Falco Suspension Tuning -- My current setup

This page used to be a diary of mistakes and successes I had made in the quest to make the Falco handle well. It was interesting to me to keep track of what I had done, but it was getting quite long-winded. If you are interested in how I got to my present setup, you can still have a look at my suspension tuning diary. But the abbreviated version appears below.

My Set-up As Of January 17, 2002

Me
Weight	145 lbs in street clothes
Riding style	Intermediate on bumpy mostly 45-75 mph roads
Preference	Softer suspension (more traction, more motion)

Bike
Description	2000.5 Falco with aftermarket slip-ons
Weight	450-475 lbs depending on fuel

Fork Setup
Specification	My setting	Stock setting
Description	Stock Showas 43 mm USDs with steel cartridge
Installed height	4 spaces showing (16 mm triple to anodized cap)	3 spaces (12 mm)
Valving	Stock	-
Rebound screw setting	0.75 turns out	1.5 turns out
Compression screw setting	1.75 turns out	1.5 turns out
Oil viscosity	5W (Showa/Honda Pro)	probably 5W or 7.5W ?
Oil level	150 mm (from top, collapsed, no spring)	116-120 mm
Spring rate	0.95 kg/mm	1.01 kg/mm
Spring free length	272 mm	292 mm
Preload spacer	128 mm plus stock washers	100 mm
Preload cap	6 lines (12 mm from anodized to taper)	5 lines (10 mm)
Sag (bike)	22 mm	?
Sag (rider)	35 mm	25 mm

Shock Setup
Specification	My setting	Stock setting
Description	Penske 8981 (8900 series deCarbon damper with 8100 reservoir)	Sachs emulsion-type damper
Installed height	~320 mm eye-to-eye ~ 1 thread showing on adjuster	~312 mm non-adjustable
Sag (bike)	~5 mm	?
Sag (rider)	32 mm	41 mm
Spring rate	800 lb/in (6-inch spring)	-
Oil viscosity	standard	-
Valving	standard (track)	-
Rebound screw setting	? about midscale +2 to +4 more clicks	-16 clicks from full-in
Compression knob setting	"1" of 6 (largest orifice)	non-adjustable
Preload	20 mm threads above lock ring	41 mm threads above lock ring

Tires
Specification	My setting	Stock setting
Type	Dunlop D207	Metzeler MEZ3
Front size	120/70	120/70
Rear size	180/55	180/55
Tire pressure (F/R)	32/34 psi ?	35/36 psi

Update: Some advice (July 2003)

People email me a lot asking for setup adice. Although its pretty much up to your tastes, I've done a lot of trial-and-error and can offer this:

Set your sag. This step is free and the target numbers are easily measured (not a subjective measurement). Don't worry about number of lines or threads showing, or spacer lengths. Just try to hit the sag targets and if you can't you know that you need to change your springs.
Replace your Metzlers. When you wear out your Metzlers, try a set of BT-010/020's, Pilot Sports, or my favorites, D208's.
Replace your shock. From here, there are no cheap knob changes that are going to hide the fact that the stock Falco shock is just terrible. I hate to say that I could not make it work with this bike. It needs to be revalved, lengthened, and from some owner's reports, fitted with a spring that doesn't permanently set.

Go back to the Falco home page.