"service manual"
Contents
1. Repeat the R3 and F3 measuring procedure Note measures R1 R2 R3 Recommended Measures If no other recommendations are given in the Mounting Instructions follow these measures Formula F1 F2 7 7 x100 15 30 wheel travel Free sag F1 F3 wheel travel Ride height x100 20 40 Free sag Ride height 3 2 Adjust spring preload 1 If your measures differ significantly from the recommendations adjust the spring preload See chapter Spring Preload in this manual 2 If the ride height still differs from the recom mendations you may need to change to soft er harder spring Contact an hlins dealer for advice AWaring gt S Incorrect spring rate may result in a front geometry that is either too steep or too flat This can result in a tendency of under or over steering that could seriously affect the han dling characteristics of the motorcycle 4 ADJUSTERS A Warning Before riding always ensure that the basic settings made by hlins are intact Make only one adjustment at a time adjust in small steps and take notes Note For recommended setup see the Mounting Instructions or contact an hlins dealer Spring preload adjuster To turn the adjuster use a 14 mm wrench One 1 turn eguals 1 mm change in spring preload Turn the adjuster counter clockwise to fully closed position zero 0 Then turn clock wise and count2. SS lt gt SS SS SS SS S I gt 7 Measure the oil level and adjust if necessary See chapter 2 2 8 See the Spring recommendation in the Mounting Instructions or contact an hlins dealer for cor rect spring Install Pull up tool 01765 04 on top of the shaft extension Install the spring with the marking up over the tool 9 Install the guide sleeve and spring support over the tool 10 Pull up the shaft assembly and grab the spring support with a 19 mm wrench 11 Make sure that the compression rebound adjusters are fully open Remove the Pull up tool 01765 04 and mount the top cap on the shaft extension Use a 14 mm socket wrench Tightening torque 30 Nm 10 5 CHANGE SPRING AND OR OILE m 12 Make sure the fork leg is in a fully extend ed position Use Sleeve pin tool 00797 08 to tighten the top cap to the outer tube Tightening torque 10 Nm 13 Set the compression rebound and spring preload adjusters according to the Setup Data in the Mounting Instructions 14 Install the front fork legs into the triple clamps at the recommended Fork leg position according to Setup data in the Mounting instructions Tightening torgue according to vehicle service manual Note Measure the fork leg position from the upper triple clamp to the top of the outer tube 15 Reinstall all removed parts in the same way as they were before the installation See the vehicle service manua
3. Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to any one working with inspecting or using the product or to bystanders Mm Caution The Caution Symbol means Special precautions must be taken to avoid damage to the product 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 rec ommendations 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 O hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited 4 Adjusters nee 9 5 Change Spring and or Oil Level 10 6 Inspection and Maintenance 11 1 DESIGN Congratulations on your choice of purchas ing the h
4. handling ability and outstanding feedback from your vehicle Along comes the fact that your hlins product will be a long lasting friend deliv ering the very best of comfort and performance every time you go for a ride Go explore SAFETY PRECAUTIONS General Warnings Note The shock absorber front fork steering damper is an impor tant part of the vehicle and will affect the stability Note Read and ensure you understand the information in this manual and other technical documents provided by Ohlins before using the product Note Ohlins Racing AB can not be held responsible for any damage to the shock absorber front fork steering damp er vehicle other property or injury to persons if the instructions for mounting usage and maintenance are not followed exactly A Warning After installing the Ohlins 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 func tion is irregular or if you notice any leakage from the prod uct stop the vehicle immediately and return the product to an Ohlins dealer A Warning SAFETY SYMBOLS In this manual mounting instructions and other techni cal 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
5. the turns until you reach the desired number Adjustment range 0 18 mm Compression damping adjuster Left front fork leg Rebound damping adjuster Right front fork leg Adjust Compression and Rebound To adjust turn the adjuster using a 3 mm Allen key Turn the adjuster clockwise to fully closed position zero 0 Then turn counter clockwise to open and count the clicks until you reach the recommended number of clicks Adjustment range from fully closed valve to fully open valve is 24 clicks m Caution Turn gently not to damage delicate sealing surfaces Hand tighten only Compression damping adjuster Pa A Warnin g This procedure requires high technical knowledge and or experience of working with front forks Contact an hlins dealer for advice See the Vehicle Service Manual M Caution Work with only one fork leg at a time Do not mix the parts 1 Release the spring preload fully counter clockwise 2 Loosen the upper triple clamp by loosening the screws Loosen the top cap turn do not remove it use tool 00797 08 3 Remove the front fork from the vehicle accord ing to the vehicle service manual 4 Loosen the top cap from the outer tube use tool 00797 08 5 Use a 19 and a 14 mm wrench to loosen the top cap and remove it from the shaft extension 6 Remove the spring support guide sleeve and spring lt gt SS
6. FORCE Oil level high Oil level low 2 1 Fill Oil and Aerate A Warning Always aerate the damping system after changing adding oil Air in the system may cause poor or no function at all Note The following process applies to cartridge kit installed in the fork legs without spring support guide sleeve or spring 2 1 1 Make sure the shaft assembly is in bottom posi tion Pour Ohlins front fork fluid into the fork leg Fill up so that the oil level is above the top of the seal head during the aeration process Note Note that the oil level drops during the aeration process since the air goes out of the system 2 1 2 Open the adjusters fully Install the top cap directly to the shaft extension No spring guide sleeve or spring support 2 1 3 Pull up the outer tube and tighten it to the top cap Hand tighten only Make sure that the fork leg is fully extended 2 1 4 Close the adjusters fully and pump out all air from the damping system by pulling the outer tube up and down from fully extended to fully compressed 15 20 times 2 1 5 If aeration process was successful continue with step 2 2 Measure Oil Level If after aerating the oil level is below the top of the seal head fill up with more oil and repeat the aeration process f the oil level is below the top of the seal head there may be air trapped in the da
7. Fax 46 0 8 590 025 80 Sweden www ohlins com
8. Ohlins Fork Kit Adventure FKA 100 series Owner s Manual 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 continuously drawn to one specific detail moto cross 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 35 years the search for perfection and new functions is still the main focus of the company hlins Headquarters Uppl nds V sby Sweden Congratulations You are now the owner of an hlins product More than two hundred World Championships and other major world titles are definitive proof that hlins suspension offer out standing performance and reliability Every product has gone through rigorous test ing and engineers have spent thousands of hours doing their very best to use every possi ble experience from our 35 years within the rac ing sport The product that you now have in your pos session is pure racing breed that is built to withstand By installing this product on your vehicle you have made a clear statement you are a seri ous rider with a focus on getting the maximal
9. ession base valve At a compression movement the fluid is forced through the compression shim stack the com pression base valve shim stack and at the same time through the rebound check valve At a rebound movement the fluid is forced through the rebound shim stack and through the compression check valve The fluid displaced by the piston shafts is directed either into or out of the cylinder tubes through the holes Main Piston Bleed valve Compression and rebound damping Small needle valve that creates a flow restriction simply by being small Shim valve Compression and rebound damping Fluid pressure has to deflect thin steel washers shims to open up an orifice and allow fluid to flow through it Check valve Compression and rebound damping A spring preloaded shim that opens easily for return flow of fluid when the direction of move ment of the front fork changes Base valve Shim valve Compression damping only Fluid pressure has to deflect thin steel washers shims to open up an orifice and allow fluid to flow through it Compression Cartridge Top cap marked COMP Top cap marked REB Function The bleed valve and shim valve are used to build up damping force At slow stroke speeds the percentage going through the bleed valve is higher and at fast strokes the shim valve takes care of most of the flow The compression main piston shim valve works together with the compression base shim va
10. l for correct procedure and torque specifications 6 INSPECTION AND MAINTENANCE Preventive maintenance and regular inspection reduces the risk of poor performance If there is any need for additional service please contact an Ohlins dealer m Caution Never use strong detergents that can damage the surfaces of the front fork Thinner and brake cleaner will dry out seals increase the risk of friction oil leakage or even poor function n Caution Always use hlins High Performance Front Fork fluid 01309 Inspection points 1 Check the front fork for external oil leakage 2 Check the inner fork leg for scratches dents or other defects that may damage the seal bushing 3 Check the fender brackets and brake calliper attachments 4 Check the front fork attachments to the vehicle 11 Inspection Intervals Normal use Once a year or every 5000km Race track Every 10 hours Once every 2nd year or 20 000km 1 Change front fork fluid 2 Remove the outer fork leg and inspect the bushings seals and the full length of the inner fork leg 3 Check and replace seals and bushings if necessary Note Discarded Ohlins products should be handed over to an Ohlins dealer for proper disposal hlins Owner s Manual FKA kit Part No 07287 01 0 Issued 2013 07 02 O hlins Racing AB Your hlins retailer hlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands V sby
11. lins cartridge kit for adventure bikes The medium sized adventure bikes used in their right element on true adventures both on and off the road can now enjoy the improved com fort and performance from an Ohlins cartridge kit The Ohlins R amp D decided to go for a solution based on the successful Ohlins NIX technology to develop a cartridge kit that offers comfort and performance and will work long between ser vice intervals The cartridge kit is designed to fit easily in the upside down forks most adventure bikes are equipped with today Thanks to these new FKA100 kits the adventure bikes now have a fully adjustable front end The Ohlins front fork cartridge kit consists of one compression cartridge and one rebound cartridge Install the compression cartridge in the left front fork leg and the rebound cartridge in the right front fork leg The cartridges are marked at the top cap COMP for compression adjustment and REB for rebound adjustment Brief Description The compression and rebound cartridges are largely identical but work in opposite ways In the compression cartridge there is a base valve installed in the adaptor To achieve rebound damping instead of compression damping force the cylinder tubes and the main pistons are posi tioned in opposite directions in the compression and rebound cartridges When the front fork moves the fluid inside is forced to flow through the compression and rebound main pistons and the compr
12. lve Most of the oil flows through the main pis ton and at higher speed the base valve opens for oil flow The check valve together with the bleed valve since it can flow both directions handle return flows To control damping force the bleed valve can be changed by the external compression and rebound adjuster Action characteristics can be changed by alter ing the stiffness of the shim stack number of shims shim thickness diameter and shape Altering the shim stack should only be per formed by an authorized hlins dealer Oil lock During the last part of the stroke the oil lock pis ton enters the oil lock cup which gives a firmer damping Cylinder tube holes Cylinder tube holes Rebound Cartridge Oil Level The upside down front forks are very sensitive to oil level variations compared to the conven tional front fork types Therefore adjust the oil level with special care A change in the front fork oil level will not affect the air spring force in the early stage of the movement but will have a greater effect in the later stage Oil level Diagram The diagram below shows two different types of curves for the force that eguals to a specific oil level Raised Oil Level The air spring in the later half stage of travel is stronger which makes the front fork firmer Lowered Oil Level The air spring in the later half stage of travel is lessened which makes the front fork softer Oil Level Diagram
13. mping system which may cause poor or no function at all 2 2 Measure Oil Level Make sure that the shaft assembly is in the bot tom of the fork leg and that the outer tube is in its bottom position Measure the oil level with a ruler See figure For recommended oil level see the Mounting Instructions or contact an Ohlins dealer Add or remove oil to adjust to the recommended level The upper edge of the outer front fork leg seal head 3 1 Measure Sag Spring Preload Free Sag Ride Height Spring preload is a crucial part of setting your motorcycle since it affects the height of the motorcycle and the fork angle Before setting the preload measure the sag O Note The following procedure should be performed on a flat surface 1 Put the motorcycle on a work stand so that both wheels are off the ground and the sus pension 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 marked point to a fixed point for example the wheel axle R1 4 Measure the distance from the bottom of the upper triple clamp to a fixed point for exam ple 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 proce dures R2 and F2 6 Sit on the motorcycle in normal riding posi tion properly outfitted in your riding gear
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