Mod. ISTRUZIONI KIT_DS Rev.

00 del 17/04/2018

INSTALLATION MANUAL
Code: H0152DST216
Model: HONDA CRF1000L AFRICA TWIN /
DCT ABS
Rev. 00 Mod. ISTR. MONT. DS
Date: 29/03/19 Pag. 28 / 54

SERIAL N°:

(SEE PAGE 1)

TO BE MENTIONATED IN CASE OF CLAIM

FIRST YOUR SAFETY !

The Sospension KIT is an important component of the motorcycle and this
manual describes the correct way to assemble it.

NOTE: The Sospension KIT must be installed exclusively in a specialised

workshop; if you have any doubts regarding these instructions, please contact
a Bitubo engineer straight away.

Bitubo cannot be held responsible for any modifications to the Sospension KIT
not described in this handbook or not authorised in writing. Moreover Bitubo
cannot be held responsible for the incorrect installation of Sospension KIT.

Read this handbook carefully so that you can get the best performance and
efficiency out of the Sospensions.

NOTE: The warranty for the Sospension KIT will be

invalidated by incorrect installation or modifications
carried out without Bitubo’s written authorisation.

Bitubo cannot be held responsible for any damages to

the product or injuries to people if the instructions of
this handbook are not followed to the letter or if the
KIT is not fitted in a specialised workshop or by
qualified personnel.

BITUBO RECOMMENDS

Pictures and notes reported are purely as an indications; Bitubo s.r.l. reserves the faculty to make any modification or changes.

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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

INSTALLATION MANUAL INDEX:

Index

Presentation of the products…………………………………………………….………….………………...30

Precautions and safety..………….…………………………………………………………….……………..30

DigiShox components……………………………….………………………………………………………...31

DigiShox installation………………………….………………………………………………………………..32

Wiring and Control units………….…………………………………………………………………..32

Introduction………….………………………………………………………………………...32
Installation……….…………………………………………………………………………….33

Front cartridges………………………………………………………………………………………..37

Base setting…………………………………………………………….……………………..37
Compression & Rebound adjustment………………………………………………………38
Fork slipping adjustment……………………………………………………………………..38
Spring preload adjustment…………………………………………………………………...39
Installation……………………………………………………………………………………..40

Rear shock absorber………………………………………………………………………………….45

Base setting……………………………………………………………………………………45
Compression & Rebound adjustment ……………………………………………………...46
Spring preload adjustment …………………………………………………………………..46
Length adjustment…………………………………………………………………………….47
Installation …………………………………………………………………………………….49

Verifica e regolazione del SAG pilota………………………………………………………………………..53

Manutenzione e controlli periodici …………………………………………………………………………...54

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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

PRESENTATION OF THE PRODUCT

The Bitubo DigiShox DS system is a cutting-edge product that incorporates high technology, high performance
and simplicity of interaction for use on the track, road and off-road.
The innovation introduced by this Sospension KIT (front cartridges, rear shock absorber and control unit)
consists in a very-quickly and efficient electronic management of the compression, extension and spring preload
adjustments.
The Bitubo JBH cartridge, on the front, is equipped with hydraulic spring preload adjustment and electronic
adjustment of compression and extension.
The Bitubo XXT shock absorber, at the rear, is equipped with electronic adjustment of compression, rebound
and spring preload.
The electronic regulation takes place thanks to the use of micro-motors that allow a very high regulation speed.
The control unit is equipped with 9 settings preset by the House, not editable. You can add other 3 customized
settings by the appropriate application, downloadable from the most known Appstore in your smartphone.

PRECAUTIONS AND SAFETY

Before removing the motorbike fork, take note of the sag values and fork assembly position compared
to the steering plates, in the currently used configuration.
To identify the adjustment position, see photo on page 37.

Before mounting the shock absorber on the bike, take note of all values of sag, length, hydraulic
adjustments and mounting position of the bike fork as standard configuration. Check that Bitubo base
setting (length, spring preload and hydraulic adjustments) is according to the data written on the chart
at page 45.

Once the shock gets installed, check that there are no interferences with the frame of the bike or
moving parts.

Considering that during the production steps the shock and the fork are lubricated, you could find out some
trace of oil and grease on the suspension.

WARRANTY
Bitubo cannot be held liable for product installation operations other than those described herein. Furthermore,
Bitubo cannot be held liable for any modifications to the product not described in this manual or not authorised
in writing.
Read this manual carefully to obtain the best performance.

The product warranty will be invalidated by incorrect installation or modifications carried out without
Bitubo’s written authorisation.

WARNINGS
- The Bitubo shock absorber contains pressurised nitrogen gas.

- If no specific mounting instructions are supplied, observe the procedures described in the Technical
Manuals of the motorbike Constructor.

- Please keep this manual in a safe place since it contains information on the initial set-up in addition to
the serial number to be used for warranty service.

BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75 30
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

DigiShox COMPONENTS LIST

The System is composed by the following components:

A. 1 Led Panel (Trident): Coloured leds F. 1 KIT JBHG1: Fork cartridges with
dashboard. electronically controlled hydraulic
adjustment; hydraulic spring preload.
B. 1 Selector: Handlebar selector.
G. 1 KIT XXTC1: Rear shock absorber
C. 1 CPU (Neptuny): Adjustment unit with electronically controlled hydraulic
control. adjustment; electronically controlled
hydraulic spring preload.
D. 1 GPS sensor (E-Shark).
H. IOS / Android App for the
E. 1 Wiring: Plug and play wiring. customization of the adjusment.

A B C
F
AB
C
D E

D F G

31
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

WIRING and CONTROL UNITS

WARNING:

- Before the installation of the Bitubo Wiring it is advised to disconnect the vehicle battery.

- The Bitubo Wiring is equipped with identified connectors.

This system speeds up and simplifies the placing of the connectors in the vehicle.

- Do not allow that the Bitubo Wiring be crushed while the fuel tank mounting.

- The Bitubo wiring must be arranged so as not to be forced (pulled) or crushed during the steering
movement.

- The Bitubo wiring must not interpose with the clutch control wire and the accelerator control wires.

Bitubo Wiring is composed by 3 parts:

a. MAIN WIRING
b. CONNECTION WIRING (LINEA CAN-BUS)
c. POWER SUPPLY WIRING

b c
a

Bitubo wiring assembly:

1) Connect the MAIN WIRING to the POWER SUPPLY WIRING by the connectors identified with the
name: “NEPTUNY-POWER”

MAIN
WIRING

POWER SUPPLY
WIRING

2) Connect the MAIN WIRING to the CONNECTION WIRING by the connectors identified with the
name: “CAN-BUS”

MAIN
WIRING
CONNECTION
WIRING

32
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

INSTALLATION OF THE BITUBO WIRING ON THE VEHICLE:

1) The Bitubo wiring must be arranged, if possible, next to the main motorcycle wiring, so as to place
the CPU in the area of the pigtail / underseat and the battery power cables in the battery
compartment.

C
F

a. Orient the wires with connectors identified with the following names towards the forecarriage of the
vehicle:
- COMPRESSION FRONT
- REBOUND FRONT
- TRIDENT

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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

b. Orient the wire with connector identified with the following name towards the rear area of the vehicle:
- GPS

c. Orient the wires with connectors identified with the following names towards the central area of the
vehicle:
- COMPRESSION REAR
- REBOUND REAR
- PRELOAD MOTOR (IF PRESENT)
- PRELOAD ENCODER (IF PRESENT)

2) The system powered occur by 2 BLUE wires (-) and 2 BROWN wires (+):
a. The BLUE wires have to be connected directly to the negative pole of the battery.
The BLUE wire paired to the BROWN wire without fuse could be connected to any
GROUND CABLE via current stub
b. The BROWN wire with the FUSE must be connected to the positive pole of the battery.
c. The single BROWN wire must be connected via a current stub to a + 12v wire controlled
by an ignition key near the battery compartment, or in any case a comfortable position to
work on.

34
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

Positive wire
(with FUSE)

Negative wire

a b

+12V wire controlled

by an ignition key

Positive wire
(without FUSE)
c
3) The Led Panel (TRIDENT) Bitubo has to be placed and fixed near the dashboard of the vehicle or
above the upper plate. It has to be visible during the riding.

LED PANEL
(TRIDENT)

BITUBO
WIRING

35
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

4) The Selector (SWITCH) Bitubo has to be placed on the LEFT side of the handlebar between the grip
and the controls. Place it in a pratical and confortable position.

LED PANEL
(TRIDENT)

SELECTOR
(SWITCH)

5) The GPS sensor (E-Shark) Bitubo has to be placed on the rear side of the vehicle (ex. rear tail). It is
not necessary that the sensor is exposed, it can also be placed inside the fairing.

For the position of the GPS sensor (E-Shark) refer to the scheme here below:

GPS
FORECARRIAGE

(E-SHARK)

MAX +20°

0° BITUBO
WIRING

min -20°

36
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

FRONT FORK CARTRIDGES

Sfilamento
Cost. Molla Regolazione Differenza interasse
Livello forcella
Gambale Cost. Molla interna Precarico Smorzamento dall’originale
olio Fork
forcella Setting Spring rate Top out Preload Damping Length difference
Oil level strip out
Fork leg [kg/mm] Spring rate [mm] Adjuster From the original
[mm] Q
[kg/mm] [clicks] [mm]
[mm]

COMP. GR50230 0,60 0,45 5 10 120

Orig. 0
REB. GR50229 0,60 0,45 5 11 120

Precarico molla
(pomello di comando)
Spring preload
(adjuster knob)

Identificazione regolazione
Compressione (GIALLO)
Compression adustment
Identification (YELLOW)

Identificazione regolazione
Estensione (BLU)
Rebound adjustment
identification (BLUE)

Precarico molla
(pomello di comando)
Spring preload
(adjuster knob)

37
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

CARTRIDGES ADJUSTMENT
Spring pre-load and hydraulic compression and rebound regulations are found on the upper cap. The two
cartridges perform separate hydraulic functions: the cartridge with the yellow identifier performs hydraulic
compression while the cartridge with the blue identifier performs hydraulic rebound.
Thus is it normal that hydraulic rebound force is not felt when the fork leg on which the compression
cartridge is installed is compressed and vice versa for the rebound fork leg.

HOW TO ADJUST THE FORK CARTRIDGES

The hydraulic adjustments of Compression and Rebound are electronically adjusted by Bitubo Digishox
system.
For all the functionality, refer to the "System User's Guide".

FORK SLIPPING ADJUSTMENT

The Bitubo cartridges are of the same length (at maximum extension) as the original cartridges, since
equipped with internal spring. Bitubo also supplies cartridges with lengths other than the original.
In these cases, the "distance difference from the original" value is indicated in the "base setting" table on
page 37.
Thus, restore the correct front axle height (see drawing below):
the Q quota is indicated in the “base setting” table on page 1:
Q = orig.  the measurement is like the original assembly (refer to the vehicle technical manual).
Q = value (example: +/- 5mm)  change the original fork slipping by the indicated value.

GAMBALI FORCELLA
FORK ROD Q

PIASTRA FORCELLA SUPERIORE

UPPER FORK PLATE

WARNING: The riding quotas are the result of long tests by the manufacturer, and the Q quote
was set to provide safe manageability and stability. A 2 or 3mm adjustment changes the vehicle's
behaviour.
Changing the Q quote changes some riding quotas recommended by the vehicle manufacturer and can
reduce vehicle stability, both when riding and parking (on the central or lateral stand), jeopardising riding
behaviour and safety.

INTERASSE / LENGHT

ESTENDERE CON FORZA = 30Kgf

EXTEND WITH FORCE = 30Kgf

38
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

SPRING PRE-LOAD ADJUSTMENT

The adjustment range is 12mm (12 clicks).

Each click (½ adjuster knob turn) corresponds to 1mm spring pre-load.

1 complete turn (2 clicks) = 2mm

To increase the spring pre-load value rotate the adjuster knob clockwise. To decrease the pre-load value,
rotate it counter-clockwise.

For better handling of the preload adjuster kno, you can use the tool (cod. 00416) included in the Cartridge
Kit.

ATTREZZO / TOOL:
00416

The pre-load values are as important as the fork slipping quota. Pre-load set the bike height off the ground
and the dynamic trim in curves thus the fork angle, front axle values, etc., that characterise vehicle
behaviour. Generally, the optimal pre-load values range from 3 to 8mm. To optimise the pre-load
adjustment, see paragraph "SAG ADJUSTMENT AND MEASUREMENTS".

WARNING: this type of fork cartridge is equipped with an internal spring. Thus, check the fully
extended suspension measurements not only lifting the bike off the ground, but forcing the
suspension, extending them, to fully compress the internal counter-spring.

Spring pre-load is the crushing it suffers when installed on the cartridge  PRELOAD=F-M

F
M

39
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

MOUNTING INSTRUCTIONS

WARNING:

- The upper cap of the cartridge is not tightened by Bitubo since it must be removed and
subsequently tightened for assembly.

1- Safely position the vehicle making sure the front wheel is off the ground, use a suitable tool to work
on the fork free of restrictions.
2- Find the Q quote indicated in the table in paragraph “FORK SLIPPING ADJUSTMENT” on page 5
and refer to the indicated technical recommendations.
3- Loosen the upper steering plate screws that secure the fork legs (indicated with the arrows in
illustrative example photo 1) and loosen the upper original fork caps 1 turn.
1

4- Remove the fork legs from the vehicle: to remove the fork legs and original parts, follow the vehicle
manufacturer's instructions (User/Maintenance handbook - Garage Manual).

OPERATIONS ON BOTH THE FORK LEGS

5- Secure the fork foot in a clamp being careful not to damage it (we recommend using a clamp with
soft aluminium or plastic jaws).
6- Unscrew the upper fork leg original cap, loosened to point 3 of the outer tube.
7- Slowly lower the outer tube and unscrew the cap from the rod inside the cartridge and remove it (see
example in photo 2).
2

8- Remove the spacers and the original spring.

9- Remove the original cartridge complete with all its components and separate the outer tube from the
stem; given the variety of forks, refer to the vehicle manufacturer's instructions (User/Maintenance
handbook - Garage manual).

JBH CARTRIDGES INSTALLATION PROCEDURE

10- It’s suggested to place on the stem of one of the two fork legs a fork stroke reference ring.

11- To re-insert the outer tube in the rod, given the variety of forks, refer to the vehicle manufacturer's
instructions (User/Maintenance handbook - Garage manual).

N.B.: For better sliding, we recommend you check outer tube-stem bushing play: upper bushings
from 0.10 to 0.15 mm, lower from 0.08 to 0.12 mm. Otherwise the bushings must be adjusted or
replaced. In alternative, see the Bitubo catalogue to check whether the “KITS” sliding kit made up

40
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

of bushings with tolerances already optimised by the Bitubo Race Department and high sliding oil
guards can be applied.
When assembled, adequately grease with the specific Bitubo grease, code 997608.

12- Remove the upper cap, the spacers (if used) and the spring from the JBH Bitubo cartridge: to make
easier the operation hold the lock nut with the tool 00531, after that unscrew manually the upper
cap.(photo 3).

In some cases the springs are not mounted in the cartridges but inserted in the shipment box.

WARNING: once the upper cap is removed, do not touch the adjuster knobs.

TAPPO SUPERIORE
UPPER CAP

CONTRODADO 00531
LOCK NUT

MOLLA
SPRING

13- Insert the cartridge in the fork and secure it with the orignal Allen screw and washer. To facilitate the
operation is recommended to use a low intensity impact wrench.

WARNING: Insert the compression cartridge on the left and the rebound cartridge on the right.

VITE E RONDELLA ORIGINALI

SERRARE CON FRENAFILETTI TIPO LOCTITE 243 O
EQUIVALENTE: 30Nm
ORIGINAL SCREW AND WASHER
TIGHTEN WITH TREADLOCKER AS LOCTITE 243 OR SIMILAR: 30Nm

14- Bring the outer tube to the maximum compression position. Put BITUBO oil 997630 ISO 22 untill the
level is over the cartridge body.

41
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

15- With the tool 00512 perform some compression-extension movements of the piston rod to facilitate
the filling of the cartridge and to drain any air.
During the filling operation continue to put oil until the piston rod make fluid movements, that means
the cartridge has been correctly filled.
Leave the cartridge to stand for a few minutes and check the fluidity of movements.

5 00512

OLIO /
OIL

ASTA POMPANTE
PISTON ROD

16- Move the piston rod to the maximum compression position. Check the oil level from the edge of the
outer tube. The oil level is reported in table in page 37.
If necessary, restore the oil level.

00512
6

LIVELLO OLIO
OIL LEVEL
ASTA POMPANTE
PISTON ROD

FODERO
OUTER TUBE

17- Perform some compression-extension movements of the outer tube and re-check the oil level
repeating the operations of point 16.
18- Insert the spring, removed in point 12 (end with engraved constant elastic K towards the cap).
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

19- Hold and extend the piston rod with the tool 00512 so keep the lock nut with the tool 00531. After
that removed the tool 00512.
7
00512

00531

ASTA POMPANTE
PISTON ROD

20- Screw manually the upper cap on the lock nut until il reaches limit stop.

TAPPO SUPERIORE
UPPER CAP

CH24

00531

CH13

21- Tighten the lock nut to the upper cap. Tighten to 9 Nm.

CH24

00531

22- Bring the outer tube towards the upper cap. Screw the upper cap without tighten.
43
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

10

TAPPO SUPERIORE
UPPER CAP

FODERO
OUTER TUBE

23- Reassemble the fork legs on the bike following the instructions in the vehicle manufacturer's Garage
manual. Restore sliding Q indicated in the table on page 37 and tighten the screws of the lower
plate.

24- tighten the upper caps to the torque of 15Nm using the tool 00398. After that tighten the screws of
the upper plate.

11

00398

SERRARE A /
TIGHTEN TO:
15Nm

25- Connect the cartridges connectors to the Bitubo wiring:

a. COMPRESSION cartridge connector to the Bitubo wiring connector identified as

“COMPRESSION FRONT”.

b. REBOUND cartridge connector to the Bitubo wiring connector identified as “REBOUND

FRONT”.

44
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

REAR SHOCK ABSORBER

Precarico
Schema est. molla /
Schema comp. Rigidezza Rigidezza molla Compressione/
/ Rebound. Spring Estensione/ Interasse /
/ Comp. molla / interna / Compression/
Scheme / Preload / Rebound/ Length /
Scheme / Spring rate / Top Out Druckstufe/
Zugstufen Vor- Zugstuf / Länge /
Druck-stufen Federrate / Spring rate / Compression
Schema / spannung / Extension Entraxe
Schema / Ressort Innenfederrate
Extension Precontrainte
Compression [clicks]
regime du ressort [clicks] [mm]
regime [kg/mm] [kg/mm]
[mm]

GR7209 GR7210 9,0 10,0 11,0 15 12 395,0

Regolazione elettronica
Compressione
Electronic Compression
adjustment
Regolazione elettronica
Estensione
Electronic Rebound
adjustment

Precarico molla idraulico

Hydraulic spring preload

Attuatore precarico
molla idraulico
Hydraulic spring
preload actuator

Regolazione
Interasse Dado di bloccaggio
Length regolazione Interasse
adjustment Length adjustment
locking nut

45
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 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

REAR SHOCK ABSORBER SDJUSTMENT

The hydraulic adjustments of Compression and Rebound are electronically adjusted by Bitubo Digishox
system.
For all the functionality, refer to the "System User's Guide".

C - COMPRESSIONE E - ESTENSIONE

SPRING PRELOAD ADJUSTMENT

The adjustment range is 12mm.

The hydraulic spring preload is electronically adjusted by Bitubo Digishox system.

For all the functionality, refer to the "System User's Guide".

The preload defines the height of the bike from the ground as well as the dynamic set-up on a bend,
therefore also the angle values of the fork, the front, etc. which characterize the behaviour of the vehicle.

WARNING: this kind of damper is provided by an internal top out spring. Verify the measures at
completely extended suspension, not only by lifting the bike from the ground, but forcing the
suspension in extension too, in order to compress totally the top out spring.

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BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

The spring preload is the pressure to the spring when it is installed on the shock.  PRELOAD=F-M

F
M

LENGTH ADJUSTMENT

WARNING: The riding quotas are the result of long tests by the manufacturer, and the Q quote was
set to provide safe manageability and stability. A 2 or 3mm adjustment changes the vehicle's
behaviour. Changing the Q quote changes some riding quotas recommended by the vehicle
manufacturer and can reduce vehicle stability, both when riding and parking (on the central or lateral
stand), jeopardising riding behaviour and safety
The length has to be adjusted only on the lower attachment (unless different information reported on the
specific instruction) because the upper attachment adjustment change the position of the shock absorber refer
to the vehicle frame and it could get interference with the other parts.

WARNING: adjust the lower attachment being sure that inside the boss you keep at least 8 mm
thread.

According to the lower head layout (with holes – left figures; with nut – right figures), insert the Ø8mm tool,
supplied inside the package, inside one of the holes or 27mm key in the nut.
After positioning the bike on a special stand so to avoid any weight on the rear swing arm, loosen the lock nut
with 27mm key as for the picture.

If the shock absorber is removed from the bike:

- Unscrew the lower head for increasing the length
- Screw the lower head for decreasing the length
47
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

If the shock absorber is mounted in the bike:

- Turn clockwise the lower attachment for increasing the length

- turn anticlockwise the lower attachment for decreasing the length

Note: One complete turn of the length adjuster modifies the shock absorber length for 1mm

48
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

MOUNTING INSTRUCTIONS
ATTENTION: for all assembling and disassembling operations, and the torque settings of the retaining pins,
follow the Manufacturer's instructions carefully (Workshop Manual).

1) Place the motorbike on a suitable support and lift the back wheel off the ground without any load on the
suspension.

2) In order to simplify the disassembly-reassembly operations is recommended to remove the back wheel
and the passenger RH footpeg (the original screws will not be reused).
To carry out these operations, follow the Manufacturer's instructions (Workshop Manual).

3) In sequence: Unscrew the front link bold (A) and make the leverage fork rotate downwards, unscrew the
lower bolt of the original shock absorber (B) and remove the link unscrewing the back bolt (C). To carry
out these operations, follow the Manufacturer's instructions (Workshop Manual).

B A

4) To remove the original shock absorber, the fork must be released from the frame removing the retaining
pin, and then withdrawing it from its housing.

5) Unscrew the upper bolt of the shock absorber and take it out from its housing.

6) Assemble the BITUBO shock absorber; in sequence insert the hydr. spring preload actuator and place it
on the right of the bike, near the passenger's RH footpeg anchoring (to avoid impacts, please protect
the actuator group carefully), then insert the shock absorber into its housing bringing it near the upper
attachment, screw it without tighten.

49
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

7) Place the swing arm back in its housing, insert the pin and tighten it.

8) Refit the link carrying out the following operations in sequence: screw in and tighten the back bolt (A),
screw in and tighten the lower bolt of the shock absorber onto the link (B) and screw in and tighten the
front bolt (C).

A C

50
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

9) Insert the actuator group on the support bracket. Place it at 95mm of slipping and tighten the screw to 5
Nm.

95mm

10) Place the support bracket between the frame of the motorbike and the RH. Tighten the screws of the
footpeg.

11) Insert the wires of the actuator group into the fairing then connect them with the Bitubo wiring.

51
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

Bitubo wiring
connectors

12) Put down the vehicle, and tighten the upper bolt of the shock absorber.

13) Refit all the original components, following the instructions supplied by the Manufacturer.

N.B. To adjust the shock absorber, refer to the suspension manual

52
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

ADJUSTMENT AND MEASUREMENT OF SAG

1) Lift the bike (fork free from loading

and lifted tyre from the ground) and press the
spring retainer forcing the full extension of the
kinematic mechanism of the rear suspension.
Follow the same procedure also on the fore-
carriage.
2) Individuate two reference points on
the vertical axe of the tyre pin: one on the
centre, the other one fixed on the little frame
under the seat of the bike. Both points shall
be precise and well defined in order to make
this operation again more and more times.
Follow the same procedure on the fore-
carriage.

Measure the distance between the two points

Z1 and F1.

3) Place the bike to the ground with both

tyres, press slowly the suspension twice and
leave it then be extended freely.
4) Measure the new distance between
the two points Z2 and F2.
5) Z2-Z1 (static sag) shall be included
between 5mm and 15mm for road replica
bikes, between 10mm and 20mm for road
and naked bikes, between 15 and 25mm for
enduro tourism bikes; F2-F1 (static sag)
shall be included between 25mm and 32mm
for road and naked bikes; between 30mm
and 40mm for enduro tourism bikes.

6) Make all measurements again having

the rider on the bike in position of riding.

7) Z3-Z1 (rider sag) shall be included

between 25mm and 30mm for road replica
and naked bikes. For enduro and tourism
bikes the value shall be included between
30mm and 40mm. F3-F1 (rider sag) shall be
included between 35mm and 40mm for road
race replica and naked bikes. For enduro
tourism bikes the value should be included
between 40mm and 50mm.

In order to decrease the value of static sag, you shall increase the spring preload adjusting it clockwise
(screwing); on the other hand, in order to increase the static sag, you shall decrease the spring preload anti-
clockwise (unscrewing the adjustment).

53
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com
 Mod. ISTRUZIONI KIT_DS Rev.00 del 17/04/2018

MAINTENANCE

FRONT FORK
- Fork cleaning and maintenance prevents premature wear and increases performance over time.

- When cleaning the vehicle, be careful not to aim pressurised water jets directly on the fork rod oil guards or
upper fork leg caps (upper steering plate).

- Clean the fork and upper caps using non aggressive detergent.

- We recommend checking correct cartridge operations every 10000 Km or at least once a year.

- Every 24 months or 20,000 km of use, we advise you to have the cartridge overhauled at a BITUBO
Authorised Service Centre.

- We recommend you periodically check cartridge efficiency checking the damping forces with hydraulic
regulations fully open and fully closed. A change in damping is a positive result.

- For best purchased product performance, BITUBO recommends you use its lubricants.

REAR SHOCK ABSORBER

- Cleaning and lubricating your shock prevents its early wear and tear and increases its performances
longer.

- On clearing the bike, pay attention not to turn the water jet at high pressure directly to the body and head of
the shock absorber.

- Keep clean the shock absorber from dust, ground and any other impurities using a non-aggressive
detergent.

- After cleaning vaporize on the shock some cleaner like WD40 or similar and then dry with compressed air
jet.

- Bitubo recommends to check yearly, or after 10000Km, the correct work of the shock absorber:
o inspection the joints of upper and/or lower attachments, clean with a proper cleaner and
lubricant the moving parts.
o inspection the shock and check if there are any components leaking oil.
o check the internal gas pressure.

- Bitubo recommends the service every 2 years or 20.000 km.

- Bitubo recommends to check periodically the efficiency of the shock absorber performing some
compression and extension movement set the hydraulic adjustments from “fully-open” to ”fully-closed”. The
positive result is the damping change.

Maintenance and overhaul frequency suggested by Bitubo at Bitubo service centres (service centre list in the
"service" section at www.bitubo.com).

54
BITUBO srl – Via A. Volta,24 – 35037 Z.I. Teolo (PD) ITALY – Tel. (+39) 049-990.34.75
Fax (+39) 049-990.34.47 – Cod Fisc. e Part. IVA 02007650282 – E-mail: [email protected] - Internet: http://www.bitubo.com