Motocross and Enduro
Contents
1. hlins Front Fork Cartridge Kit for Motocross and Enduro Owner s Manual and General Mounting Instructions N g ADVANCED SUSPENSION TECHNOLOGY hlins Racing AB The Story It was the 1970 s a young man named Kenth hlin spent most of his spare time pursuing his favourite sport motocross Being a careful observer Kenth s attention was continously drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension hlins Racing was established in 1976 and just two years later the company won its first World Championship title Despite being in the business for almost 40 years the search for perfection and new functions is still the main focus of the company T hlins Headquarters pplands V shy Wy Congratulations You are now the owner of an Ohlins product More than two hundred World Championships and other major world titles are definitive proof that Ohlins suspension offer outstanding performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible experience from our almost 40 years within the racing sport The product that you now have in your possession is pure racing breed that is built to with2. the hlins cartridge kit Remove the original fork legs Install the Ohlins cartridge kit 2 Change spring TOOLS OEM Fork cap tool hlins fork cap tool octagon 50 mm Socket for OEM Base plug Socket for hlins Base plug Socket for hlins shaft end 12 mm Pliers for security snapring Plug 01890 01 See the Mounting Instructions Remove the original fork legs A Warning We strongly recommend to let an hlins dealer install this product A Warning If you work with a lifted vehicle make sure that it is safely supported to prevent it from tipping over o Note When you work with this product see the vehicle service manual for vehicle specific procedures and important data o Note Before you install this product clean the vehicle 1 Place the motorcycle on a work stand so that the front wheel barely touches the ground 2 Remove the front wheel and the brake caliper 3 Measure the distance from the top of the fork leg to the top of the upper triple clamp see figure Note measure Fork height position 4 Loosen the upper triple clamp screws 5 Loosen the top cap turn Use an OEM Fork cap tool 6 Loosen the lower triple clamp screws 7 Remove the fork legs from the vehicle 8 Clean the fork legs make sure to clean underne
3. this keeps the fork running higher in the stroke withstanding their additional forces due to their higher velocities Note Since small amounts of oil have great influence on the performance make sure to service a fork that leaks immediately We highly recommend to have an hlins dealer service the fork When you drain the fork it is very important to let all oil drain out to obtain a proper oil level in the fork after service less oil Compression damping adjuster Use a 3 mm Allen key to adjust the compression damping adjuster Rebound damping adjuster Use a 3 mm Allen key to adjust the rebound damping adjuster To set The adjusters have a normal right hand thread Turn the damping adjusters gently clockwise to fully closed pos zero 0 To open turn counter clockwise and count the clicks until you reach the recommended number For recommended clicks see the Setup data in the Mounting instructions or contact an hlins dealer for advice To adjust the static sag you need to change to a softer or harder spring rate Y Caution Turn the adjusters gently not to damage delicate sealing surfaces o Note The total front fork stroke may differ from the original stroke so that more or less of the steel tube will be visible when the fork is fully compressed Compression damping adjuster closed position zero 0 Rebound damping adjuster closed position ze
4. aft end groove 16 Pour hlins Front fork fluid in the fork leg refer to the recommended setup in the Mounting instructions 17 Make sure that the front fork is fully extended Use the wrench 01892 01 to tighten the hlins fork top cap to maximum 10 Nm 18 Check and set the rebound and compression valves click positions refer to the recommended setup in the Mounting instructions 19 Install the front fork legs into the triple clamps Set the fork legs at the same height position as before Refer to the vehicle service manual for correct tightening torque 20 Install the brake caliper and the front wheel Make sure that all removed parts are installed in the same positions that they were before amp Note Cartridge shaft end Base valve plug Security snap ring It is very important to tighten the triple clamps to the correct torque refer to the vehicle service manual a NGE SPRING Remove the original fork legs see chapter 1 2 Use a pair of pliers to remove the security snap ring at the bottom of the fork 3 Turn clockwise to loosen the bottom end of the cartridge kit 4 Insert the plug 01890 01 into the fork bottom The plug will keep the oil in the fork while you change the spring 5 Remove the cartridge kit from the fork leg change the spring Note the plastic preload washer s if any amp Note Security
5. ath the fork bottom 9 Refer to the vehicle service manual to remove the original front fork and spring from the fork leg Turn the fork legs upside down and pour out all oil Install the hlins cartridge kit o Note Step 10 shall not be performed for some models See the Mounting Instructions for the product 10 Use contact cleaner to clean the contact surfaces between the hydraulic stop cup and the fork bottom Insert the hydraulic stop cup in the original fork leg insert from the upper end of the fork tube Y Caution Make sure that the hydraulic stop cup is in correct position before you tighten 11 Install and tighten the base plug into the fork bottom tighten to 45 Nm Y Caution If the hydraulic stop cup rotates when you install and tighten carefully use an impact machine 12 Insert the spring support washer if any the optional preload washer s recommeded spring and the cartridge kit into the original fork leg See the Mounting Instructions for the product o Note Place the preload washer s below the spring at the bottom end of the fork leg 13 Apply grease on the thread of the piston rod end N Hydraulic stop cup 14 Use a 12 mm socket to tighten the cartridge shaft end into the base plug turn counter clockwise and tighten to maximum 18 Nm Do not over tighten 15 Install the security snap ring at the sh
6. cartridge left with full length The internal gas pressure extends the cartridge MY 2014 MX only The internal spring will prevent the gas pressure from extending the cartridge thus you must extend the cartridge with your hand 0 4 mm 2 Measure B 3 Measure C 4 Calculate preload Preload B A C Note measure A B C Preload B A C 5 For recommended preload refer to the setup data in the Mounting Instructions or contact an hlins dealer for advice To adjust the preload you add or remove washers below the spring Measure the spring preload 10 5 OIL LEVEL AND DAMPING To set the oil level Proper oil level is a balance between sufficient bottoming resistance and comfort Higher oil level will give better bottoming resistance but might reduce comfort over smaller bumps Bottoming issues Increase oil level in steps of 10 ml until unpleasant bottoming no longer occurs or until comfort on rest of the track becomes too harsh Harsh fork Try to decrease oil level in steps of 10 ml to gain comfort until harshness no longer occurs or bottoming resistance gets too low FORCE Additionally lower oil level will let the fork dive longer into the stroke during braking before additional damping effect stiffens up the stroke see position C in the figure below Very fast riders may appreciate the additional damping from a higher oil level on all parts of the track as
7. cess 5 Measure R3 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Repeat the measurement process Note measures R1 R2 R3 Recommended measures See the recommended free sag and ride height measures in the hlins Mounting Instructions for the shock absorber or in the vehicle service manual If the ride height still differs from the recommendations you may need to change spring contact an hlins dealer for advice A Warning Incorrect spring rate may produce a fork angle that is too steep or too flat This in turn can lead to a tendency for over och understeering which could seriously affect the handling characteristics of the motorcycle E THE SPRING PRELOAD Fork springs may differ in length Thus we recommend to measure the preload on each fork leg and install the required preload washers to get the correct measure Preload less than 0 mm will make the fork springs loose when the front wheel is off the ground which can increase the risk of wear inside the fork Front Forks MY 2014 Recommended minimum spring preload 4 mm Y Caution Preload washers must be placed below the spring otherwise they will restrict oil flow and the fork may break Measure the spring preload according to the steps 1 5 and see the figure below 1 Measure A Fork outer tube slid down to stop MY lt 2013 Fork outer tube slid down to stop and
8. ng safety is distinguished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the shock absorber or to bystanders Y Caution The Caution Symbol means Special precautions must be taken to avoid damage to the shock absorber o Note The Note Symbol indicates information that is important regarding procedures Product Specific Warnings A Warning The product warranty shall only apply if the product has been operated and maintained in accordance with recommendations in this manual If you have any questions regarding usage service inspection and or maintenance please contact hlins Note When working with the hlins product always read the vehicle service manual Note This manual shall be considered as a part of the product and shall accompany the product throughout its life cycle This product was developed and designed exclusively for a specific vehicle model and shall only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited 1 Install
9. ro 0 12 Preventive maintenance and regular inspection reduces the risk of poor performance If there is any need for additional service please contact an hlins dealer After every ride 1 Place the motorcycle on a work stand so that the wheels barely touch the ground suspension unloaded 2 Let the bike cool off 3 Aerate the front fork Loosen the Breather plug to release excessive pressure in the front fork Make sure to tighten the Breather plug after Recommended service intervals Recommended service every 20 hours amp Note Contact an approved hlins dealer for service Disposal Hand over your discarded hlins products to an approved hlins dealer for proper disposal 13 14 Ohlins Owner s Manual MX Enduro Cartridge Part No 07296 90_3 Issued 2014 02 11 Ohlins Racing AB Your hlins retailer hlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands Vasby Fax 46 0 8 590 025 80 Sweden www ohlins com
10. snap ring Place the preload washer s below the spring at the bottom end of the fork leg 6 Extend the cartridge kit as much as possible with your hands Install the cartridge kit into the fork leg and push out the plug 01890 01 7 Tighten the shaft end counter clockwise into the fork bottom tighten to 18 Nm 8 Insert the security snap ring 9 Make sure the front fork is fully extended and tighten the hlins fork top cap Use wrench 01892 01 and tighten to maximum 10 Nm Y Caution Do not tighten to more than 10 Nm 10 Install the front fork legs into the triple clamps Set the fork legs at the same height position as before Refer to the vehicle service manual for correct tightening torque 11 Install the brake caliper and the front wheel Make sure that all removed parts are installed in the same positions that they were before Cartridge kit 3 SETUP Check sag and ride height 1 Work on a flat surface Put the motorcycle on a workstand so that both wheels are off the ground and the suspension is unloaded 2 Mark for example with a piece of tape a point immediately above the rear wheel axle 3 Measure R1 Measure the distance from the marked point to a fixed point for example the wheel axle 4 Measure R2 Put the motorcycle on the ground so that the rear suspensions is slightly compressed Repeat the measurement pro
11. stand By installing this product on your vehicle you have made a clear statement you are a serious rider with a focus on getting the maximal handling ability and outstanding feedback from your vehicle Along comes the fact that your Ohlins product will be a long lasting friend delivering the very best of comfort and performance every time you go for a ride Go explore SAFETY PRECAUTIONS General Warnings amp Note The shock absorber front fork steering damper is an important part of the vehicle and will affect the stability amp Note Read and ensure you understand the information in this manual and other technical documents provided by hlins before using the product Note hlins Racing AB can not be held responsible for any damage to the shock absorber front fork steering damper vehicle other property or injury to persons if the instructions for mounting usage and maintenance are not followed exactly A Warning After installing the hlins product take a test ride at low speed to ensure your vehicle has maintained stability A Warning If the suspension makes an abnormal noise or the function is irregular or if you notice any leakage from the product stop the vehicle immediately and return the product to an hlins dealer A Warning SAFETY SYMBOLS In this manual mounting instructions and other technical documents important information concerni
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