"service manual"
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1. 6 Install the cartridge kit into the fork leg and push out the oil plug tool 01890 01 7 Tighten the shaft end counter clockwise into the fork bottom Tightening torque 18 Nm 8 Install the security snapring Note When removing spring and cartridge kit there will be a loss of front fork fluid Therefore we recommend adding 15 ml hlins Front Fork fluid into each fork leg 9 Tighten the hlins fork top cap gently Use the 50 mm octagon Fork Cap Tool Tightening torque maximum 10 Nm Spring support washer on 5 some brands models Preload washer plastic optional Fork leg 10 Install the front fork legs into the triple clamps Use to begin with the same height position as before Tightening torque see your Vehicle Service Manual Reinstall the brake caliper and front wheel make sure that all removed parts are reinstalled as they were before the installation of the hlins Kit A Warning Before riding always ensure that the basic settings made by hlins are intact Take notes adjust in small steps and make only one adjustment at a time Check Sag and Ride Height Note The following procedure should be performed on a flat surface 1 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 the distance from the marked2. hlins Front Fork Kit for fol tolo gol t m lalom Tele Elze Owner s Manual General Mounting Instructions Note The front fork is a very important part of the vehicle and will therefore affect the stability Read and make sure that you understand the information in this manual and the mounting instructions before you use this product If you have any questions regarding installation or maintenance please contact your hlins dealer Ohlins Racing AB can not be held responsible for any damage to the front fork vehicle other property or injury to persons if the instructions for installing and maintenance are not followed exactly A Warning 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 A This product contains pressurized nitrogen gas N Do not open service or modify this product without proper education authorized Ohlins dealer distributor and proper tools A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability Alf the suspension makes an abnormal noise or the function is irregular or if you notice any leakage from the product please stop the vehicle immediately and return the product to an Ohlins Service Centre Note When wor
3. be changed with softer or harder spring rate m Caution Do not use much force delicate sealing surfaces can be damaged Note The total stroke of the front fork 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 more oil less oil Force Stroke Spring Guide Rider s weight Spring rate kg pounds N mm Motocross Enduro 250 70 154 4 1 4 4 75 165 4 3 4 5 80 176 4 5 4 8 85 187 4 6 4 9 90 198 4 7 5 0 95 209 4 8 5 1 Motocross Enduro 450 70 154 4 3 4 6 75 165 4 4 4 7 80 176 4 5 4 8 85 187 4 6 4 9 90 198 4 7 5 0 95 209 4 8 5 1 Rider s weight Rider wearing all riding equipment Preventive maintenance and regular inspection reduces the risk of functional disturbance Breather plug Make sure to aerate the front fork at regular intervals 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground 2 Loosen the breather plug to release excessive pressure in the front fork Recommended Service Intervals Every 25 hours Make your service and maintenance according to Ohlins Workshop manual Disposal Discarded Ohlins products should be handed over to an authorized Ohlins workshop or distributor for proper disposal Breather plug 10 Your hlins retailer hlins Racing A
4. B Box 722 SE 194 27 Upplands V sby Sweden Phone 46 0 8 590 025 00 Fax 46 0 8 590 025 80 www ohlins com hlins Owner s Manual and ener Mounting Instructions Part No 07296 90_1 Issued 2010 06 10 hlins Racing AB
5. ap gently Use the 50 mm octagon Fork Cap Tool Tightening torque maximum 10 Nm 17 Check and set the rebound and compression valves click positions according to the recommended settings in Set up data in the Application Specific Instruction Sheet 18 Install the front fork legs into the triple clamps Use to begin with the same height position as before Tightening torque see your Vehicle Service Manual Reinstall the brake caliper and front wheel Make sure that all removed parts are reinstalled as they were before the installation of the hlins Front Fork Kit Note It is very important that the triple clamps are tightened to the correct torque See your Vehicle Service Manual Cartridge shaft end Base valve plug Security snapring Top cap tool Replace Spring only 1 Follow steps 1 8 in chapter Remove the fork legs from the vehicle 2 Unthread top cap from the outer tube 3 Remove the security snapring in the bottom of the fork with a pair of pliers Loosen the bottom end of the cartridge kit by turning clockwise 4 Install the tool 01890 01 oil plug by pushing it into the fork bottom The plug will keep the oil in the fork while changing the spring 5 Remove the cartridge kit from the fork leg and change the spring Note the plastic preload washer s and spring support washer if any Note The preload washers must be below the spring at the bottom end of the fork leg
6. gas pressure extends cartridge Measure B Measure C Calculate preload Preload B A C Adjust preload according to the desired value according to set up data by adding removing preload washers below the spring O BON For recommended Spring Preload see Application Specific Mounting Instructions Fork springs may differ in length Therefore we recommend you to check the preload on each fork leg and if necessary install preload washers to get the correct value A negative preload of up to minus 2 mm is possible since the top out spring still gives a small compression on the main spring Preload less than 2 mm will make the fork spring loose when the front wheel is off the ground which increases wear inside the fork m Caution Preload washers must be placed below the spring otherwise they will restrict oil flow and the fork may break Compression damping adjuster The compression adjuster is located at the top of the fork leg Adjust by turning the screw with a 3 mm allen key Rebound damping adjuster The rebound adjuster is located at the bottom of the fork leg Adjust by turning the screw with a 3 mm allen key To Reset 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 Set up data Static sag can only
7. king on this product always consult your Vehicle Service Manual This Manual shall be considered a part of the product and shall therefore accompany the product throughout its life cycle Safety Symbols In this manual mounting instructions and other technical documents important information concerning 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 front fork or to bystanders Mm Caution The Caution Symbol means Special precautions must be taken to avoid damage to the front fork Note The Note Symbol indicates information that is important regarding procedures Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Page Safety Precautions Contents Recommended Tools How to Install Replace Spring Set up Measure Spring Preload Adjustments Oil Volume Force Diagram Spring Guide Inspection and Maintenance 000 NOODDMN oOo lt amp Note To install the Cartridge Kit on your motorcycle you will also need the Application Specific Mounting Instructions Contact an hlins dealer for advice OEM Fork Cap Tool hlins Fork Cap Tool octag
8. on 50 mm Socket for OEM Base Plug Socket for hlins Base Plug Socket 12 mm for hlins Shaft End Pliers for security snapring Tool 01890 01 Plug See Application Specific Mounting Instructions Remove the fork legs from the vehicle A Warning It is advisable to have an hlins dealer install the front fork kit When installing consult your Vehicle Service Manual 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground A Warning Make sure the vehicle is securely supported so that it will not tip 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 according to figure Note Note this dimension as fork height position 4 Loosen the upper triple clamp by loosening the screws 5 Loosen but do not remove the top cap 1 2 turn Use the OEM Fork Cap tool from the motorcycle manufacturer 6 Loosen the lower triple clamp by loosening the screws 7 Remove the front fork legs from the motorcycle 8 Clean the fork legs thoroughly Make sure to clean underneath the fork bottoms VEHICLE SERVICE MANUAL Upper triple clamp Lower triple clamp Front wheel Disassemble the original front fork 9 Follow your vehicle service manual to remove the original front fork kit and spring from the fork leg Turn the fork leg upside down to po
9. point to a fixed point for example the wheel axle See figure below R1 4 Measure the distance from the bottom of the upper triple clamp to a fixed point for example the front wheel axle F1 5 Put the motorcycle on the ground so that the front and the rear suspensions are slightly compressed Repeat the measuring procedures R2 and F2 6 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Repeat the measuring procedures R3 and F3 R1 i As Ks RY S Ki A Recommended Measures If no other recommendations are given in the Vehicle Manual follow the measures below Free sag R1 R2 Rear 30 45 mm Ride height R1 R3 F1 F3 Rear 100 115 mm Front 40 50 mm Adjust spring preload 1 If your measurements differ significantly from the recommendations from the table above adjust the spring preload See section Spring Preload in this manual 2 If the ride height still differs from the recomendations you may need to change spring Contact your Ohlins dealer for advise A Warning Incorrect spring rate may produce a fork angle that is too steep or too flat This in turn will give a tendency for over or understeering which could seriously affect the handling characteristics of the motorcycle Five Steps to measure and adjust spring preload 1 Measure A Fork outer tube should be slid down to stop and cartridge left at free length internal
10. ur out the oil Install the hlins front fork kit Note On some brands models step 10 shall not be performed See Application Specific Mounting Instructions for information lL 1 D Install the hydraulic stop cup from the upper Fork bottom end of the fork tube Clean contact surfaces between the hydraulic stop cup and fork bottom with contact cleaner Hydraulic plug stop cup Mm Caution Make sure that the hydraulic stop cup is well seated before tightening 11 Install and tighten the base plug into the fork bottom Tightening torque 45 Nm Mm Caution If the hydraulic stop cup is turning carefully use an impact machine Spring support washer 12 if applicable Install spring support washer if applicable see Application Specific Instruction Sheet 2 De m Install optional preload washer s optional see Set up data Spring preload the WA recommended hlins spring see Spring guide and the cartridge kit into the standard Fork leg fork leg Note The preload washers must be below the spring at the bottom end of the fork leg 13 Tighten the cartridge shaft end into the base plug by turning counter clockwise Use a 12 mm socket Tightening torque 18 Nm Do not overtighten 14 Install the security snap ring at the shaft end groove according to figure 15 Pour hlins Front Fork Fluid in the fork leg according to the recommended settings 16 Tighten the hlins fork top c
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