OHLINS FCX 0202 TTX Cartridge Kit for Honda Suzuki Kawasaki Instruction Manual

: June 4, 2024
: OHLINS

Table of Contents

OHLINS FCX 0202 TTX Cartridge Kit for Honda Suzuki Kawasaki
MOUNTING INSTRUCTIONS
SETUP DATA
SPRING GUIDE
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OHLINS FCX 0202 TTX Cartridge Kit for Honda Suzuki Kawasaki

OHLINS FCX 0202 TTX Cartridge Kit for Honda Suzuki
PRODUCT Note
No springs included in this kit. Use appropriate Öhlins Front Fork springs, part no. 08431-XX. See the Spring guide in this folder or contact Öhlins for advice.

Please note that this image is a general representation of the product and may differ slightly from your product.
Please note that during storage and transportation, especially at high ambient temperature, some of the oil and grease used for assembling may leak and stain the packaging. This is in no way detrimental to the product, wipe off the excessive oil/grease with a cloth.
Kit Contents

Description| Part No| Pcs
TTX Cartridge Kit| FCX 0202| 1
TTX Cartridge sticker| 00191-63| 2
Sticker set Öhlins| | 1
Owner’s manual| 07296-91| 1
Base plug (with o-rings)| 15430-20| 2
Circlip| 15440-01| 2
Spacer 2 mm| 15443-02| 8
Spacer 10 mm| 15443-10| 2

Sticker service schedule
MX fork & shock

| 15211-01| 1

Note
Before installing this product, check the contents of the kit. If anything is missing, please contact an Öhlins dealer.
Warning
Before installing this product, read the Öhlins Owner’s Manual. The shock absorber/front fork/steering damper is an important part of your vehicle and will affect the stability.

MOUNTING INSTRUCTIONS

SPECIAL TOOLS

Tool	Part no	Size
Öhlins Fork cap tool, octagon	01892-03	50 mm

Remove the original fork legs

Warning
We strongly recommend to let an Öhlins dealer install this product.

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.

Before you install this product clean the vehicle.

Place the motorcycle on a work stand so that the front wheel barely touches the ground.
Remove the front wheel, plastic fork leg protectors and the brake caliper.
Measure the distance from the top of the upper triple clamp to the center of the front wheel axle,
Note measure

Fork height position|
Loosen the upper triple clamp screws.
Loosen the top cap ½ turn. Use an Öhlins Fork cap tool.
Loosen the lower triple clamp screws.
Remove the fork legs from the vehicle.
Clean the fork legs, make sure to clean underneath the fork bottom.
Refer to the vehicle service manual to remove the original front fork and spring from the fork leg. Turn the fork legs upside down and pour out all oil.

Install the Öhlins cartridge kit

Note
Standard OEM hydraulic stop cup is used together with the Öhlins cartridge kit.

Install and tighten the base plug into the fork bottom, tighten to 45 Nm.
Apply grease on the thread of the piston rod end.
Insert, if any, the preload washer/s, recommended spring and the cartridge kit into the original fork leg. Note
Place the preload washer/s below the spring, at the bottom end of the fork leg.
Use a 12 mm socket to tighten the cartridge shaft end into the base plug, turn counter clockwise and tighten to maximum 18 Nm. Do not over tighten.
Install the security snap-ring at the shaft end groove.
Pour Öhlins Front fork fluid in the fork leg, refer to the recommended setup in Setup data.
Make sure that the front fork is fully extended. Use to tighten the Öhlins fork top cap to maximum 10 Nm.
Check and set the rebound and compression valves click positions, refer to the recommended setup in Setup data.
Install the front fork legs into the triple clamps. Set the fork legs at the same height position as before. Refer to the vehicle service manual for correct tightening torque.
Note The front fork length might change when installing the Öhlins cartridge kit. See setup data for front fork length before and after installation of Öhlins cartridge kit.
Install the brake caliper and the front wheel. Make sure that all removed parts are installed in the same positions that they were before.

Note It is very important to tighten the triple clamps to the correct torque, refer to the vehicle service manual.

SETUP DATA

Front fork length Kawasaki KX 450 & Suzuki RM-Z450 (OEM)	942	mm

Front fork length CRF 250R/450R
(OEM)| 945| mm
Front fork length (Öhlins cartridge kit)| 944| mm
Front fork stroke (Öhlins cartridge kit)| 299| mm
Öhlins cartridge kit length| 950| mm
Rebound damping| 14| clicks
Compression damping| 14| clicks
Spring preload*| 10| mm
Total spring installation length| 479| mm
Fluid volume 450 (each leg)| 0,390| litre
---|---|---
Fluid volume 250 (each leg)| 0,370| litre
Fluid volume range| 0,320-0,420 litre
Öhlins front fork fluid| 01330-XX
Recommended preload range:

Over all spring rate [N/mm]| 4,1| 4,2| 4,3| 4,4| 4,5| 4,6| 4,7| 4,8| 4,9| 5,0| 5,1| 5,2
Rec. preload range [mm]| 8-13| 8-13| 8-12| 8-12| 8-12| 8-12| 8-11| 8-11| 7-11| 7-11| 7-11| 7-11

Adjust by adding/removing preload washer(s) 15443-XX.

To achieve specified spring preload the total spring installation length can be controlled prior installation into fork leg. See model specific length in setup data.

SPRING GUIDE

Honda CRF, Suzuki RM-Z, Kawasaki KX

| 250R| 450R, 450
**kg/pound *| Low| Mid| High| Low| Mid| High**
60/132| 4,3| 4,4| 4,5| 4,5| 4,6| 4,7
65/143| 4,4| 4,5| 4,6| 4,6| 4,7| 4,8
70/154| 4,4| 4,5| 4,6| 4,6| 4,7| 4,8
75/165| 4,5| 4,6| 4,7| 4,7| 4,8| 4,9
80/176| 4,5| 4,6| 4,7| 4,7| 4,8| 4,9
85/187| 4,6| 4,7| 4,8| 4,8| 4,9| 5,0
90/198| 4,6| 4,7| 4,8| 4,8| 4,9| 5,0
95/209| 4,6| 4,7| 4,8| 4,8| 4,9| 5,0
100/220| 4,7| 4,8| 4,9| 4,9| 5,0| 5,1
105/231| 4,7| 4,8| 4,9| 4,9| 5,0| 5,1
110/242| 4,8| 4,9| 5,0| 5,0| 5,1| 5,2
115/253| 4,8| 4,9| 5,0| 5,0| 5,1| 5,2
120/264| 4,9| 5,0| 5,1| 5,1| 5,2| 5,3
125/275| 5,1| 5,2| 5,3| 5,3| 5,4| 5,5

Available spring rates
08431-series: -43, -45, -47, -49, -51, -53
To get spring rates between the available rates, combine two springs with different rates. One with a lower and one with a higher spring rate. Example: To get spring rate 4,6: Use spring with 4,5 in one fork leg and 4,7 in the other fork leg.