TUNING DR-Z 400E/K SUSPENSIONS
Last update: 23 Feb. 2006
BEWARE: ALL THE MATERIAL IN THIS
WEBSITE MUST BE ASSUMED AS SUGGESTIONS FOR THE BEST TUNING OF THE RACE
BIKE. NO RESPONSIBILITIES WILL BE TAKEN FOR ANY PROBLEM OR ACCIDENT
WILL ARISE WITH MODIFIED BIKES. IF YOU ARE NOT SURE OF YOUR ABILITY
IN DISMOUNTING - REMOUNTING SUSPENSIONS, PLEASE REFER TO QUALIFIED
PERSONNEL ONLY.
2) SUZUKI DR-Z 400E/K FORK/SHOCK SPRINGS
The springs stiffness' ratio R' = shock spring stiffness
/ one fork spring stiffness) is 13.0, with both values in N/mm or
kgf/mm. The original ratio is about 12.0 .
This is my personal table reporting springs stiffness'
related to rider's weight (neglecting the fork air stiffness, near to
0.1 N/mm):
fork--------shock-------rider's net weight (kg)
4.1-----------54----------------65
4.25---------56----------------72.5
4.4----------58----------------80
4.55---------60----------------88
4.7----------62----------------95
4.85---------64---------------102.5
5.0----------66---------------110
Example: if your weight is about 105 kg, then the
springs right for you should be 4.8 N/mm (fork) and 64 N/mm (shock)
if you want a medium-soft tuning, 5.0 and 66 if you want a stiffer one.
These values come down from this facts:
a) The stock shock spring stiffness (SS) is 54 N/mm, as
reported by the Suspension Network database. This value should be
measured with the spring pre-loaded by a weight of about 50 kg.
b) The fork springs stiffness' (FS) that is nearly
perfect (in my personal tests) with the stock shock spring is 4.1 N/mm.
c) R' = SS / FS = 54 / 4.1 ~= 13, thus every rear/front
springs that respect this stiffness' ratio should work as well as the
54 / 4.1 springs.
d) Multiplying shock spring stiffness by the factor
3.7593
we will obtain the TW = total weight = motorcycle + rider weight.
e) Subtracting from TW the bike weight + gear weight (I
assume 130+8 kg)
we will obtain the RW = rider's weight (kg):
RW = TW - 138 = (SS * 3.7593) - 138 .
The reasoning is correct if every point is satisfied.
1) INTRODUCTION TO THE "SPRINGS STIFFNESS' RATIO"
Springs stiffness' ratio is a strange concept for a lot
of people, even for some suspension engineers, I suspect. It come down
from this idea: the dynamical behavior of a motorbike has an optimum
when:
(Front suspension stiffness) * (distance of front wheel
from BB) = (Rear suspension stiffness) * (distance of rear wheel from
BB)
BB = barycentre of the byke + rider system
This relationship is verified when the stiffness' are in
the ratio R:
(Rear suspension stiffness) / (Front suspension
stiffness) = R ,
where R = (distance of front wheel from BB) / (distance
of rear wheel from BB)
If the rider's barycentre is exactly over the bike
barycentre, then increasing the rider's weight the value R is constant.
This is my hypothesis.
On the other hand, suspensions stiffness' must be
increased when rider's weight increase, in order to avoid bottoming
problems and so on.
R is not a springs stiffness' ratio, but a suspensions
stiffness' ratio. For our purposes it's better to have:
R' = (Rear spring stiffness) / (fork spring stiffness)
"Fork spring stiffness" means "one fork spring
stiffness"; in the "Front suspension stiffness" are involved all the
two springs, with a factor to account that the fork isn't vertical.
Normally it's very difficult to calculate the R' value
in a real bike, thus it's better to perform drive tests with various
springs. It's not difficult to find out the front spring that better
fit the rear spring. A set of 54 - 4.1 is almost perfect for 70
kg riders, thus the R' ratio become:
R' = 54 / 4.1 = 13.17 ~= 13
This value should be valid with every rider's weight.
Maximum error admitted on the springs stiffness' is 5%, maintaining a
given hydraulic set-up. There is, however, the opportunity of
balancing an R' out-of-range value by changing the compression
dampening of both shock/fork, i.e.: if R' is higher than normal, it's
better to increase the fork comp. damp. and/or reduce the shock comp.
damp. . The opposite operation will be performed if R' is lower than
normal. All this can account for the big differences in R' values
between american and italian settings. Most american websites springs
calculators works on R' = 11 or around this.
Because the
transmission ratio between the rear wheel and the shock is variable,
all this stuff is referred to the standard value of SAG. If the SAG is
altered, the R' can change slightly. Bigger changes in R' will happen
if rear suspension links are modified or substituted.