1 otee!

Please note that there can be small differences between your product and the images in these instructions.

1 otee!

Please note that during storage and transport, especially at high ambient temperature, some of the oil and grease used for assembly may leak and stain the packaging. This will not cause damage to the product, wipe off the excessive oil or grease with a cloth.

Kit Contents

Description

Cartridge kit

Part o

FKR 105

O-ring 33x2

O-ring 40x2.5

00438-50

00576-02

Main spring 9.5 N/mm 04744-95

Main spring 10.0 N/mm 04744-10

Main spring 10.5 N/mm 04744-05

Sticker 00191-32

Sticker

Owner’s manual

00191-33

07291-01

1 otee!

Before you install this product, check the kit contents. If anything is missing, please contact an Öhlins dealer.

⚠ arninge!

Before you install this product, read the Öhlins

Owner’s manual. This product is an important part of the vehicle and the vehicle stability.

2

1

2

2

2

2

2

2

Pcs

1

Cartridge kit for Kawasaki ZX-10R

FKR 105

Mounting Instructions

MOUNTING INSTRUCTIONS

⚠ arninge!

We strongly recommend to let an Öhlins dealer install this product.

⚠ arninge!

If you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over.

⚠ arninge!

Spring compression creates a potential danger because of the violent force that loaded springs are capable of. Beware of this when you work with the front fork.

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When you work with this product, see the vehicle service manual for vehicle specific procedures and important data.

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Before you install this product clean the vehicle.

Tool

Vehicle service manual

Torque wrench 10-60 Nm

Heat gun

Hex key

Extended hex key

Socket

Wrench

Suspension fluid

Grease

Loctite 2400

Loctite 2700

Shaft extension tool

Seal head tool

Clip

Top cap tool

Inner tube tool

Part no Applies Size

01309-xx

00146-01

01791-25

01791-27

01765-03

01797-07

02810-01

00797-08

00786-05

Torque

Soften thread locker

Compression and rebound adjuster

3 mm

Cylinder tube assembly 14 mm

Main preload adjuster

Spring support

14 mm

19 mm

100 g

50 ml

50 ml

43 mm

2

MOUNTING INSTRUCTIONS

1 Remove original front fork

4

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The following procedure applies to both front fork legs.

1

Put the motorcycle on a workstand so that the front wheel barely touches the ground.

⚠ arninge!

Make sure the vehicle is securely supported so that it will not fall over.

2

Remove front fender, brake calipers, speed sensor (if present) and front wheel.

3

Release main spring preload fully (if present).

4

Note front fork leg position.

5

Loosen upper triple clamp.

6

Loosen (do not remove) top cap ½ turn.

7

Loosen lower triple clamp.

8

Remove front fork legs from triple clamps.

3

MOUNTING INSTRUCTIONS

2 Disassemble original front fork

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The following procedure applies to both front fork legs.

1

Remove top cap from outer tube.

10

Soften thread locker between inner tube and fork bottom with a heat gun.

[Heat gun]

11

Remove inner tube from fork bottom.

2

Slide outer tube down until it stops.

3

Remove top cap from shaft according to instructions in the vehicle service manual.

4

Release pressure from gas reservoir according to instructions in the vehicle service manual.

5

Remove main spring and associated parts according to instructions in the vehicle service manual.

12

Remove and replace o-ring if worn or damaged.

[Part no according to the vehicle spare part list]

13

Remove cartridge from inner tube.

14

Fill gas reservoir with pressure approximately

5 bar, according to instructions in the vehicle service manual.

6

Drain front fork leg from suspension fluid.

7

Remove outer tube from inner tube according to instructions in the vehicle service manual.

8

Remove inner tube lock screw .

⚠ arninge!

If lock screw is not removed inner tube and fork bottom will be damaged.

⚠ arninge!

Inner tube thread must be repaired before removing inner tube.

9

Install inner tube tool on inner tube. Do not place tool at sealing or gliding surface.

[00786-05 inner tube tool]

4

MOUNTING INSTRUCTIONS

3 Install Öhlins cartridge kit

1

1 otee!

The following procedure applies to both front fork legs.

✋ Cautione!

The cartridge kit is divided into compression and rebound cartridges.

Install compression cartridge marked “COMP” in left hand side front fork leg.

Install rebound cartridge marked “REB” in right hand side front fork leg.

1

Remove top cap, spring support and preload tube.

2

Remove cylinder tube assembly from shaft assembly.

3

Remove adaptor ring from cylinder tube assembly.

4

Clean and degrease inner tube, fork bottom, adaptor ring and washer.

5

Install o-ring on adaptor ring. Apply grease on o-ring.

[00438-50 o-ring]

[00146-01 grease]

6

Install adaptor ring in fork bottom.

7

Install washer in fork bottom.

8

Install o-ring in fork bottom. Apply grease on o-ring.

[00146-01 grease]

2

5-8

3

5

MOUNTING INSTRUCTIONS

9

Install inner tube using inner tube tool.

Apply Loctite 2700. Tighten to 130 Nm.

[00786-05 inner tube tool]

[01791-27 Loctite 2700]

⚠ arninge!

Make sure no air is trapped in piston by carefully pumping shaft assembly up and down with piston below fluid surface.

17

Install shaft assembly and tighten with your hand.

10

Install cylinder tube assembly in front fork leg with an extended hex key. Apply Loctite 2400 on adaptor thread. Tighten to 60 Nm.

[Extended hex key 14 mm]

[01791-25 Loctite 2400]

11

Install outer tube according to instructions in the vehicle service manual.

12

Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg.

18

Remove clip and shaft extension tool.

19

Tighten seal head to 30 Nm and remove seal head tool.

9

10

⚠ arninge!

Fluid level must be approximately 50 mm above top of cylinder tube assembly.

13

Install tool on shaft extension.

[01765-03 shaft extension tool]

14

Install tool on seal head.

[01797-07 seal head tool]

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Make sure teeth are securely connected to seal head.

15

Compress top out spring fully and insert clip.

[02810-01 clip]

⚠ arninge!

If top out spring is not completely compressed, adjust shaft extension tool to achieve complete compression of top out spring.

16

Insert shaft assembly in front fork leg.

15 16

6

MOUNTING INSTRUCTIONS

20

Make sure that shaft assembly and outer tube are in their bottom positions.

Set suspension fluid level according to chapter

“Setup Data”.

21

Install tool on shaft extension.

Install preload tube (A), main spring (B) and spring support (C) over shaft extension tool. Select main spring according to chapter

“Main spring guide”.

[01765-03 shaft extension tool]

22

Pull up shaft assembly and grab spring support with a wrench.

[ rench 19 mm]

23

Remove shaft extension tool.

29

Set compression, rebound and main spring adjusters according to chapter “Setup Data”.

Use a hex key for compression and rebound adjusters. Use a socket for main spring preload adjuster.

[Hex key 3 mm]

[Socket 14 mm]

30

Install front fork legs in vehicle at recommended front fork leg position, according to chapter “Setup data”.

31

Remaining installation, instructions according to vehicle service manual.

21

24

Make sure that compression and rebound adjusters are fully open before installing top cap. Use a hex key to open compression and rebound adjusters.

[Hex key 3 mm]

25

Install o-ring on top cap. Apply grease on o-ring and thread.

[00576-02 o-ring]

[00146-01 grease]

26

Install top cap on shaft extension. Tighten to

20 Nm.

[Socket 14 mm]

27

Remove wrench from spring support.

28

Pull up outer tube. Make sure front fork leg is in a fully extended position. Use top cap tool to tighten top cap to outer tube. Tighten to 10 Nm.

[00797-08 top cap tool]

C

B

A

22

26

7

SETUP DATA

Recommended setup

Compression adjustment

Rebound adjustment

14

14

Suspension fluid level 180

Minimum suspension fluid level 208

Suspension fluid part number

Front fork leg position

01309-xx

Standard clicks clicks mm mm

MAI SPRI G GUIDE

Make sure you choose the correct main spring for your rider weight, driving style and preferences.

Below you find a general recommendation of main spring rate for your weight. Contact an authorized

Öhlins service center for advice.

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Only 8790-xx main springs are packed in pairs.

Rider weight [kg]

Spring rate [N/mm]

Preload [mm]

50

9

5

60

9,5

4

70

10

4

80

10

6

90

10,5

5

100

11

5

110

11

7

Part number (pair) 08790-90 08790-95 08790-10 08790-10 08790-05 08790-11 08790-11

Part number (single) 04744-90 04744-95 04744-10 04744-10 04744-05 04744-11 04744-11

Air spring force diagram

550

300

250

200

150

100

50

0

0

500

450

400

350

10 20 30 40 50 60 70

Stroke [mm]

80 90 100 110 120 130

Level

130

140

150

160

170

180

190

200

Part no. MI_FKR105_0

Issued 2076-02-20

Öhlins 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.

© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited.

To find the latest information contact an Öhlins distributor.

Please contact Öhlins if you have any questions regarding the contents in this document.

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00 fax +46 8 590 025 80