TOURATECH 09-048-5840-0 Suspension Cartridge Kit Extreme Instruction Manual
- October 30, 2023
- Touratech
Table of Contents
TOURATECH 09-048-5840-0 Suspension Cartridge Kit Extreme Instruction Manual
We recommend having the accessory parts fitted by a apecialist workshop.
Caution
Note
Warning
Liquid
Torque
Temple
2 Persons
Original motorcycle part
These instructions are written based on our current state of knowledge. Information is provided without any guarantee as to its accuracy. Subject to technical modifications. The order of assembly steps must be followed. Touratech accepts no liability for incorrectly fitted parts and resulting material damage or personal injury! Please observe applicable road vehicle (construction and use) regulations as well as EC/ECE Directives and applicable laws in your country. If parts are fitted which require inspection and/or approval after fitting, take your vehicle to a testing station immediately and have the vehicle papers updated. Check and if necessary tighten all bolted connections after 50 km. Standard tightening torques in Nm for bolted connections with strength class 8.8. For special tightening torques refer to your specialist workshop! Please take into account that fitting panniers, crash bars, foot peg lowering kits (rider and pillion),Kickstand enlargmentplate, front spoilers and engine guards may restrict the bike’s lean angle! If modifications are made to the fairing, stem, handlebar, fairing parts, etc., ensure that electrical wiring, brake lines, accelerator and clutch cables are refitted correctly. Check clearance, both sides with full steering lock . Always disconnect the battery when working on the electrics! We recommend cutting protective film to size and applying it to impact areas that are likely to be chipped by stones. Work on the brake system and suspension should always be carried out by a specialist workshop. The maximum load on luggage racks is 5 kg! Luggage racks ZegaPro TC is 10 kg! If other original accessories or aftermarket accessories are used, ensure clearance, fitment and do not come into contact with other parts! Apply conventional lubricant to stainless steel bolts prior to assembly. PDF fitting instructions also can be downloaded from the Touratech webshop.
Mounting Instructions
Touratech Suspension Cartridge Kit Extreme
Step by step instructions:
- Disassemble the fork legs from the fork clamp. (Figs. 1 + 2)
- Open the cap of the original fork. (Fig. 4)
- Remove the original fork springs and the spacers. (Fig. 5)
- Disassemble and remove the serial cartridge from the fork. (Fig. 5) “Attention: the original fastening screws will be used again.”
- Completely drain the oil in the fork from the fork stanchions.
- Remove the cap on the Touratech Suspension Closed Cartridge. Disassemble the spring and the bush. (Fig. 6)
- Slide the outer fork tube down all the way. (to the stop on the fork leg)
- Insert the Touratech Suspension Closed Cartridge into the fork tube and fasten the Touratech Suspension Closed Cartridge with the original screw. (Fig. 7)
- Fill approx. 250m1 of fork oil (Motorex SAE 15) into the fork tube, slide the outer tube upwards and downwards several times to ensure lubrication of the sliding bushes.
- Push the piston rod of the Touratech Suspension Closed Cartridge in completely. At the end of the piston travel, the “hydraulic end stop” creates noticeable resistance. (Fig. 8)
- Fill the fork tube with the supplied oil (Motorex SAE 1 5) with the air chamber quoted here.
- You can also use the “optional” oil level assembly tool (01 -058-0250-0) here for adjusting the air chamber.
- Now assemble the fork spring, the spacers and the cap on the Touratech Suspension Closed Cartridge. Use the supplied fork tool for hand-tightening the cap.
- Push the fork tube upwards and screw the cap and outer tube together with the supplied fork tool. (Fig. 11)