What can cause a damaged Kw v3 dust caps?
 

I installed my kw v3 coilovers a couple days ago and today I decided to double check that everything was nice and tight. Will I noticed that my bump stops were stuck at the very top of the coilover and my dust caps were badly damaged on both front sides.
What could have caused this? I just been doing normal driving and havent bottomed out my bump stops.

Has this happen to anyone?

This has happened on our Club Sports. Usually caused from the car being lower and compressing shorter than the distance the dust cap is.

The dust covers are pretty unimportant. I wouldn't worry about it. Also, bump stops are going to end up at the top. They get pushed up under compression and they're a snug enough that they don't slide back down.

I've read its pretty common on KW parts. You can buy new ones from KW for fairly cheap if you really want, but they will likely break too. Probably just a bad design.

Would you guys recommend to remove the broken dust caps? Without replacing them.

It looks like your perches are all the way down. If you want to run that low you should probably trim the dust boots.

- Andy

I was adjusting my KWV3s yesterday and saw the exact same thing on one of my front dust covers - even the top washer was cracked! One of my rear ones also seemed to have somehow rubbed the shock body on the way down and scraped off the KW sticker. Bummers but seems like it is not that unusual...

Its because you've run them too low and compressing beyond the length of the dust cover. Not a big deal really...you could remove them without affecting anything apart from having less protection against the elements. Why not try getting some plastic glue and see if it helps.

By the way, you may want to check the owners manual to see whats the recommended minimum adjustment range. You are probably running outside this range even though threads physically allow you to go that low.

Figured that had to be slammed my helpers are fully compressed no gap..

My car is not slammed and I am lowered 1/2 through the KWV3 recommended range. My helper is also fully compressed. It probably happened when I unknowingly ran over a speed bump. Oh well...what's done is done.....

I'm at the very top of the KW adjustment range, and this happened to one of my rear shocks within the first mile of driving right after install (just the test drive around the block). :iono:

I just installed my V3's the other weekend and I've just discovered this same issue. I made a left hand turn coming out of a stop light on my way to work, gave it a little gas causing some lateral G loading the right front, and I heard a snap/clunk. It sounded similar to running over a twig or something. Once I got to work, I peaked through the wheel and noticed the dust cover had broken. WTF?! :eyebulge:
Has anyone called KW's warranty department for an answer regarding replacement? I think I'll give them a call and post results.

I called KW support and spoke with Phil. Usually KW doesn't cover the dust caps under warranty because breaking one of those would fall under the "wear and tear" clause, however, because my coilovers are only a week old, Phil told me he could replace them under warranty. All I have to provide is proof of purchase and a photo of the damage.

Phil recommended double checking all the ride height settings to make sure I was within the recommended thresholds. He could only speculate as to what my issue was, but he echoed what everyone hear has already stated: if you exceed KW's recommended settings (i.e. are too low) the dust cap could experience more load than it was designed to handle (which isn't much because it's just plastic). Also, he reminded me that the coilovers do not come preset and are adjusted from the factory to fit in the package and be safe during transportation. So, be sure to use the A & B measurements they give you when installing and adjusting your ride height!