TTX Fork Information - MX-Tech
Contents
1. Recommended Tools Tool 00727 06 Tool 01781 01 Soft jaws for cartridge tube Gas filling device assy Tool 00727 08 Soft jaws Tool 01890 01 Oil plug tool Tool 01761 01 Peg spanner for top cap Tool 01837 01 Gas Piston Set Tool Tool 01820 27 Adapter for oil filling machine h it OM Remove Cartidgen 1 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground and the suspension is unloaded A Warning Make sure that the vehicle is securely supported so that it will not tip 1 2 Remove the front wheel and the brake caliper Consult your Vehicle Service Manual 1 3 Measure the position of the front fork Measure the distance from the top of the fork leg to the top of the upper triple clamp according to the figure Note Note this dimension as fork height position 1 4 Loosen the screws that hold the fork legs in the upper triple clamps 1 5 Use a 50 mm fork top cap tool Loosen the top cap turn Do not remove the top cap yet 1 6 Loosen the screws that hold the fork legs in the lower triple clamps 1 7 Remove the front fork legs from the vehicle Clean the fork legs thoroughly Make sure to clean underneath the fork bottoms 1 8 Remove the security snap ring at the bottom of the fork with a pair of pliers 1 9 Remove the top cap from the fork leg 1 10 Use a 12 mm socket Loosen the shaft end of the cartridge ki2. MX amp Enduro TTX Front Fork Cartridge Kit Workshop Manual OHLINS Safety Precautions Note The front fork is a very important part of the vehicle and will therefore affect the stability of the vehicle 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 nearest hlins dealer lt gt hlins Racing AB can not be held responsible for any damage to the cartridge kit 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 should 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 hlins dealer distributor or proper tools A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability lt Note When working on this product always consult your Vehicle Service Manual lt This Manual should be considered as a part of the product and should therefore accompany the product throughout its life cycle Safet
3. and spring seat onto cartridge 2 4 Install the cartridge kit into the fork leg Remove the oil plug tool 01890 01 at the same time when pushing the cartridge kit into the fork bottom 2 5 Tighten the shaft end into the fork bottom Tightening torgue 18Nm Note counter clockwise rotation 2 6 Install the security snap ring Note If any oil is needed use hlins Front Fork Fluid only For recommended oil volume see Mounting Instructions If you have any questions regarding oil please contact an hlins dealer for advice 2 7 Tighten the hlins fork top cap gently into the fork leg Use a 50 mm fork top cap tool Maximum torgue 10 Nm 2 8 Check and set the rebound and compression valve click positions according to the set up data in the Mounting Instructions and the Owner s Manual To reinstall the front fork legs into the vehicle go to chapter 7 Spring seat and washer Spring Preload washer optional Spring support gt washer steel some models Fork leg 3 Measure Spring Preload Measure the spring preload according to the following steps 3 1 Measure A Fork outer tube should be slid down to stop and cartridge pulled out to distinct stop requires a force of about 30 kg 3 2 Measure B 3 3 Measure C 3 4 Calculate preload Preload B A C 3 5 Adjust preload according to the desi
4. the rebound adjuster is fully open Install and tighten the shaft end Tightening torgue according to assembly drawing 5 20 Set the adjusters to recommended settings according to the Mounting Instructions 6 1 Follow chapter 2 to reinstall the cartridge kit into the fork leg 7 1 Install the front fork legs into the triple clamps Note the position of the front fork see measured distance in chapter 1 step 3 7 2 Tighten the screws that hold the fork legs in the upper and lower triple clamps Consult your Vehicle Service Manual for correct tightening torgues 7 3 Install brake caliper and front wheel For further instructions consult your Vehicle Service Manual 10 Ohlins Workshop Manual TTX Cartridge Kit 1 Issued 2010 06 07 2010 hlins Racing AB Your hlins retailer hlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands V sby Fax 46 0 8 590 025 80 Sweden www ohlins com
5. Sleeve 6 stack SI NI i SA Sleeve f Co S Clamp Shin SI washer SI 2008 2009 2010 2011 PAI ANIL OL dr Je 3 D ad m OX D Steps 5 7 5 11 Manual Filling 5 7 Fill up the cartridge tube with hlins Front Fork fluid to the top of the inner tube Move the shaft up and down slowly to bleed out the air underneath the piston 5 8 Reinstall the compression valve unit compression valve shims and shaft Fill up with more fork oil to the small bleed hole 2008 2009 Note Compression valve shim stack thickness 2008 2009 4 0 4 5 mm 2010 2011 4 5 5 0 mm 2008 2009 2010 2011 Note Make sure there is no air left by moving the shaft up and down a few times Also make sure that there is no air left in the outer chamber by pushing the rebound check valve shim open with a suitable tool 5 9 Install the gas reservoir piston Apply some hlins Red Grease on to the seals Push the reservoir piston down as far as possible 5 10 Make sure the compression adjuster is fully open Install the top cap and tighten Use tool 01761 01 Tightening torgue according to assembly drawing 5 11 Release cartridge from vice and hold it over a container while pushing on the shaft end so that full stroke is achieved Excessive oil will exit through the
6. bleed hole Keep the top cap as the high end while pushing to remove excessive oil This will make any trapped air to also be removed gt Goto step 5 15 Steps 5 12 5 14 Oil Filling Machine 5 12 Reinstall the compression valve unit compression valve shims and shaft lt Note Compression valve shim stack thickness 2008 2009 4 0 4 5mm 5 13 Install the gas reservoir piston Apply some hlins Red Grease on to the seals Push the reservoir piston down as far as possible 5 14 Install Gas piston set tool 01837 01 and Oil filling adapter 01820 27 Use hlins Oil Filling Machine and fill oil Remove oil filling tools and install screw and washer in oil filling hole 2010 2011 4 5 5 0 mm 5 15 Make sure the compression adjuster is fully open Install the top cap and tighten Use tool 01761 01 Tightening torgue according to assembly drawing A Warning Working with gas pressure can be hazardous Only perform this operation if you are an authorized service centre 5 16 Pressurize the cartridge to 5 bar 5 17 Install the screw for the gas valve 5 18 Install the rebound adjuster pin Apply red grease according to assembly drawing m Caution Apply generously with red grease This will prevent adjuster pin from moving spinning due to vibrations when in use 5 19 Remove the Teflon tape from shaft and clean shaft thread with contact cleaner Make sure
7. g to assembly drawing Note To measure compression shim stack play e Install sleeve into piston without any spacer shims e Measure how much sleeve extends x This dimension x minus compression shim stack thickness all the shims and wave washers with inner diameter 8 mm is the play Recommended play 0 4 mm Adjust by adding spacer shims between sleeve and piston 5 2 If hydraulic stop plastic tube has been removed Install lock nut all the way past the thread and the slit end Keep the nut from sliding back towards the thread Push or tap with plastic hammer hydraulic stop tube against bottom cap until it snaps in place Tightening torque according to assembly drawing 5 3 Clamp bottom cap in a vice using soft jaw tool 00727 08 Install parts according to figure m Caution Make sure the main seal is correctly positioned Also make sure to fit the bell washers in correct position convex sides facing each other 5 4 Install the inner tube into the bottom cap 5 5 Mount the cartridge outer tube on the bottom cap Tightening torgue according to assembly drawing 5 6 Wrap some Teflon tape around the thread on the shaft end to protect the seal from damages Apply some red grease on top of the Teflon tape Mount the shaft assembly into the cartridge tube Note For best result use the Ohlins Oil Filling Machine Go to step 5 12 2008 2009 2010 2011 O Spacer shim O
8. of service until gas pressure is completely released 4 7 Insert Pressure gas tool 01781 01 Release the gas pressure 4 8 Use tool 01761 01 Remove the end cap assembly 4 9 Push the damper shaft end all the way in Make sure the shaft end goes into the plastic hydraulic stop tube Then use appropriate tool to keep pushing shaft until reservoir piston compression valve shaft and compression valve come off Place all parts in correct order on the work bench Clean all parts thoroughly m Caution Make sure you do not damage the shaft seal Wrap some Teflon tape around the thread before pulling out the shaft 4 10 Drain the oil from the damper tube 4 11 Pull out the shaft from the damper tube 2008 2009 gt S Jp 5 H H O UD O a5 O D lt Note Steps 4 12 4 15 describe how to remove the hydraulic stop tube If the tube is in good condition you do not need to remove it lt Note Depending of version the hydraulic stop tube can be of type with two plastic halves kept together with two circlips This type should be removed and replaced by one piece plastic 15408 02 03 04 with nut 15455 01 and bushing 01056 09 4 12 If the 5 mm hole in the plastic tube is only on one side we recommend drilling in order to achieve a 5 mm through hole 4 13 Use a heat gun to gently heat the aluminium tube end and nu
9. red value according to set up data by adding removing preload washers below the spring 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 4 Disz ssemble Note The following procedure requires that you have removed the cartridge kit from the fork leg See chapter 1 4 1 Remove the spring seat and washer Note The Compression and Rebound adjusters should be set at fully open position 4 2 Fasten the cartridge in a horizontal position in a vice Use soft jaws 00727 08 to clamp shaft 4 3 Use a heat gun to warm up the Loctite Use a 12 mm socket and remove the shaft end 4 4 Remove the rebound adjuster pin 4 5 Fasten the damper tube in a vertical position in a vice Use soft jaws 00727 08 to clamp around bottom cap 4 6 Remove the right torx screw and o ring at the top of the reservoir A Warning Releasing pressure from the gas reservoir can be hazardous Do not perform any kind
10. t Caution Avoid heating the plastic more than necessary 4 14 Use an appropriate tool through the 5 mm plastic tube hole to keep it from rotating while loosening the nut with a spanner 4 15 Unthread the nut completely and move it away past the slot end Use a flat screwdriver to open the slot and remove hydraulic stop tube 4 16 Use a heat gun to warm up the Loctite on bottom cap thread Remove the outer cartridge tube use standard OEM top cap tool 4 17 Remove the inner tube from the bottom cap 4 18 Remove the parts according to figure Check all parts for wear or damage Replace parts if necessary Note We recommend you to replace all x rings and o rings 4 19 Put the shaft in a vice use soft jaws 00727 08 Remove the nut rebound shim stack piston sleeve and compression shim stack from the shaft Place all parts in correct order on the workbench Clean all parts thoroughly 2008 2009 2010 2011 2008 2009 2010 2011 4 20 Check the shafts The shafts may be slightly deformed when used This will not affect the safety or function of the product as long as the run out is within the tolerance See figure Note If the run out is outside the tolerance the piston rod must be replaced Maximum 2 mm 5 1 Fasten the shaft in a vice Use soft jaws 00727 08 Install parts according to figure Tighten the nut accordin
11. t Note clockwise rotation 1 11 At the same time when pulling the cartridge assembly out of the fork leg install the tool 01890 01 oil plug by pushing the plug into the fork bottom The plug will keep the oil in the fork while working with the cartridge kit 1 12 Remove the cartridge kit from the fork leg 1 13 Note that spring seat and washer will depending on cartridge version stay in fork tube or come out with cartridge gt To replace spring and or spacers go to chapter 2 gt To disassemble Cartridge Kit go to chapter 4 2 Replace Spring and or Pre lt Note The following procedure requires that you have removed the cartridge kit from the fork leg See chapter 1 2 1 Remove the spring from the fork leg Note Note that plastic preload washers and or steel spring support washers may be installed To remove the washers you must drain the fork tube from oil Use a solvent contact cleaner to clean inside of fork tube then preload washers will fall out when fork tube is turned up side down Note To change the spring preload change the thickness of the preload washers See figure on the next page for spring preload calculation 2 2 Install the preload washers and the new spring lt Note The preload washer s must be below the spring at the bottom end of the fork leg 2 3 If needed install washer
12. y Precautions Recommended Tools 1 Remove Cartridge kit from Fork Leg 2 Replace Spring and or Preload Washer 3 Measure Spring Preload 4 Disassemble Cartridge Kit 5 Assemble Cartridge Kit 6 Reinstall Cartridge Kit into Fork Leg 7 Reinstall Fork Leg on the Vehicle 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 cartridge kit or to bystanders m Caution The Caution Symbol means Special precautions must be taken to avoid damage to the cartridge kit lt Note The Note Symbol indicates information that is important regarding procedures hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Service Interval Rec service interval for Cartridge kit every 25 hrs At 25 hour service replace the following Part no Top out rubber 15486 01 8 mm seal 15428 01 Piston ring 15409 01 Separating piston seal years 2010 2011 part no 00338 96 2x years 2008 2009 part no 01027 12 2x Vv Q o 0 O 0 S ON oo
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