Technical Manual

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.

P1 Introduction



Warning!!
  • 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!!
Please read the instructions before installation.
  • 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.
P2 Important Product Message
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.
P3 Before and After 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.
Removal of the shock absorber Warning!!
  • Remove the nut at the top by depressing the spring with the spring depression tool.
  • When taking out the nut at the top, make sure the spring is depressed and is not in contact with the upper and lower holders.
  • When releasing the spring depression tool, pull the spring out of the shock evenly and carefully.
  • Do not re-use the used nut removed from the cylinder.
P4 Installation of Shock Absorber
Warning!!
  • The adjustable damper uses a hollow cylinder. To protect against damage, be sure to note the torque applied for turning.
  • When tightening the nut at the top, be sure the tool does not contact the adjustment point at the top.
  • After installation, ensure using an adjustment level so that the adjustment scale is truly in a clockwise direction.
  • Adjust it with the adjustment level.
  • Lowering the vehicle with lowest setting of the spring holder may damage the body of the vehicle.
Note!!
  • The shock absorber will be coated with a lubricant at factory to protect against rusting, which is not leaked fluid.
Warning!!
  • After the height is adjusted, be sure that the spring holder has been tightened.
  • Dirt or small pebbles may attach to the spring holders, which may also cause damage.
  • Dirt or small pebbles may attach to the threads of the spring holders, which may cause damage if adjustment is made without clearing them.
P5
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.
P6 Adjustion of Damping after installation
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.
P7 Important note
  • 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.

1
ANTI-RATTLE CLIP  
10
GASKET/WASHER
2
BRAKE PAD  
11
CALIPER MTG BOLT
3
PAD RETAINER BOLT  
12
BANJO
4
BLEED NIPPLES  
13
BRAKE CALIPER
5
CALIPER MOUNTING BRACKET  
14
HOSE LOCATION WASHER
6
OE CALIPER MOUNTING BRACKET  
15
CALIPER MTG BOLT
7
BRAKE DISC MOUNTING  
16
BRAKE HYDRAULIC HOSE
8
BRAKE DISC  
17
GASKET/WASHER
9
HUB      

P8 Production Description
When getting this production, please read this description as follows:
  1. Kits include:
    a.
    2 X Brake calipers with either 6 or 8 pot (pistons)
    b.
    2 X Brake discs
    c.
    2 X Caliper mounting brackets
    d.
    4 X Brake pads
    e.
    2 X Brake hydraulic hoses
    f.
    1 X Workbag
    g.
    X Brochure

  2. When opening the box, please note and see if there are any kits (a-f) missing. If you have those problems, please feel free to contact your retailer immediately.
  3. Before fitting the brake system, a. you have to make sure the measurement of the bolt hose for brake disc and the measurement of the bolt for your caliper mounting bracket are the same. (pic I) b. ensure the central point of the brake disc and that of the brake disc mounting match.(pic B and pic C) c. you have to check that the size of the two holes for the caliper mounting bracket and the hub are the same. (pic F) d. You have to check to be sure the size of the brake hydraulic hose joint connecting to your vehicle is the same as the original joint. (pic H). Normally, the brake hydraulic hose length which is supplied is longer.
  4. Please absolutely verify each step mentioned above then fit the brake system. Returning the goods is unacceptable once the brake system has been fit on the vehicle or any scratches on the goods have occurred.
  5. Upon fitting the brake system correctly, you have to run your vehicle around 10 to 20 miles. Please note and see and hear if there is any unusual noise and/or vibration. Please check that all bolts are tightened.
  6. It is important that new discs and pads are allowed to bed properly for around 300 to 400 miles, during which time you should avoid excessive or hard braking, as this may cause overheating and/or warping of the discs which will seriously affect braking performance.
  7. The product is meant to increase braking performance. In order to obtain optimum performance, our brake pads and brake discs are made from particularly tough material. It is common for a weak squeal of brakes and this will void the warranty.
  8. The brake system is the most important safety system in your car, hence any brake modifications must be carried out by mechanics licensed and experienced in the installation of the brake system.
  9. It is very important for fitting the brake system to have practical experience. Please communicate with licensed technician to qualify the safety. If any problems happen, the installer has to take all responsibilities for them. We only indemnify the value of products.
  10. The fitting methods of brake hydraulic hoses may vary on each vehicle. The technician has to make sure of the angle and the position and/or turn the tires back and forth and vibrate your vehicle to ensure the brake hydraulic hose won’t be dragged and be damaged by your tires. You should fit the brake hydraulic hose by approved methods.
  11. Fitting the brake caliper, please note that the bleed nipple (pic M) should be upturned. Please remember the air in the brake fluid should absolutely exhausted.
  12. It is recommended that the new brake pads and the brake disc are applied during the same application when replacing the worn ones.
  13. You can choose the same applications but different parts by manufacturers, such as AP, FERODO, MINTEX, CARBON METALLIC…. The warranty is void if damaging for discs.
  14. Our discs are all qualified by balance testing. Normally, there are some snicks on the discs. You cannot drill a hole and/or snicks in brake disc unless brake disc lacks balance.
  15. The production of OE hub for each vehicle all has tolerances (pic F). When the hubs are in conflict with the discs, it is possible to alter the hub.
  16. 99% of brake hydraulic hose joints connecting to the vehicle are either raised-type or concave-type (pic H). If you figure out the joint cannot connect to your vehicle, please use the proper adapting joint (pic N) in the workbag to connect onto.
  17. Please replace the brake pads when a minimum of 3mm of pad material is left on the pad. Please replace the brake disc when a minimum of 30.5mm of brake disc is left.
  18. Do not use SILICONE brake fluid.
  19. This product is special design for racing and particular propose and cannot be used for street. You have to change the OE wheel.
P9 Installation Instruction
  • 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 0.25m/m 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.
  • Tightening Torques Table
    Part Number
    Tightening Torques
    D
    68-70 NM
    G
    25 NM
    J
    58 NM
    K
    14 NM
    L
    14 NM
    M
    17 NM
Warranty
Warranty includes any fault in production. After our examination, it shows that most brake systems’ problems (failures) result not from production fault, but from consumers’ misuse or improper installation. Any warranty claim is subject to our examination results. The warranty is void if:
  1. The disc face shows blue/purple marks, meaning overheating.
  2. Brake discs crack owing to misuse or braking at high speed.
  3. While you are washing the car or the car is wading through water, brake systems under high temperature get wet, which will lead to deformation of brake discs and vibration.
  4. Soft sharp noise.
  5. Overuse of brake, and excessive wear of brake pads and brake discs.

All costs of transportation are born by the customer when the products are sent back to the original manufacturer for overhaul during its warranty period. After our examination, no matter if the responsibility (who leads to the failure in the product) comes from the buyer or seller, the manufacturer (the seller) is responsible for sending the product back to the buyer by sea transportation.

During the maintenance period, if it inconveniences you not to have your car driven, the warranty does not cover this part.
Trouble Shooting
  • Fluid Leaking
    • Please check if the joint of the brake hydraulic hose has any foreign bodies or wrong specification. (raised-type or concave-type)
    • It is normal to see a small amount of oil sludge around bleed nipples. If obvious oil leaking is found, disassemble and cleanse the screws, then refit them.
    • Brake systems must be sent back to the original manufacturer if excessive use of it leads the piston to leak oil.
  • Vibration on driving
    • The brake discs and brake discs mounting do not closely fit together at their central aperture. Add a ring of iron to improve that.
    • Take out the brake disc, then revolve it 90o and put it back.
    • If the car’s bushing is worn, please replace it with a new one.
    • Brake systems do not lock-in tightly themselves.
    • Please use the power stabilizer to test and improve.
    • The maximum disc run out must be no more than 0.10 mm (0.004"). The brake discs are handed, therefore it is important to refer to the disc brake identification sheet attached to ensure that the discs are mounted to the correct side of the car.
  • Vibration on braking
    • If the brake disc is overused or when it, in high temperature, gets wet in water, both of the two above conditions will lead to deformation of the brake disc. It must be replaced with new one.
    • If the car’s bushing is worn, please replace it with new one.
  • Unusual noise
    • When you drive forward and brake, it will lead to a loud noise. When you reverse, it will also lead to a loud noise. Noise caused by both of the two above conditions result from the incomplete installation of anti-rattle clips.
    • It is normal to hear soft sharp noise when you brake. Use anti-noise wax.
Racing, Speed, Upgrades, Cars, Performance, Drag, Drifting, K Sport, coilover, Suspension, Dyno, Drag Racing, Car Accessories, Race Parts, Motorsport Racing Development, ADR wheels, ADR, Turbo, Exhaust



All Rights Reserves. A&B motorsport 2008
Web Developed by Fly Design.com.au .