TTX25 Pressurized Cartridge Kit
Contents
1. Check stack ay EB valve Piston Piston Check Shims valve Cylinder g tY stack tube I a hoes WE All o Dividing a Oil piston 3 z movement 2a Or ae Gas 3 Setting up the Front Fork 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 Step 1 Spring Preload Free Sag Ride Height Spring preload is a crucial part of setting your motorcycle since it affects the height of the mo torcycle and the fork angle Before setting the preload measure the sag 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 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 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 proce dures R2 and F2 6 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Repeat t2. When the oil level is lowered The air spring in the later half stage of travel is lessened and thus the front fork is softer Note When measuring oil level remove spring and preload tube make sure the shaft assembly is in the bottom of the fork leg and that the outer tube is in its bottom position Measure the oil level with a ruler See set up data and oil level force diagram in this folder Oil level diagram The Diagram shows several curves for the force that equals to a specific oil level For recom mended oil level see the Mounting Instructions If the Mounting Instructions was not included in your Front Fork Cartridge Kit please con tact an Ohlins dealer 4 4 Fork Leg Position The Fork Leg Position changes the ride height at the front To measure the Fork Leg Position measure the distance between the outer tube and the upper triple clamp For recommended Fork Leg Position see the Mounting Instructions Ohlins Front Fork Fluid R The upper edge of the outer front fork leg Oil level Fork leg position 11 5 Change Spring and Check Change Oil Level A Warning This procedure requires high technical knowledge and or experience of working with front forks If you feel any insecurity regarding this procedure contact an hlins dealer for advice See the Vehicle Service Manual Note The following procedure is p
3. I JB JUL Compression Cylinder tube BA r shims stack holes i r Piston es ares Check valve er shims stack A A A nA Dividing wall Cylinder tube Fig 3 Piston Oil Flow Compression Compression f shims stack Piston Check valve flow Bleed valve flow Shim valve flow Check valve shims stack Rebound Front Fork Leg Check valve shims stack Piston Rebound shims stack Cylinder tube Cylinder tube holes Dividing wall Oil Dividing piston Gas 6 bar Rebound Bleed valve flow Check valve shims stack Check valve flow Piston Shim valve flow shims stack 2 Design and Function Compression damping Compression front fork leg When movement of the motorcycle causes com pression of the front fork Fig 4 compression movement the fluid below the compression pis ton is pressurized and goes through Compression shims stack Compression bleed valve Rebound front fork leg The gas pressure behind the dividing piston causes the fluid to go through e Rebound check valve shims stack Rebound bleed valve Small and insignificant flow compared to the check valve Displaced fluid During compression movement the shaft enters the cylinder tube and the correspondingly dis placed volume of fluid has to flow out of the cyl inder tube through the holes The fluid flows
4. Racing TTX25 Pressurized Cartridge Kit Owner s Manual ADVANCED SUSPENSION TECHNOLOGY Introduction 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 A careful observer Kenth s attention was continu ally drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth real ised 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 30 years the search for perfection and new functions is still the main focus of the company Congratulations You are now the owner of an Ohlins Front Fork Cartridge Kit More than two hundred World Championships and other major world titles are definitive proof that Ohlins products offer outstanding performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible expe rience from our 30 years within the racing sport The product that you now have in your posses sion is pure racing breed that is built to withstand By installing this Front Fork Cartridge Kit on your bike you have made a clear statement you are a serio
5. cated craftsmen at our facility in Up plands V sby Sweden Its predecessors have battled their way on numerous race tracks in World Superbike Supersport Superstock and AMA and the legacy continues in your front fork Thousands of hours have been spent together with some of the best teams in the world to find the optimal design and functionality to give you as much performance and comfort as possible You will feel the difference be sure Design The DNA of this new TTX25 front fork cartridge kit originates in the most prestigious race series in the world and the front fork cartridge kit is weight optimized as a result of that fact We have used exclusive racing components from our R amp D department to increase the performance of the front fork cartridge kit Our engineers that work on a daily basis with the top riders in the world often hear the word feel ing and control when they debrief after tests and races We wanted to pour as much of these important factors into your front fork cartridge kit and as a result the new TTX25 front fork cartridge kit gives you improved brake support and tire feel when riding For all of you that have your mind set on doing some serious racing we have some really good news Of course we have improved the design so that you easily can have it properly maintained and every kit is individually tested with an optimum setting spring and top out spring The new top cap desi
6. cle Service Manual This Manual should be considered a part of the product and should therefore accompany the product throughout its life cycle Safety Precautions Safety Symbol In this manual mounting instructions and other technical documents important infor mation 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 M 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 Contents Introduction Safety Precautions 1 Front Fork Cartridge Kit 2 Design and Function 3 Setting up the Front Fork 4 Adjustments 4 1 Adjusters 4 2 Spring 4 3 Oil Level 4 4 Fork Leg Position 5 Change Spring and Check Change Oil Level 6 Technical Specifications 7 Inspection and Maintenance onFND 10 11 11 12 14 14 1 Front Fork Cartridge Kit Introduction The product in your hand is an artwork prepared by our dedi
7. erformed on front fork legs installed in the vehicle 1 Release the spring preload fully counter clock wise 2 Loosen the upper triple clamp by loosening the screws 3 Loosen the top cap from the outer tube use tool 00797 08 4 Remove the top cap from the shaft extension Use a 19 and a 14 mm wrench to loosen the top cap 5 Remove the spring support the spring and the preload tube Check the oil level see figure Check Change Oil Level Note We recommend you to check the oil level since spring removal affects the oil level Measure oil level without spring or preload tube according to chapter Setting Up Oil Level 5 Change Spring and Check Change Oil Level 6 Put the preload tube and the spring on top of the cartridge See available springs in chapter Technical Specifications 7 Fasten tool 01765 03 on the top of the shaft ex 1 3 j Rn amp b Spring tension Install the spring support by leading it over the tool 8 Pull up the shaft assembly and grab the spring support with a 19 mm wrench 9 Open the compression and rebound adjusters fully Remove the pull up tool and install the top cap to the shaft extension Torque 15 Nm 10 Make sure the front fork leg is in a fully extended position Use tool 00797 08 to tighten the top cap to the outer tube Torque 10 Nm 11 Set the spring preload rebound and compress
8. for racing use only Recommended Service and Maintenance every 10 hrs Note Discarded hlins products should be handed over to an authorized work shop or distributor for proper disposal Owner s Manual 25mm Pressurized Cartridge Kit Part No 07286 01_0 Issued 2011 01 20 2011 Ohlins Racing AB Your Ohlins retailer Ohlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands Vasby Fax 46 0 8 590 025 80 Sweden www ohlins com
9. gn will send a signal to all curious spectators when you pull over next to your favourite caf or local race track its a signal that says that the owner of the bike has made his choice to go straight for the podium Now we are raising the new TTX25 front fork cartridge kit to a new level 2 Design and Function The front fork cartridge kit is divided into one compression cartridge and one rebound car tridge The compression cartridge is installed in the left front fork leg and the rebound cartridge in the right front fork leg Marked at the top cap is COMP for compression adjustment and REB for rebound adjustment Fig 1 The compression and rebound cartridges are both of the same design but works opposite each other To achieve rebound damping force instead of compression damping force the cylinder tubes and the pistons are turned opposite each other between the compression and the rebound cartridges Fig 2 When the front fork moves the fluid inside is forced to flow through the pistons At a compression movement the fluid is forced through the compression shim stack and at the same time through the rebound check valve And opposite at a rebound movement the fluid is forced through the rebound shim stack and through the compression check valve The fluid displaced by the shafts are directed to a reservoir in the bottom of the cartridges In the reservoir a dividing piston pressurizes the oil with 6 Bars
10. he measuring procedure R3 and F3 Recommended Measures If no other recommendations are given in the Mounting Instructions follow the measures below Free sag Without Rider R1 R2 F1 F2 Rear 5 15mm Front 20 30 mm Ride height With Rider R1 R3 F1 F3 Rear 25 35 mm Front 30 40 mm Note Always check on the Ohlins web site www ohlins com or with your Ohlins dealer distributor for the latest information Step 2 Adjust spring preload 1 If your measures differ significantly from the recommendations in the Mounting Instructions or the table above 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 your Ohlins dealer for advise A Warning 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 handling characteristics of the motorcycle 4 1 Adjusters Spring preload adjuster Use a 14 mm wrench to turn the upper adjust ment screw Maximum adjustment range is 18 mm One turn of the adjustment screw will cause 1 mm change in spring preload Compression damping adjuster Left front fork leg e Rebound damping adjuster Right front fork leg Adjust Compression and Rebound Use a 3 mm allen key Adjustment range from fully c
11. ion adjusters according to adjustments and set up data in the Mounting Instructions 12 Tighten the upper triple clamp with 20 Nm The marking facing up 19 mm wrench 13 6 Technical Specifications Front Fork length See specification card for your specific Front Fork Cartridge Kit Stroke See specification card for your specific Front Fork Cartridge Kit Free spring length 260 mm Compression adjustment Maximum open valve about 20 clicks Rebound adjustment Maximum open valve about 20 clicks Spring preload adjustment 0 18 mm 0 18 turns Spring rate Please see specification card or Mounting Instructions for your specific Front Fork Car tridge Kit Available Springs Part No Spring Rate 08790 65 6 5 N mm 08790 70 7 0 N mm 08790 75 7 5 N mm 08790 80 8 0 N mm 08790 85 8 5 N mm 08790 90 9 0 N mm 08790 95 9 5 N mm 08790 10 10 0 N mm 08790 05 10 5 N mm 08790 11 11 0 N mm 08790 15 11 5 N mm Oil Level See specification card or Mounting Instructions for your specific Front Fork Cartridge Kit m Caution Use only hlins high performance Front Fork Fluid 01309 01 7 Inspection and Maintenance Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for additional service please contact an authorised hlins service workshop Service Intervals This product is designed
12. losed valve clockwise to fully open valve counter clockwise is about 20 clicks Recom mended clicks from closed position according to your mounting instruction for your Front Fork Cartridge Kit 4 2 Spring The spring recommended in the Mounting In structions is chosen after evaluations performed on a test track according to motorcycle charac teristics for your specific motorcycle model Due to variations in ride style track conditions body shape etc the spring is often a subject for addi tional fine tuning Springs are available in 0 5 N mm intervals from 6 5 N mm to 11 5 N mm but the rate can be set to 0 25 N mm increments by using two different rates A method used on the race track Example Using 9 5 N mm in the right front fork leg and 10 0 N in the left front fork leg gives a com bined spring rate of 9 75 N mm 4 Adjustments Spring preload adjuster Compression adjuster Rebound adjuster 10 4 Adjustments 4 3 Oil Level Compared to conventional type of front forks the upside down front forks are very sensitive to vari ations in oil level 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 ef fect in the later stage When the oil level is raised The air spring in the later half stage of travel is stronger and thus the front fork harder
13. of gas Fig 2 Fig 1 Cartridges Top cap marked REB The compression and the rebound pistons are both of the same design The pistons have three flow paths for the fluid 1 Bleed valve Fig 3 centre gray arrows Small orifice that creates a flow restriction simply by being small 2 Shim valve Fig 3 outer black arrows Fluid pressure has to deflect thin steel washers shims to open up an orifice and allow fluid to flow through it 3 Check valve Fig 3 outer white arrows A spring preloaded shim that opens easily for return flow of fluid when the direction of movement of the front fork changes The bleed valve and shim valve build up damp ing 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 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 adjuster compression and rebound By altering the stiffness of the shim stack number thickness diameter and shape on the shim valve the characteristics of the damping action can be changed This should only be done by an authorized hlins service workshop Rebound Cartridge Compression Cartridge Fig 2 Schematic View Compression Front Fork Leg 2 Design and Function APU S
14. out from the holes in the cylinder tube between the cylinder tube and the outer cylinder tube down through the dividing wall to the reservoir in the bottom of the cartridge In the reservoir a dividing piston pressurizes the oil with 6 Bars of gas The dividing piston moves by the displaced fluid Rebound damping Rebound front fork leg When the spring forces the front fork to ex tend again Fig 5 rebound movement the fluid above the rebound piston is pressurized and in a similar pattern as compression movement goes through Rebound shims stack e Rebound bleed valve Compression front fork leg Similar to rebound front fork leg at compression damping the gas pressure behind the dividing piston causes the fluid to go through e Compression check valve shims stack Compression bleed valve Small and insignifi cant flow compared to the check valve Displaced fluid The fluid that was displaced by the piston shaft is now pushed back from the reservoir into the cyl inder tube by the dividing piston movement 2 Design and Function Fig 4 Front Fork Oil Flow Compression Movement Fig 5 Front Fork Oil Flow Rebound Movement Compression Rebound Compression Rebound Front Fork Leg Front Fork Leg Front Fork Leg Front Fork Leg Cylinder SG tube i holes Shims
15. us rider with a focus on getting the maxi mal handling ability and outstanding feedback from your bike Along comes the fact that your Front Fork Cartridge Kit will be a long lasting friend delivering the very best of comfort and performance every time you go for a ride Go explore Note The front fork is a very important part ofthe 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 an 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 After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability A 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 Vehi
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