OHLINS FCX 0205 Off-Road TTX Cartridge Kit Instructions

TTX Cartridge Kit for Husqvarna TC/FC
FCX 0205
Mounting Instructions

FCX 0205 Off-Road TTX Cartridge Kit

Note!
No springs are included in this kit. Use appropriate Öhlins Front Fork springs, part no. 08765-XX.
See the Spring guide in this folder or contact Öhlins for advice.

Note!
Please note that this image is a general representation of the product and may differ slightly from your product.

Note!
Please note that during storage and transportation, especially at high ambient temperatures, 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 0205| 1
TTX Cartridge sticker| 00191-63| 2
Sticker set Öhlins| | 1
Owner’s manual| 07296-91| 1
Base plug (with o-rings)| 15430-01| 2
Circlip| 15440-01| 2
Spacer 2 mm| 15443-02| 8
Spacer 10 mm| 15443-10| 4
Hydraulic stop cup| 15456-23| 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 its stability.

MOUNTING INSTRUCTIONS

SPECIAL TOOLS

Remove the original fork legs
⚠ 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.

1. Place the motorcycle on a work stand so that the front wheel barely touches the ground.

2. Remove the front wheel, plastic fork leg protectors, and the brake caliper.

3. Measure the distance from the top of the upper triple clamp to the center of the front wheel axle, see figure.
   Note measure
   Fork height position

4. Loosen the upper triple clamp screws.

5. Loosen the top cap ½ turn. Use an OEM Fork cap tool.

6. Loosen the lower triple clamp screws.

7. Remove the fork legs from the vehicle.

8. Clean the fork legs, and make sure to clean underneath the fork bottom.

9. 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

10. Use contact cleaner to clean the contact surfaces between the hydraulic stop cup and the fork bottom.
    Insert the hydraulic stop cup in the original fork leg, and insert it from the upper end of the fork tube.
    ✋ Caution!
    Make sure that the hydraulic stop cup is in the correct position before you tighten it.

11. Install and tighten the base plug into the fork bottom, tighten to 45 Nm.

12. Apply grease on the thread of the piston rod end.

13. 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.

14. Use a 12 mm socket to tighten the cartridge shaft end into the base plug, turn counterclockwise and tighten to a maximum of 18 Nm. Do not over-tighten.

15. Install the security snap-ring at the shaft end groove.

16. Pour Öhlins Front fork fluid into the fork leg, refer to the recommended setup in the Setup data.

17. Make sure that the front fork is fully extended.
    Use an Öhlins fork cap tool to tighten theÖhlins fork top cap to a maximum of 10 Nm.

18. Check and set the rebound and compression valves click positions, refer to the recommended setup in Setup data.

19. 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.

20. 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

Recommended preload range:

Overall 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 a specified spring preload the total spring installation length can be controlled prior to installation into the fork leg. See model-specific length in setup data.

SPRING GUIDE

Husqvarna TC/FC

| 125| 250| 350| 450
**kg/pound *| Low| Mid| High| Low| Mid| High| Low| Mid| High| Low| Mid| High**
60/132| 4,1| 4,2| 4,3| 4,3| 4,4| 4,5| 4,4| 4,5| 4,6| 4,5| 4,6| 4,7
65/143| 4,2| 4,3| 4,4| 4,4| 4,5| 4,6| 4,5| 4,6| 4,7| 4,6| 4,7| 4,8
70/154| 4,2| 4,3| 4,4| 4,4| 4,5| 4,6| 4,5| 4,6| 4,7| 4,6| 4,7| 4,8
75/165| 4,3| 4,4| 4,5| 4,5| 4,6| 4,7| 4,6| 4,7| 4,8| 4,7| 4,8| 4,9
80/176| 4,3| 4,4| 4,5| 4,5| 4,6| 4,7| 4,6| 4,7| 4,8| 4,7| 4,8| 4,9
85/187| 4,4| 4,5| 4,6| 4,6| 4,7| 4,8| 4,7| 4,8| 4,9| 4,8| 4,9| 5,0
90/198| 4,4| 4,5| 4,6| 4,6| 4,7| 4,8| 4,7| 4,8| 4,9| 4,8| 4,9| 5,0
95/209| 4,4| 4,5| 4,6| 4,6| 4,7| 4,8| 4,7| 4,8| 4,9| 4,8| 4,9| 5,0
100/220| 4,5| 4,6| 4,7| 4,7| 4,8| 4,9| 4,8| 4,9| 5,0| 4,9| 5,0| 5,1
105/231| 4,5| 4,6| 4,7| 4,7| 4,8| 4,9| 4,8| 4,9| 5,0| 4,9| 5,0| 5,1
110/242| 4,6| 4,7| 4,8| 4,8| 4,9| 5,0| 4,9| 5,0| 5,1| 5,0| 5,1| 5,2
115/253| 4,6| 4,7| 4,8| 4,8| 4,9| 5,0| 4,9| 5,0| 5,1| 5,0| 5,1| 5,2
120/264| 4,7| 4,8| 4,9| 4,9| 5,0| 5,1| 5,0| 5,1| 5,2| 5,1| 5,2| 5,3
125/275| 4,9| 5,0| 5,1| 5,1| 5,2| 5,3| 5,2| 5,3| 5,4| 5,3| 5,4| 5,5

Available spring rates 08765-series:
-39, -41, -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.
*Rider’s weight: Rider wearing proper riding gear. Make sure you know your total weight with riding gear. Riding gear weighs between 5 and 15 kg.

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.
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited.

Part no. MI_FCX 0205_0
Issued 2021-05-17
Öhlins Racing AB
Box 722
S-194 27 Upplands Väsby, Sweden
Phone +46 8 590 025 00
fax +46 8 590 025 80www.ohlins.com

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