FGKT 993/994 - Maxx Racing Performances
Contents
1. 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 O ring 00338 19 Oring 00338 10 Preload washer optional Base valve plug a3 Cartridge shaft end 16 Tighten the Ohlins fork top cap gently Use the standard top cap tool from the motorcycle manufacturer Handtighten only 17 Check and set the rebound and compression valves click positions according to the recommended settings in Set up data 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 Note It is very important that the triple clamps are tightened to the correct torque See your Vehicle Service Manual Top cap tool Replace Spring only 1 Put the motorcycle on a work stand 2 Loosen the screws that hold the fork legs in the upper triple clamps 3 Open up the top cap on the fork leg Use the proper fork top cap tool from the motorcycle manufacturer 4 Remove the security snapring in the bottom of the fork with a pair of pliers 5 Loosen the bottom end of the cartridge kit by turning clockwise 6 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 7 Remove the cartridge kit from the fork2. hlins 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 your Ohlins distributor Please consult your Ohlins dealer if you have any questions regarding the contents in this document Part no 07296 61_1 Issued 2008 12 15 Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 ADVANCED SUSPENSION TECHNOLOGY www ohlins com Before installing this product check the contents of the kit If anything is missing please contact your Ohlins dealer Kit Contents Part No Pcs Front Fork kit FGKT 993 994 1 Sticker TTX Cartridge 00191 29 2 Sticker Ohlins 00197 01 2 O ring 00338 10 2 O ring 00338 19 2 Base Plug 15430 01 2 Circlip 15440 01 2 Spacer 2 mm 15443 02 2 Spacer 3 mm 15443 03 2 Owner s Manual Mounting Instructions 07296 61 1 Note Order Oil and Spring Kit separately For correct spring rate see Spring Guide in this manual Use hlins Front Fork fluid 01312 xx only Please note that during storage and transportation especially at high ambient temperature some of the oil and grease used for assembling may leak and
3. 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 CS Disassemble the original front fork 9 Follow your vehicle service manual to remove the original front fork kit from the fork leg Turn the fork leg upside down to pour out the oil Make sure that the fork spring does not fall out Install the Ohlins front fork kit 10 Smear some red grease or similar on the o rings and install them onto the base plug according to figure 11 Install and tighten the base plug into the fork bottom use a 20 mm socket tightening torque 45 Nm 12 Install the preload washer s 15443 xx optional see Set up data Spring preload the recommended hlins spring see Spring guide and the cartridge kit into the standard 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
4. Loosen the upper triple clamp by loosening the screws 5 Loosen but not remove the top cap 1 2 turn Use a standard tool from the motorcycle manufacturer 6 Loosen the lower triple clamp by loosening the screws 7 Remove the front fork legs from the motorcycle gt i Clean the fork legs thoroughly Make sure to C2 clean underneath the fork bottoms Rebound damping 10 click Compression damping 15 click Spring preload 2mm Oil volume for 250F 0 340 litre Oil volume for 450F 0 370 litre Spring preload range 2to8mm can be adjusted by adding removing washers 15443 xx Oil volume range 0 330 0 400 litre Ohlins Front Fork fluid 01312 xx Measure the spring preload according to the following steps 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 2 Measure B 3 Measure C 4 Calculate preload Preload B A C 5 Adjust preload according to the desired 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 t
5. SX F 450 70 154 08765 43 75 165 08765 45 80 176 08765 47 85 187 08765 47 90 198 08765 49 95 209 08765 49 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 hlins products should be handed over to an authorized hlins workshop or distributor for proper disposal Breather plug 10 Spring rate N mm 3 9 4 1 4 3 4 3 4 5 4 7 4 3 4 5 4 7 4 7 4 9 4 9 Compression damping adjuster The compression adjuster is located at the top of the fork leg Adjust by turning the slotted screw with a screwdriver Compression damping adjuster Rebound damping adjuster The rebound adjuster is located at the bottom of the fork leg Adjust by turning the slotted screw with a screwdriver 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 St
6. leg and change the spring Note the preload washer if any Note The preload washers must be below the spring at the bottom end of the fork leg 8 Install the cartridge kit into the fork leg and push out the oil plug tool 01890 01 9 Tighten the shaft end counter clockwise into the fork bottom with tightening torque 18 Nm 10 Install the security snapring 11 Tighten the hlins fork top cap gently Use the standard top cap tool from the motorcycle manufacturer Handtighten only 3 Top cap tool Cy Security snapring Preload washer optional W Caution The top cap should only be tightened by hand or maximum torque of 10 Nm into the fork leg
7. stain the packaging This is in no way detrimental to the product wipe off the excessive oil grease with a cloth A Warning Before installing this product read this manual carefully The front fork is an important part of your vehicle and may affect the stability The installation procedure requires certain tools hlins Front Fork Kit for KTM SX F 250 450 Owner s Manual Mounting Instructions ADVANCED SUSPENSION TECHNOLOGY 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 Ohlins 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 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 Ohlins dealer distributor and proper tools A After installing this product take a test ride at low sp
8. atic sag can only be changed with softer or harder spring rate m Caution Do not use too 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 Oil volume Force 390cc 370cc 350cc 330cc Force Stroke Recommended Tools How to Install Replace Spring Set up Set up Data Spring Preload Adjustments Oil Volume Force Diagram Spring Guide Inspection and Maintenance Standard OEM Top Cap Tool Socket 20 mm Bottom Plug Socket 12 mm Shaft end Adjuster Housing Pliers for the security snapring Tool 01890 01 Plug 00 WON DWN oo Remove the fork legs from the vehicle VEHICLE ina A Warning i SERVICE It is advisable to have an Ohlins 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 Upper triple clamp 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 Lower triple clamp Front leg cover Note Note this dimension as fork height position 4
9. eed to make sure that your vehicle has maintained its stability If 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 working on this product always consult your Vehicle Service Manual This Manual should be considered as a part of the product and should 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 w 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 hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Brand Rider s weight Spring kg pounds KTM SX F 250 70 154 08765 39 75 165 08765 41 80 176 08765 43 85 187 08765 43 90 198 08765 45 95 209 08765 47 KTM
10. he 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 A Warning Before riding always ensure that the basic settings made by Ohlins 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 marked 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 es i QIN Recommended Measures If no other recommendations are given in the Vehicle Manual follow the measures below Free sag R1 R2 Rear 30410 mm Ride height R1 R3 F1 F3 Rear 100 10 mm Front 45 10 mm Adjust spring preload
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