1. Introduction
This manual provides essential information for the proper installation, operation, and maintenance of your Ohlins KT 303 Shock Absorber. Please read this manual thoroughly before attempting any installation or adjustments to ensure optimal performance and safety. Retain this manual for future reference.
2. Product Overview
The Ohlins KT 303 Shock Absorber represents the latest evolution in championship-winning twin-tube shock technology. It incorporates new needle profiles for both compression and rebound adjusters, leading to improved oil flow guidance and volume control. This design enhancement ensures more precise and consistent damping, allowing for finer tuning capabilities.
Figure 1: A detailed view of the Ohlins KT 303 Shock Absorber, featuring its gold-colored reservoir, silver body, and yellow spring. Visible are the adjustment mechanisms for compression and rebound.
3. Key Features
- Newest version of Ohlins championship-winning twin-tube shock technology.
- Features new needle profiles for compression and rebound adjusters.
- Updated design for improved oil flow guidance and volume control.
- Enables more precise, consistent damping and better fine-tuning.
- Wider available range of preload and compression adjustment.
- Rebound and compression are completely separated within the shock, eliminating the risk of cavitation.
4. What's in the Box
Upon unpacking, please verify that all components are present and undamaged. The standard package for the Ohlins KT 303 Shock Absorber includes:
- TTX GP Shock Absorber(s)
- User Manual (this document)
If any items are missing or damaged, please contact your authorized Ohlins dealer immediately.
5. Setup and Installation
Proper installation is crucial for the performance and safety of your vehicle. It is highly recommended that installation be performed by a qualified technician with experience in motorcycle suspension systems.
5.1 Pre-Installation Checks
- Ensure the shock absorber model (KT 303) is compatible with your specific vehicle.
- Inspect the shock absorber for any signs of shipping damage.
- Gather all necessary tools and safety equipment.
5.2 Installation Steps (General Guidance)
- Secure the vehicle on a stable stand, ensuring it cannot tip over.
- Carefully remove the existing shock absorber, noting the orientation and any spacers.
- Install the Ohlins KT 303 Shock Absorber in the correct orientation, ensuring all mounting points align.
- Tighten all mounting bolts to the vehicle manufacturer's specified torque settings. Refer to your vehicle's service manual.
- Perform initial sag adjustments as per Ohlins recommendations or your vehicle's specifications.
- Check for proper clearance with all surrounding components throughout the suspension's full range of motion.
Warning: Incorrect installation can lead to serious injury or damage to the vehicle. If you are unsure, seek professional assistance.
6. Operating and Adjustments
The Ohlins KT 303 Shock Absorber is designed for high performance and offers extensive adjustability to fine-tune your vehicle's handling characteristics. Understanding these adjustments is key to optimizing your ride.
6.1 Preload Adjustment
Preload adjusts the initial compression of the spring, affecting ride height and static sag. Adjusting preload requires specific tools and careful measurement to achieve the desired sag for your weight and riding style.
6.2 Compression Damping Adjustment
The compression adjuster controls the resistance to the shock's compression stroke. Turning the adjuster typically increases or decreases the damping force. This affects how the suspension reacts to bumps and impacts.
6.3 Rebound Damping Adjustment
The rebound adjuster controls the resistance to the shock's extension stroke. Proper rebound damping prevents the suspension from extending too quickly after compression, which can lead to a bouncy feel. Adjustments should be made incrementally.
For detailed adjustment procedures and recommended settings, refer to the specific Ohlins setup guide for your vehicle model or consult an authorized Ohlins service center.
7. Maintenance
Regular maintenance is essential to ensure the longevity and consistent performance of your Ohlins KT 303 Shock Absorber.
7.1 Cleaning
- Clean the shock absorber regularly with mild soap and water to remove dirt, dust, and road grime.
- Avoid using high-pressure washers directly on seals or adjusters.
- Dry thoroughly after cleaning.
7.2 Inspection
- Periodically inspect the shock for any signs of oil leaks, especially around the shaft seals.
- Check for damage to the spring, body, or mounting points.
- Ensure all bolts are securely tightened.
7.3 Service Intervals
Ohlins shock absorbers require periodic servicing to maintain peak performance. Service intervals vary depending on usage (e.g., street, track, off-road). Consult an authorized Ohlins service center for recommended service schedules and professional rebuilds.
8. Troubleshooting
This section provides basic troubleshooting steps for common issues. For complex problems, always consult an authorized Ohlins service center.
| Problem | Possible Cause | Solution |
|---|---|---|
| Excessive Bounciness | Insufficient rebound damping. | Increase rebound damping (turn adjuster as per manual). |
| Harsh Ride | Too much compression damping; incorrect spring rate; excessive preload. | Decrease compression damping; verify correct spring rate for rider weight; reduce preload. |
| Bottoming Out | Insufficient compression damping; insufficient preload; incorrect spring rate. | Increase compression damping; increase preload; consider a stiffer spring. |
| Oil Leakage | Damaged seals; internal component wear. | Requires professional inspection and service/rebuild. Do not operate with leaks. |
9. Specifications
The following table outlines the key specifications for the Ohlins KT 303 Shock Absorber:
| Specification | Detail |
|---|---|
| Brand | Ohlins |
| Model | KT 303 |
| Auto Part Position | Rear |
| Style | Modern |
| Vehicle Service Type | Street-Sport Motorcycles |
| Exterior Finish | Black |
| Material | Iron |
| Item Weight | 7.7 pounds (approx. 3.5 kg) |
| Product Dimensions | 19.5 x 9 x 5 inches (approx. 49.5 x 22.9 x 12.7 cm) |
10. Warranty Information
For detailed warranty terms and conditions applicable to your Ohlins KT 303 Shock Absorber, please refer to the warranty card included with your product or visit the official Ohlins website. Warranty claims should be processed through your original point of purchase or an authorized Ohlins dealer.
11. Support
Should you require technical assistance, service, or have questions regarding your Ohlins KT 303 Shock Absorber, please contact your authorized Ohlins dealer or the official Ohlins customer support channels. Providing your product model (KT 303) and purchase details will help expedite your request.
