Suspension forks & shock absorbers: How big will suspension manufacturer KYB become in the MTB sector?

When it comes to suspension components in mountain biking, there’s no getting round the big players, RockShox and Fox around. Of course are there many more**:** SR Suntour, Formula, Marzocchi and others, but the two US brands have been setting the tone. Until now, that is. Because KYB is now making inroads into the MTB sector. The Japanese The giant KYB Corporation (Kayaba Industry Co., Ltd.), headquartered in Tokyo, is one of the world’s largest manufacturers of hydraulic systems and shock absorbers. Founded in 1919, the company develops and manufactures, amongst other things, suspension components for motorbikes, bicycles, cars, construction machinery and the aviation industry.

Interview with Deniz Sayki, KYB Senior Project Leader

How does a corporation of your size come up with the idea of entering the MTB segment, which is probably peanuts compared to your other markets?

That is actually the typical reaction. We originally come from the hydraulics industry – having started out in Japan over 100 years ago. From there, we grew alongside companies such as Toyota in the automotive sector and are now one of the world’s top three manufacturers of automotive shock absorbers. Over the decades, we’ve also significantly expanded our presence in the motorcycling sector; we’re particularly well-positioned in the off-road segment. And it was precisely through this motorcycling division that we established contact with Yamaha, who approached us a few years ago to ask if we’d like to collaborate on developing something new for the mountain bike sector.

How did this collaboration with Yamaha work in practice?

Yamaha unveiled its mountain bike range at a major Japanese motor show back then – including a full-suspension prototype fitted with KYB suspension. Over the years, the concept was then developed into a finished product. At some point, however, Yamaha withdrew from the project. We at KYB, however, had already invested so much time and passion into the project that we decided to complete the development independently and adapt the product for the open market. Hence the 160-millimetre travel – a measurement that is now standard for mainstream e-mountain bikes.

The fork doesn’t have a proper name yet. What do you call it?

The official product code is 2025-DF-FF – where FF stands for Front Fork. For a teaser video we’re currently planning, we’ll simply refer to the fork as the ‘KYB 160mm fork’. It’s a shame – I’d have liked a name that does the product justice too.

Perhaps another name will turn up after all.

The second generation – which we’re currently developing with 170 millimetres of suspension travel – will definitely be given a proper name. Unfortunately, that won’t be possible for this first version.

A massive upside-down fork with just 160 millimetres of travel – why not 170?

It’s almost like a glimpse into the future. The second generation is in the planning stage and will feature 170 millimetres of travel. In the long term, we’ll probably cover both travel options – 160 and 170 millimetres. The base design will be identical; riders will be able to choose between the variants by selecting different spring lengths. However, we’re still missing the right shock absorber – that’s also in development. Only then will we be able to offer the complete package.

Why upside down?

This has a lot to do with our motorcycling heritage. The engineers who developed this fork all come from the motocross and enduro sectors – upside-down forks are their bread and butter. The main advantages lie in the responsiveness and durability. With an upside-down fork, the oil seals are constantly immersed in oil, which reduces friction and keeps the seals in good working order for longer. Generally speaking, at KYB we stand for robust, long-lasting suspension systems – not necessarily with five different adjustment options, but reliable technology that works for many years.

What exactly can the driver adjust?

There is a rebound adjustment and a damping adjustment. We also recommend a full service every 100 operating hours. That is usually all that is required – the product is designed for durability.

When will the fork be available in Germany, how much will it cost – and what is the service network like?

Unfortunately, we’ve experienced a slight delay. The first small batches will start arriving in September. We’re planning the major roll-out for the end of the year, around December – that’s when we’ll launch across Europe. When it comes to the service network, we’re benefiting greatly from our automotive division: we already have branches and colleagues in every European country. In the key markets – Germany, France, Spain, Italy and the UK – we’re currently building up a partner network with selected garages that will be officially certified as KYB service partners. The RRP is 1,800 euros including tax.

What about spare parts?

We will make all parts available as individual components – thanks to our European logistics network, we are well-positioned to do so. In theory, you could assemble a complete fork from spare parts. Whether a stanchion is damaged or a cap has a scratch – everything can be replaced individually. Even the damping cartridge can be replaced, although this should be done by a professional.

Are you already in talks with system integrators?

Yes, there are already interested parties and we’ve had some initial exploratory discussions. The main problem at the moment is that we can only offer the fork. If a manufacturer had to combine a KYB fork with a Fox shock, that’s usually not very appealing in OEM discussions. However, as soon as we can offer the fork and shock absorber as a complete package, interest will increase significantly – that’s the clear feedback from our discussions. There will definitely be a bike with KYB suspension. I can’t say any more about it at the moment.

One last question: Which forks did you look at for reference – or were the engineers so influenced by the motorbike that they simply did their own thing?

Naturally, you’ve looked at the relevant products on the market. Amongst others, a Fox and a Marzocchi were used for comparative tests – from torsional stiffness tests on the bench right through to ISO certification, we already had the necessary expertise and machinery from the motorcycling sector.