OHLINS FKS 524 NIX 30 Street Cartridge Kit Instruction Manual

OHLINS FKS 524 NIX 30 Street Cartridge Kit

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

Note!
Please note that during storage and transport, especially at high ambient temperatures, 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 excess oil or grease with a cloth.

Kit Contents

Kit Contents

Description| Part No| Pcs
Front fork kit| FKS 524| 1
O-ring| 00576-01| 2
Sticker set Öhlins| –| –
Owner’s manual| 07284-01| 1

Warning!
This kit should only be installed by an authorized Öhlins dealer. The installation procedure requires certain tools.

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 and this document. This product is an important part of the vehicle and the vehicle stability.

Warning!
We strongly recommend letting 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.

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 needed for the original front fork

• 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 Öhlins cartridge kit

Remove the original front fork

Note!
The following procedure applies to both front fork legs.

1. Put the motorcycle on a work stand 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 the front fender, brake calipers, speed sensor (if present), and front wheel.

3. Note the front fork leg position.

4. Loosen upper triple clamp.

5. Loosen lower triple clamp.

6. Remove front fork legs from triple clamps.

Disassemble the original front fork

Remove original

1. Loosen the top cap from the outer tube.

2. Slide the outer tube down until it stops.

3. Loosen and remove the top cap from the shaft according to the vehicle service manual.

4. Remove the main spring and surrounding parts from the front fork leg.

5. Drain the front fork leg of the suspension fluid.

6. Loosen the cartridge according to the vehicle service manual.

7. Remove the cartridge from the front fork leg.
   Install the Öhlins 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. Install rebound cartridge marked “REB” in right-hand side front fork leg.

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

9. Insert the cartridge in the front fork leg.

10. Install the bottom screw according to the instructions in the vehicle service manual.

11. Pour approximately 0.5-liter Öhlins suspension fluid into the front fork leg.
    Warning!
    The fluid level must be approximately 50 mm above the top of the cylinder tube assembly.

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

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

14. Remove the top cap from the front fork leg.

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

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

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

18. Install an O-ring on the top cap. Apply grease on the o-ring and thread.

19. [00576-01 o-ring]

20. [00146-01 grease]

21. Make sure that the compression and rebound adjusters are fully open before installing the top cap. Use a hex key to open the compression and rebound adjusters. Remove the pull-up tool and install the top cap to the shaft extension. Tighten to 20 Nm.

22. [Hex key 3 mm]

23. [Socket 14 mm]

24. Remove the wrench from the spring support.

25. Pull up the outer tube. Make sure the front fork leg is in a fully extended position. Tighten the top cap to the outer tube. Tighten to 10 Nm.
    [Wrench 46 mm]

26. Set main spring preload, compression and rebound adjusters according to the chapter “Setup Data”. Use a hex key for compression and rebound adjusters. Use a socket for the preload adjuster.

27. [Hex key 3 mm]

28. [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 the setup data (Front fork leg position). See the vehicle service manual for the 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 the vehicle service manual.

SETUP DATA

MAINSPRING GUIDE

Make sure you choose the correct main spring for your rider’s weight, driving style, and preferences. Below you find a general recommendation of the main spring rate for your weight. Contact an authorized Öhlins service center for advice.

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

www.ohlins.com.

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