1. Introduction and Overview
This manual provides essential information for the proper installation, operation, and maintenance of your DJ-Motor DNM MK-BAG 290mm 250LBS Rear Shock. This high-performance nitrogen oil rebound shock is designed to enhance the suspension of CRF110 and TTR110 Pit Dirt Bikes, offering improved handling and ride comfort. Please read this manual thoroughly before installation and use to ensure safety and optimal performance.
2. Safety Information
- High Pressure Nitrogen Gas: This shock absorber contains high-pressure nitrogen gas. Do not attempt to open, puncture, or disassemble the shock. Improper handling can lead to serious injury.
- Professional Installation Recommended: Installation of suspension components requires specialized knowledge and tools. It is highly recommended that installation be performed by a qualified mechanic.
- Proper Fitment: Always verify that the shock absorber is the correct size and spring rate for your specific motorcycle model before installation. Incorrect fitment can compromise safety and performance.
- Wear Protective Gear: Always wear appropriate safety gear, including eye protection and gloves, when handling and installing the shock.
- Regular Inspection: Periodically inspect the shock for any signs of damage, leaks, or wear. Replace components as necessary.
3. Package Contents
Upon opening the package, please ensure all items are present and undamaged:
- 1 x DJ-Motor DNM MK-BAG 290mm 250LBS Rear Shock
4. Specifications
| Feature | Specification |
|---|---|
| Brand | DJ-Motor |
| Model | DNM MK-BAG |
| Item Model Number | 290mm 250LBS |
| Manufacturer Part Number | TY-A1050 |
| Auto Part Position | Rear |
| Vehicle Service Type | Motorcycle (CRF110, TTR110 Pit Dirt Bikes) |
| Extended Length (Eye-to-Eye) | 290mm |
| Spring Rate | 250 LBS |
| Material | Alloy Steel |
| Exterior Finish | Polished |
| Item Weight | 4.69 pounds |
5. Setup and Installation
Before beginning installation, ensure your motorcycle is securely supported on a stand and the rear wheel is off the ground. Refer to your motorcycle's service manual for specific instructions on removing the original rear shock.
- Verify Fitment: Carefully compare the dimensions of the new DJ-Motor shock with your original shock. Pay close attention to the eye-to-eye length (290mm for this model) and mounting points.
- Remove Old Shock: Loosen and remove the upper and lower mounting bolts of the existing rear shock. Carefully remove the old shock from the motorcycle.
- Install New Shock: Position the DJ-Motor DNM MK-BAG shock into the mounting locations. Insert the upper and lower mounting bolts. Do not fully tighten yet.
- Tighten Bolts: Once the shock is properly seated, tighten the mounting bolts to the torque specifications provided in your motorcycle's service manual. Over-tightening or under-tightening can lead to damage or unsafe operation.
- Clearance Check: After installation, check for proper clearance between the shock, swingarm, frame, and any other components throughout the full range of suspension travel.
Figure 5.1: The DJ-Motor DNM MK-BAG 290mm 250LBS Rear Shock with remote reservoir.
Figure 5.2: Illustration showing the 290mm eye-to-eye measurement of the rear shock.
6. Operating and Adjustment
The DNM MK-BAG rear shock features a rebound adjustment mechanism, allowing you to fine-tune the shock's damping characteristics to suit your riding style and terrain.
- Rebound Adjustment: Locate the rebound adjustment knob, typically marked with 'Fast' and 'Slow' indicators. Turning the knob towards 'Fast' will allow the shock to extend more quickly after compression, while turning it towards 'Slow' will slow down the extension.
- Testing Adjustments: Make small adjustments (e.g., 1-2 clicks) at a time and test the bike's handling in a safe environment. Note the changes in ride feel.
- Sag Adjustment (Preload): While this specific model's spring preload adjustment details are not provided, typically, spring preload can be adjusted by rotating the threaded collar on the shock body. Adjusting preload changes the ride height and initial stiffness. Consult a professional if you are unsure about sag adjustment.
Figure 6.1: View of the rear shock showing the rebound adjustment mechanism (Fast-Slow).
7. Maintenance
Regular maintenance is crucial for the longevity and performance of your rear shock.
- Cleaning: After each ride, especially in dirty or wet conditions, clean the shock absorber with mild soap and water. Rinse thoroughly and dry. Avoid using high-pressure washers directly on seals.
- Inspection: Regularly inspect the shock for any signs of oil leaks, bent shafts, damaged seals, or loose mounting bolts. Check the spring for cracks or damage.
- Bushings and Bearings: Check the condition of the mounting bushings and bearings. Replace if there is excessive play or wear.
- Nitrogen Pressure: As stated in the safety section, the shock contains high-pressure nitrogen gas. Do not attempt to service the internal components or recharge the nitrogen yourself. This must be done by a qualified suspension specialist.
Figure 7.1: Close-up of the shock spring and a warning label indicating high pressure.
8. Troubleshooting
If you encounter issues with your DJ-Motor DNM MK-BAG rear shock, consider the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Shock feels too soft or bottoms out easily | Insufficient spring preload; worn spring; low nitrogen pressure; internal damping issue. | Adjust spring preload (if applicable). Inspect spring for damage. If issues persist, seek professional inspection. |
| Shock feels too stiff or harsh | Excessive spring preload; rebound adjustment too slow; incorrect spring rate for rider weight. | Adjust spring preload (if applicable). Adjust rebound setting towards 'Fast'. Consult a professional for spring rate assessment. |
| Oil leakage from shock | Damaged seals; bent shock shaft. | Discontinue use immediately. This indicates a serious issue. Seek professional repair or replacement. |
| Unusual noises (clunking, squeaking) | Loose mounting bolts; worn bushings/bearings; internal damage. | Check and tighten all mounting bolts. Inspect bushings and bearings for wear. If noise persists, seek professional inspection. |
| Difficulty with installation/fitment | Minor manufacturing variations; specific vehicle frame tolerances. | Double-check product specifications against your bike's requirements. Minor modifications (e.g., shaving small amounts of non-critical material) may sometimes be necessary, but proceed with extreme caution and only if confident it does not compromise structural integrity. If significant modification is needed, consult the seller or a professional. |
9. Warranty and Support
For any questions regarding product specifications, fitment, or performance, please contact DJ-Motor customer support. Information regarding specific warranty terms and conditions should be obtained directly from the seller or manufacturer at the time of purchase.
When contacting support, please have your product model (DNM MK-BAG 290mm 250LBS) and manufacturer part number (TY-A1050) available.