FKR 105 - Ohlins

FKR 105 - Ohlins
Kit Contents
11 Note!
Please note that there can be small differences
between your product and the images in
these instructions.
11 Note!
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.
Description
Part No
Pcs
Cartridge kit
FKR 105
1
O-ring 33x2
00438-50
2
O-ring 40x2.5
00576-02
2
Main spring 9.5 N/mm
04744-95
2
Main spring 10.0 N/mm
04744-10
2
Main spring 10.5 N/mm
04744-05
2
Sticker
00191-32
2
Sticker
00191-33
2
Owner’s manual
07291-01
1
11 Note!
Before you install this product, check the kit
contents. If anything is missing, please contact
an Öhlins dealer.
⚠⚠ Warning!
Before you install this product, read the Öhlins
Owner’s manual. This product is an important
part of the vehicle and the vehicle stability.
Cartridge kit for Kawasaki ZX-10R
FKR 105
Mounting Instructions
MOUNTING INSTRUCTIONS
⚠⚠ Warning!
⚠⚠ Warning!
We strongly recommend to let an Öhlins dealer
install this product.
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.
⚠⚠ Warning!
If you work with a lifted vehicle, make sure that it
is safely supported to prevent it from tipping over.
11 Note!
When you work with this product, see the
vehicle service manual for vehicle specific
procedures and important data.
11 Note!
Before you install this product clean the vehicle.
Tool
Part no
Applies
Size
Vehicle service manual
Torque wrench 10-60 Nm
Torque
Heat gun
Soften thread locker
Hex key
Compression and
rebound adjuster
Extended hex key
Cylinder tube assembly 14 mm
Socket
Main preload adjuster
14 mm
Wrench
Spring support
19 mm
3 mm
Suspension fluid
01309-xx
Grease
00146-01
100 g
Loctite 2400
01791-25
50 ml
Loctite 2700
01791-27
50 ml
Shaft extension tool
01765-03
Seal head tool
01797-07
Clip
02810-01
Top cap tool
00797-08
Inner tube tool
00786-05
43 mm
2
MOUNTING INSTRUCTIONS
1 Remove original front fork
4
11 Note!
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.
⚠⚠ Warning!
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
10
Soften thread locker between inner tube and
11 Note!
fork bottom with a heat gun.
The following procedure applies to both front
fork legs.
[Heat gun]
11
1
Remove inner tube from fork bottom.
Remove top cap from outer tube.
12
2
Remove and replace o-ring if worn or
Slide outer tube down until it stops.
damaged.
3
[Part no according to the vehicle spare part
Remove top cap from shaft according to
list]
instructions in the vehicle service manual.
13
4
Remove cartridge from inner tube.
Release pressure from gas reservoir according
14
to instructions in the vehicle service manual.
Fill gas reservoir with pressure approximately
5
5 bar, according to instructions in the vehicle
Remove main spring and associated parts
service manual.
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.
⚠⚠ Warning!
If lock screw is not removed inner tube and fork
bottom will be damaged.
⚠⚠ Warning!
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
11 Note!
The following procedure applies to both front
fork legs.
✋✋ Caution!
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
2
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.
5-8
8
Install o-ring in fork bottom. Apply grease on
o-ring.
[00146-01 grease]
5
3
MOUNTING INSTRUCTIONS
⚠⚠ Warning!
9
Make sure no air is trapped in piston by
carefully pumping shaft assembly up and down
with piston below fluid surface.
Install inner tube using inner tube tool.
Apply Loctite 2700. Tighten to 130 Nm.
[00786-05 inner tube tool]
[01791-27 Loctite 2700]
17
10
Install shaft assembly and tighten with your
hand.
Install cylinder tube assembly in front fork leg
with an extended hex key. Apply Loctite 2400
18
on adaptor thread. Tighten to 60 Nm.
Remove clip and shaft extension tool.
[Extended hex key 14 mm]
19
[01791-25 Loctite 2400]
Tighten seal head to 30 Nm and remove seal
11
head tool.
Install outer tube according to instructions in
the vehicle service manual.
9
12
Pour approximately 0.5 litre Öhlins suspension
10
fluid in front fork leg.
⚠⚠ Warning!
Fluid level must be approximately 50 mm
above top of cylinder tube assembly.
13
Install tool on shaft extension.
[01765-03 shaft extension tool]
15
14
Install tool on seal head.
[01797-07 seal head tool]
11 Note!
Make sure teeth are securely connected to seal
head.
15
Compress top out spring fully and insert clip.
[02810-01 clip]
⚠⚠ Warning!
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.
6
16
MOUNTING INSTRUCTIONS
20
29
Make sure that shaft assembly and outer tube
Set compression, rebound and main spring
are in their bottom positions.
adjusters according to chapter “Setup Data”.
Set suspension fluid level according to chapter
Use a hex key for compression and rebound
“Setup Data”.
adjusters. Use a socket for main spring preload
adjuster.
21
[Hex key 3 mm]
Install tool on shaft extension.
[Socket 14 mm]
Install preload tube (A), main spring (B) and
spring support (C) over shaft extension
30
tool. Select main spring according to chapter
Install front fork legs in vehicle at
“Main spring guide”.
recommended front fork leg position, according
[01765-03 shaft extension tool]
to chapter “Setup data”.
22
31
Pull up shaft assembly and grab spring support
Remaining installation, instructions according
with a wrench.
to vehicle service manual.
[Wrench 19 mm]
23
21
Remove shaft extension tool.
24
22
Make sure that compression and rebound
adjusters are fully open before installing top
C
cap. Use a hex key to open compression and
rebound adjusters.
[Hex key 3 mm]
B
25
Install o-ring on top cap. Apply grease on o-ring
and thread.
A
[00576-02 o-ring]
[00146-01 grease]
26
Install top cap on shaft extension. Tighten to
20 Nm.
26
[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]
7
SETUP DATA
MAIN SPRING GUIDE
Recommended setup
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.
Compression adjustment
14
clicks
Rebound adjustment
14
clicks
Suspension fluid level
180
mm
Minimum suspension fluid level
208
mm
Suspension fluid part number
01309-xx
Front fork leg position
Standard
Rider weight [kg]
11 Note!
Only 8790-xx main springs are packed in pairs.
50
60
70
80
90
100
110
Spring rate [N/mm]
9
9,5
10
10
10,5
11
11
Preload [mm]
5
4
4
6
5
5
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
500
Level
450
130
140
150
160
170
180
190
200
400
Force [N]
350
300
250
200
150
100
50
0
0
10
20
30
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.
40
50
60
70
Stroke [mm]
80
90
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
100
110
120
130
Part no. MI_FKR105_0
Issued 2076-02-20
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