Instruction Manual for OHLINS models including: FKR 129, FKR 129 Ducati Panigale V4S Cartridge Kit, Ducati Panigale V4S Cartridge Kit, Panigale V4S Cartridge Kit, V4S Cartridge Kit, Cartridge Kit
Öhlins FKR Cartridge Kit Racing TTX25S - Parts World Shop
Kit Contents Description Cartridge kit O-ring Main spring 9.0 N/mm Main spring 9.5 N/mm Main spring 10.0 N/mm Sticker set Öhlins Owner's manual Part No FKR 129 00638-11 04744-90 04744-95 04744-10 07291-01 Pcs 1 2 2 2 2 1 1 Note! Please note that there can be small differences between your product and the images in these instructions. 1 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. 1 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. Ducati Panigale V4 S FKR 129 Mounting Instructions MOUNTING INSTRUCTIONS Warning! We strongly recommend to let an Öhlins dealer install this product. Warning! If you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over. Warning! 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. 1 Note! When you work with this product, see the vehicle service manual for vehicle specific procedures and important data. 1 Note! 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 Seal head tool Clamp tool Sleeve Sleeve Part no 01309-xx 00146-01 01791-25 01791-27 01765-03 01797-07 02810-01 00797-08 04702-04 24670-01 24669-02 24669-06 Applies Size Torque Soften thread locker Compression and rebound adjuster 3 mm Cylinder tube assembly 14 mm Main preload adjuster 14 mm Spring support 19 mm 100 g 50 ml 50 ml Original front fork 24669-02/06 Original inner tube Original cylinder tube 43 mm 34.2 mm 2 MOUNTING INSTRUCTIONS 1 Remove original front fork 1 Note! 4 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 1 Note! The following procedure applies to both front fork legs. 1 Remove top cap from outer tube. 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. 6 Drain front fork leg from suspension fluid. 7 Remove cartridge from front fork leg. [04702-04 seal head tool] 1 Note! If cylinder tube does not follow with cartridge kit, follow steps 7.1-7.9. 7.1 Remove outer tube from inner tube according to instructions in the vehicle service manual. 7.2 Install inner tube tool on inner tube. Do not place tool at sealing or gliding surface. [24670-01 clamp tool] [24669-02 sleeve 43 mm] 7.3 Soften thread locker between inner tube and fork bottom with a heat gun. [Heat gun] 7.4 Remove inner tube from fork bottom. 7.5 If cylinder tube was not removed in step 7, remove cylinder tube. [24670-01 clamp tool] [24669-06 sleeve 34.2 mm] 7.6 Remove and replace o-rings if worn or damaged. [Inner tube 04722-08 o-ring 40.87x3.53] [Cylinder tube 04722-47 o-ring 32x1.9] 7.7 Clean and degrease inner tube and fork bottom. 7.8 Install o-rings. Apply grease on o-ring. [00146-01 grease] 7.9 Install inner tube using inner tube tool. Apply Loctite 2700. Tighten to 100-120 Nm. [24670-01 clamp tool] [24669-02 sleeve 43 mm] [01791-27 Loctite 2700] 1 Note! To get the correct torque, make sure to place the torque wrench in a 90 degree angle to the Fork tube tool. 4 MOUNTING INSTRUCTIONS 3 Install Öhlins cartridge kit 1 Note! 1 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 Remove top cap, spring support and preload tube. 2 Remove cylinder tube assembly from shaft assembly. 3 Apply Loctite 2400 on adaptor thread. Apply grease on cylindrical sealing surface on adaptor. Install cylinder tube assembly in front fork leg with an extended hex key. Tighten to 2 3 60 Nm. [Extended hex key 14 mm] [01791-25 Loctite 2400] [00146-01 grease] 4 Fill gas reservoir with pressure approximately 5 bar, according to instructions in the vehicle service manual. 5 Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg. Warning! Fluid level must be approximately 50 mm above top of cylinder tube assembly. 5 MOUNTING INSTRUCTIONS 6 Install tool on shaft extension. 8 9 [01765-03 shaft extension tool] 7 Install tool on seal head. [01797-07 seal head tool] 1 Note! Make sure teeth are securely connected to seal head. 8 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. 9 Insert shaft assembly in front fork leg. Warning! Make sure no air is trapped in piston by carefully pump shaft assembly up and down with piston below fluid surface. 10 Install shaft assembly and tighten with your hand. 11 Remove clip and shaft extension tool. 12 Tighten seal head to 30 Nm and remove seal head tool. 13 Make sure that shaft assembly and outer tube are in their bottom positions. Set suspension fluid level according to chapter "Setup Data". 6 MOUNTING INSTRUCTIONS 14 Install tool on top of 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] 15 Pull up shaft assembly and grab spring support with a wrench. [Wrench 19 mm] 16 Remove shaft extension tool. 17 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] 18 Install o-ring on top cap. Apply grease on o-ring and thread. [00638-11 o-ring] [00146-01 grease] 19 Install top cap on shaft extension. Tighten to 20 Nm. [Socket 14 mm] 20 Remove wrench from spring support. 21 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] 22 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] 23 Install front fork legs in vehicle at recommended front fork leg position, according to chapter "Setup data". 24 Remaining installation, instructions according to vehicle service manual. 14 15 C B A 19 7 SETUP DATA MAIN SPRING GUIDE Recommended setup Compression adjustment Rebound adjustment Suspension fluid level Minimum suspension fluid level Suspension fluid part number Front fork leg position 14 14 180 232 01309-xx Standard clicks clicks mm mm 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. 1 Note! Only 8790-xx main springs are packed in pairs. Rider weight [kg] 50 60 70 80 90 100 110 Spring rate [N/mm] 8,5 8,5 9 9,5 9,5 10 10,5 Preload [turns] 3 5 5 4 6 5 5 Part number (pair) 08790-85 08790-85 08790-90 08790-95 08790-95 08790-10 08790-05 Part number (single) 04744-85 04744-85 04744-90 04744-95 04744-95 04744-10 04744-05 Air spring force diagram for one front fork leg 500 450 400 350 300 250 200 150 100 50 0 0 Fluid level [mm] 100 110 120 130 140 150 160 170 180 190 200 210 220 230 10 20 30 40 50 60 70 80 90 100 110 120 130 Stroke [mm] Force [N] 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 Part no. MI_FKR129_0 Issued 2023-01-20Adobe InDesign 18.1 (Windows) Adobe PDF Library 17.0