fkc 101 - Ohlins
Contents
1. Kit Contents Description Part No Pcs Cartridge kit FKC101 1 Sticker top cap screw 00191 49 2 Sticker 01185 04 2 Owner s manual 07288 01 1 Top out spring 21801 01 1 B Oil lock sleeve 21802 01 1 NH Note Note Please note that there can be small differences Before you install this product check the kit between your product and the images in contents If anything is missing please contact these instructions an Ohlins dealer Note A Warning Please note that during storage and transport Before you install this product read the Ohlins especially at high ambient temperature some Owner s manual This product is an important of the oil and grease used for assembly may part of the vehicle and the vehicle stability leak and stain the packaging This will not cause damage to the product wipe off the excessive oil or grease with a cloth Cartridge kit for Harley Davidson Touring FLHx FLTx 1997 2013 FKC 101 Mounting Instructions ADVANCED SUSPENSION TECHNOLOGY ON VOUN 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 Note When you work with this product see the vehicle service manual for vehicle specific procedures and important data2. VIOUNTLIN Install the Ohlins cartridge kit all models 1 Remove the screw top cap top cap and the guide sleeve external from the shaft 2 Adjust the shaft nut as far up as possible on the shaft leave enough threads on the shaft to install the pull up tool 3 Install the pull up tool 01765 08 on the shaft Tighten with your hand W Caution Keep the fork leg in a vertical position during the installation procedure 4 Make sure that the oil lock sleeve is in correct position Ww Caution Make sure that the guide sleeve internal touches the seal head Make sure that the guide sleeve internal is correctly positioned during the installation procedure steps 5 11 5 Put the cartridge in the fork leg 6 Make sure that the cartridge is in bottom position Apply threadlocker see the vehicle service manual on the bottom screw Insert the washer and the bottom screw Use a 6 mm Allen key to tighten the bottom screw Tighten according to the vehicle service manual 7 Pour approximately 300 ml Ohlins front fork fluid 01309 XX in the fork leg If the oil level comes near the upper end of the inner tube move the steel tube up and down to let out all air from the fork leg 8 Pull the inner tube up and down approximately 10 times to aerate the fork leg Pull the shaft up and down approximately 10 times to aerate the car
3. Note Before you install this product clean the vehicle Tool Part no Pull up tool 01765 08 Stopper plate 02810 03 Wrench 13 mm Open end wrench 13 16 Open end torque wrench 13 16 Allen key 6 mm Allen key torque wrench 6 mm YM 2002 2005 specific tools Wrench 14 mm Appropriate flat head screwdriver to remove oil seal clip Oil seal installation tool 41 mm Oil seal grease according to vehicle service manual Before you begin The kit consists of one compression cartridge and one rebound cartridge Make sure you install each cartridge in the correct fork leg Compression cartridge in the left side fork leg Remove the original damping system 1 Remove the front fork from the vehicle according to the vehicle service manual VIO Note For MY 2002 2005 see the procedure on pages 4 5 A Warning Spring compression creates a potential danger because of the violent force that loaded springs are capable of Important When you remove the top cap push down the top cap and at the same time pull up the inner tube to prevent uncontrolled release 2 Use a 13 16 open end wrench to loosen and remove the top cap from the inner tube Important When you remove the top cap push down the top cap and at the same time pull up the inner tube to prevent uncontrolled release 3 Remove the main spring N
4. inner tube Tighten the top cap refer to the vehicle service manual 20 Install the fork legs in the vehicle refer to the vehicle manual A Warning Make sure to install all removed parts in the same positions as they were before the installation of the Ohlins cartridge kit Note After you have installed the cartridge in the fork leg place the sticker 01185 04 on the top cap SETUP DATA Ohlins Front fork fluid 01309 xx Recommended oil level 80 mm ems cH TE LOGY SPRING GUIDE Make sure you choose the correct spring for your rider weight driving style and preferences Contact an authorized hlins service center for advice Ride height Spring Spring rate part no N mm One driver no extra load 08419 10 10 Recommended spring Lowering kit 25 mm 08865 01 13 For best handling characteristics we recommend to combine this kit with a lowered rear 12 mm To lower the rear contact an authorized Ohlins service center Ohlins products are subject to continuous improvement and development therefore although these instructions include the most up to date information available at the time of printing minor updates may occur Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited To find the latest information contact an Ohlins d
5. istributor Please contact Ohlins if you have any questions regarding the contents in this document Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 Part no MI_FKC101_0 Issued 2014 04 16 ADVANCED SUSPENSION TECHNOLOGY www ohlins com
6. ote When you work with the fork leg make sure that the inner tube A is at lowest position to keep the oil lock sleeve B correctly positioned inside the inner tube 4 Drain the fork leg from oil 5 Use a 6 mm Allen key to remove the bottom screw Make sure not to lose the washer 6 Remove the damping rod from the fork leg Do not remove the top out spring If the top out spring falls out with the damping rod put it back in the fork leg Lowering kit 08865 01 only Install the spacer 21803 01 A and the top out spring B in the fork leg W Caution Make sure to install the spacer and the spring in the correct order 9 y nN N gt E o 2 0 gt 7 D E 2 E mo z gt e E ing VIOUNTLIN Remove the damping system MY 2002 2005 A Warning Spring compression creates a potential danger because of the violent force that loaded springs are capable of Important When you remove the top cap push down the top cap and at the same time pull up the inner tube to prevent uncontrolled release 2 Use a 13 16 open end wrench to loosen the top cap from the inner tube Important When you remove the top cap push down the top cap and at the same time pull up the inner tube to prevent uncontrolled release 3 Use a 14 mm wrench and a 13 16 open end wrench to loosen and remove the top cap from
7. the shaft 4 Remove the main spring 5 Drain the fork leg from oil 6 Use a 6 mm Allen key to remove the bottom screw Make sure not to lose the washer 7 Remove the cartridge from the fork leg ite o So q N o o N gt E 0 e o gt o D a E me o Ka w o gt e E 0 4 Use appropriate tool to carefully remove the oil seal clip 9 Remove the inner tube from the outer tube refer to the vehicle service manual 10 Examine the oil seal bushings and oil seal clip for wear Replace if needed 11 Apply oil seal grease according to the vehicle service manual on the oil seal surfaces inside the outer tube and on the outside of the oil seal 12 Put the oil lock sleeve 21802 01 in the outer tube Make sure to install it correctly 13 Install the inner tube in the outer tube Make sure that the inner tube is completely inserted in the outer tube Make sure that the oil lock sleeve is installed correctly 14 Install the oil seal and bushing according to the vehicle manual 15 Install the oil seal clip 16 Install the top out spring 21801 01 in the fork leg Lowering kit 08865 01 only Install the spacer 21803 01 A and the top out spring B in the fork leg W Caution i Lowering kit Make sure to install 1 08865 01 the spacer and the spring in the correct order
8. tridge 10 Make sure that the shaft assembly is in the bottom of the fork leg and that the outer tube is in bottom position Measure the oil level with a ruler For recommended oil level see setup data in this folder 11 Make sure that the guide sleeve internal is correctly positioned Make sure that the mark on the main spring is up Install the main spring over the pull up tool 01765 08 12 Carefully install the guide sleeve external Ww Caution The guide sleeve external is easily damaged 13 Push the spring and the guide sleeve external down and at the same time pull up the shaft Carefully insert the stopper plate tool 02810 03 below the shaft nut 14 Remove the pull up tool from the shaft 15 Make sure that the stopper plate tool stays in place Use a 13 mm wrench to adjust the shaft nut until bottomed 16 Install the top cap on the shaft until stop Note Make sure that the top cap is completely bottomed 17 Use a 13 16 open end torque wrench and a 13mm wrench to tighten the shaft nut to the top cap Tighten the shaft nut to 15 Nm 18 Push down the guide sleeve external and carefully remove the stopper plate tool Make sure not to damage the guide sleeve external 19 Pull up the inner tube and at the same time push down the top cap Use a 13 16 open end torque wrench to tighten the top cap to the
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