OHLINS FKS 523 Fork Cartridge Nix 30 Street Ducati Monster Instructions

OHLINS FKS 523 Fork Cartridge Nix 30 Street Ducati Monster Instructions

MOUNTING INSTRUCTIONS

Warning

We strongly recommend to let an 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

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

Note

Before you install this product clean the vehicle.

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

TOOLS, GREASE AND FLUID

TOOLS, GREASE AND FLUID

• Refer to the vehicle service manual for tools needed for removing/installing the front fork from the vehicle.
• Refer to the vehicle service manual for tools needed for removing the cartridge from the front fork

Tools needed for the cartridge kit

Remove the original front fork

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 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.

Left hand side front fork leg

Remove original

1. Loosen top cap from outer tube.
2. Slide outer tube down until it stops.
3. Remove seal head from inner tube according to instructions in the vehicle service manual.
4. Remove main spring and associated parts according to instructions in the vehicle service manual.
5. Drain front fork leg of suspension fluid.
6. Remove outer tube from inner tube according to instructions in the vehicle service manual.
7. Remove inner tube lock screw.

Warning! If the lock screw is not removed, the inner tube and front fork bottom will be damaged.

Warning! Inner tube thread may need to be repaired before removing inner tube [apply appropriate method].

1. Install inner tube tool on inner tube. Do not place the tool at sealing or gliding surface. [24670-01 Clamp tool] [24669-02 Sleeve 43]
2. Soften thread locker between inner tube and front fork bottom using a heat gun.
3. Remove inner tube from front fork bottom.
4. Remove and replace o-r ing if worn or damaged. Part no according to the vehicle spare part list.
5. Remove washer.

Install the compression cartridge kit

Caution! The cartridge kit is divided into compression and rebound cartridges. Install compression cartridge marked “COMP” in left hand side front fork leg

1. Remove the adaptor ring from the cartridge.

2. Install adaptor ring in front fork bottom.
   Note! Check the position and rotation of adaptor ring.

3. Install o-ring in front fork bottom. Grease according to the vehicle service manual. [00146-01 grease]

4. nstall inner tube using inner tube tool. Apply Loctite 2700. Tighten to 130 Nm. [24670-01 Clamp tool] [24669-02 Sleeve 43] [01791-27 Loctite 2700] Note! To get the correct torque, make sure to place the torque wrench in a 90 degree angle to the Fork tube tool

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

6. Remove top cap (A), spring support (B) and preload tube (C).

7. Apply Loctite 2400 on adaptor thread. Install cartridge using seal head tool. Tighten to 40 Nm. [01791-25 Loctite 2400] [01797-07 seal head tool]

8. Pour approximately 0.5 fluid in front fork leg. [01309-xx suspension fluid]

9. Use a hex key to open compression bleed adjuster fully. Install top cap directly to shaft extension (No spring or preload tube). Pull up outer tube and tighten it to the top cap with your hand. [Hex key 3 mm]

10. Pull outer tube up and down 10-15 times to pump out all air from the cartridge.

11. Remove top cap from front fork leg.

12. Make sure that shaft assembly and outer tube are in their bottom positions. Set suspension fluid level [according to chapter “Setup Data”].

13. Install shaft extension tool on top of shaft extension. Install preload tube (A), main spring (B) and upper spring support (C) over shaft extension tool. [01765-03 shaft extension tool]

14. Pull up shaft assembly and grab spring support with a wrench. [Wrench 19 mm]

15. Install o-ring on top cap. Apply grease on o-ring and thread. [00576-02 o-ring] [00146-01 grease]

16. Make sure that compression adjuster is fully  open before installing top cap. Use a hex key to open compression adjuster. Use a socket for the preload adjuster. Remove pull-up tool and install top cap to the shaft extension. Tighten to 20 Nm. [Hex key 3 mm] [Socket 14 mm]

17. Remove wrench from spring support. [Wrench 19 mm]

18. 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. [Wrench 46 mm]

19. Set main spring preload and compression adjusters [according to chapter “Setup Data”]. Use a hex key for compression adjuster. Use a socket for the preload adjuster. [Hex key 3 mm] [Socket 14 mm]

Right hand side front fork leg

Remove original

1. Loosen top cap from outer tube.
2. Slide outer tube down until it stops.
3. Loosen and remove top cap from shaft according to vehicle service manual
4. Remove main spring and surrounding parts from front fork leg
5. Drain front fork leg of suspension fluid.
6. Loosen cartridge according to vehicle service manual.
7. Remove cartridge from front fork leg.

Install the rebound cartridge kit

Caution! The cartridge kit is divided into compression and rebound cartridges. Install rebound cartridge marked “REB” in right hand side front fork leg

1. Remove top cap (A), spring support (B) and preload tube (C).
2. Insert the cartridge in the front fork leg.
3. Install bottom screw according to instructions in the vehicle service manual.
4. Pour approximately 0.5suspension fluid in front fork leg. [01309-xx suspension fluid]
5. Use a hex key to open rebound bleed adjuster fully. Install top cap directly to shaft extension (No spring or preload tube). Pull up outer tube and tighten it to the top cap with your hand. [Hex key 3 mm]
6. Pull outer tube up and down 10-15 times to pump out all air from the cartridge.
7. Remove top cap from front fork leg.  Make sure that shaft assembly and outer tube are in their bottom positions. Set suspension fluid level [according to chapter “Setup Data”]
8. Install shaft extension tool on top of shaft extension. Install preload tube (A), main spring (B) and upper spring support (C) over shaft extension tool. [01765-03 shaft extension tool]
9. Pull up shaft assembly and grab spring support with a wrench tool. [Wrench 19 mm]
10. Install o-ring on top cap. Apply grease on o-ring and thread. [00576-02 o-ring] [00146-01 grease]
11. Make sure that rebound adjuster is fully open before installing top cap. Use a hex key to open compression adjuster. Use a socket for the preload adjuster. Remove pull-up tool and install top cap to the shaft extension. Tighten to 20 Nm. [Hex key 3 mm] [Socket 14 mm]
12. Remove wrench from spring support. [Wrench 19 mm]
13. 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. [Wrench 46 mm]
14. Set main spring preload and rebound adjusters [according to chapter “Setup Data”]. Use a hex key for compression adjuster. Use a socket for the preload adjuster. [Hex key 3 mm]   [Socket 14 mm]

Install the front fork in the vehicle

Note The following procedure applies to both front  fork legs.

1. Install the front fork legs into the triple clamps at the position recommended in setup data (Fork leg position). See the vehicle service manual for correct procedure and tightening torque
   Note Measure the front fork leg position from the upper triple clamp to the top of the outer tube

2. Remaining installation, instructions according to vehicle service manual.

SETUP DATA

MAIN SPRING RECOMMENDATION

Rider weight [kg]| 50| 60| 70| 80| 90| 100| 110
---|---|---|---|---|---|---|---
Spring rate [N/mm]| 8| 8.5| 8.5| 9| 9| 9.5| 9.5
Preload [turns]| 5| 4| 6| 6| 7| 7| 8
Part number (pair)| 08423-80| 08423-85| 08423-85| 08423-90| 08423-90| 08423-95| 08423-95

Air spring force diagram for one front fork leg

Documents / Resources

| OHLINS FKS 523 Fork Cartridge Nix 30 Street Ducati Monster [pdf] Instructions
FKS 523 Fork Cartridge Nix 30 Street Ducati Monster, FKS 523, Fork Cartridge Nix 30 Street Ducati Monster, Street Ducati Monster
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