cover the adjustment holes if the adjustment knobs are not inserted into the top of the coilovers.

HOW TO ADJUST THE DAMPING FORCE

■ FOR THE HARDEST SETTING – turn the adjustment knob fully clockwise.

■ FOR THE SOFTEST SETTING – turn the adjustment knob fully counterclockwise.

■ FOR STANDARD SETTING:

FRONT Turn the adjustment knob to 12 clicks from the softest setting
REAR Turn the adjustment knob to 8 clicks from the softest setting

Note: The recommended damping setting mentioned above is just for your reference. You can adjust the damping knob to any setting you desire.

Each damping adjustment setting from 0 – 33 is discrete even though changes may not be felt in the cabin.

  • A&B Motorsports warranties the street shock insert for 12 months from the date of purchase (inserts used in racing applications are not covered under any warranty). All products sold are new and fully inspected to be free from defects in materials, manufacturing and workmanship at the time of delivery.
  • Any products sold can not be returned to the manufacturer unless specify arranged otherwise.
  • A&B Motorsports. will inspect and determine whether the products are defective before any warranty claim is issued. Warranty inspection results will be based on the findings/ data of the A&B Motorsports Technician.
  • During warranty period, the loss of time, labor cost, transportation charge, commercial loss, inconvenience

and loss of use of the product or vehicle is not covered.

  • Squeaking noise may occur in rare cases from the shock absorbers and this is normal, hence the product warranty does not cover any noise issue. Most coilover kits are fitted with pillow ball upper mounts to improve handling; however, pillow balls on some applications may create rattling sound. This is normal and does not affect the product’s performance. The product warranty does not cover any rattling sound issue caused by the pillow balls. (Hardened rubber upper mount without pillow ball is also available. Hardened rubber upper mount is offered for noise reduction).
  • The spring bearing is a consumptive product such as pillow ball bearing, rubber bushing, brake pads, brake rotor, oil seal etc.., and it will be worn out or deformed after having been used for a certain period. Therefore, the warranty does not cover spring bearings or metal shims that go on top and bottom of the spring bearings.
  • A&B Motorsports reserves the right to product’s design and change for improvements without notice.
  • A&B Motorsports assumes no responsibility for any accidents, injuries, damage or death caused directly or indirectly by the product.
  • A&B Motorsports. will not take any responsibility for errors and/or omissions in these instructions.