OHLINS FKS 522 NIX 30 Street Cartridge Kit Instruction Manual

OHLINS FKS 522 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 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.

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.

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.

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.

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.

• Remove front fender, brake calipers, speed sensor (if present) and front wheel.
• Release main spring preload fully (if present).
• Note front fork leg position.
• Loosen upper triple clamp.
• Loosen (do not remove) top cap ½ turn.
• Loosen lower triple clamp.
• Remove front fork legs from triple clamps.

Disassemble original front fork

Remove original

• Loosen top cap from outer tube and shaft.
• Slide outer tube down until it stops.
• Remove seal head from inner tube according to instructions in the vehicle service manual.
• Remove main spring and associated parts according to instructions in the vehicle service manual.
• Drain front fork leg of suspension fluid.
• Remove outer tube from inner tube according to instructions in the vehicle service manual.
• 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].

• 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]
• Soften thread locker between inner tube and front fork bottom using a heat gun. [Heat gun]
• Remove inner tube from front fork bottom.
• Remove and replace o-ring if worn or damaged. Part no according to the vehicle spare part list.
• Remove washer.

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.

• Remove the adaptor ring from the cartridge.
• Install adaptor ring in front fork bottom.

Note!
Check the position and rotation of adaptor ring.

• Install o-ring in front fork bottom. [00146-01 grease]
• Install 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.

• Install outer tube according to instructions in the vehicle service manual.
• Remove top cap (A), spring support (B) and preload tube (C).
• 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]
• Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg. [01309-xx suspension fluid]
• Use a hex key to open compression and rebound bleed adjusters fully. Install top cap directly to shaft extension (no main spring or preload tube). Pull up outer tube and tighten it to the top cap with your hand. [Hex key 3 mm]
• Pull outer tube up and down 10-15 times to pump out all air from the cartridge.
• 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”.
• Install shaft extension tool on top of shaft extension. Install preload tube (A), main spring with the marking up (B) and spring support (C) over shaft extension tool. [01765-03 shaft extension tool]
• Pull up shaft assembly and grab spring support with a wrench. [Wrench 19 mm]
• Install o-ring on top cap. Apply grease on o-ring and thread. [00576-02 o-ring] [00146-01 grease]
• Make sure that compression and rebound adjusters is fully open before installing top cap. Use a hex key to open compression and rebound adjusters. Remove pull-up tool and install top cap to the shaft extension. Tighten to 20 Nm. [Hex key 3 mm] [Socket 14 mm]
• Remove wrench from spring support. [Wrench 19 mm]
• Pull up outer tube. Make sure front fork leg is in a fully extended position. Tighten top cap to outer tube. Tighten to 10 Nm. [Wrench 46 mm]
• Set main spring preload, compression and rebound adjusters according to chapter “Setup Data”. Use a hex key for compression and rebound adjusters. 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.

• Install the front fork legs into the triple clamps at the position recommended in setup data (Front 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.

SETUP DATA

MAIN SPRING RECOMMENDATION

Spring are packed in pairs.

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. To find the latest information contact an Öhlins distributor. Please contact Öhlins if you have any questions regarding the contents in this document. Part no. MI_FKS522_0 Issued 2021-12-09 © Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited. 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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