OHLINS FKR 131 Cartridge Kit for Honda Installation Guide

OHLINS FKR 131 Cartridge Kit for Honda

OVERVIEW

Kit Contents

Description| Part No| Pcs
Cartridge kit| FKR 131| 1
O-ring| 00638-11| 2
Main spring 9.5 N/mm| 04744-95| 2
Main spring 10.0 N/mm| 04744-10| 2
Main spring 10.5 N/mm| 04744-05| 2
Sticker set Öhlins| –| –
Owner’s manual| 07291-01| 1

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 excessive oil or grease with a cloth.

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. This product is an important part of the vehicle and the vehicle’s stability.

MOUNTING INSTRUCTIONS

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.

Remove the original front fork

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

1. 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.

2. Remove the front fender, brake calipers, speed sensor (if present), and front wheel.

3. Release main spring preload fully (if present).

4. Note the front fork leg position.

5. Loosen upper triple clamp.

6. Loosen (do not remove) top cap ½ turn.

7. Loosen lower triple clamp.

8. Remove front fork legs from triple clamps.

Disassemble the original front fork

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

1. Remove the top cap from the outer tube.

2. Slide the outer tube down until it stops.

3. Remove the top cap from the shaft according to instructions in the vehicle service manual.

4. Release pressure from the gas reservoir according to instructions in the vehicle service manual.

5. Remove the main spring and associated parts according to instructions in the vehicle service manual.

6. Drain the front fork leg from suspension fluid.

7. Remove the cartridge from the front fork leg. [04702-04 seal head tool] Note!
   If the cylinder tube does not follow with the cartridge kit, remove the cylinder tube in step 12.

8. Remove the outer tube from the inner tube according to instructions in the vehicle service manual.

9. Install the inner tube tool on an inner tube. Do not place the tool at the sealing or gliding surface. [24670-01 clamp tool] [24669-02 sleeve 43 mm]

10. Soften the thread locker between the inner tube and fork bottom with a heat gun. [Heat gun]

11. Remove the inner tube from the fork bottom.

12. If the cylinder tube was not removed in step 7, remove the cylinder tube. [24670-01 clamp tool] [24669-06 sleeve 34.2 mm]

13. Remove and replace o-rings if worn or damaged. [Inner tube 04722-08 o-ring 40.87×3.53] [Cylinder tube 04722-47 o-ring 32×1.9]

14. Clean and degrease the inner tube and fork bottom.

15. Install o-rings. Apply grease on the o-ring. [00146-01 grease]

16. Install the inner tube using the inner tube tool. Apply Loctite 2700. Tighten to 100-120 Nm.

    • [24670-01 clamp tool]
    • [24669-02 sleeve 43 mm]
    • [01791-27 Loctite 2700]

Install Öhlins cartridge kit

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

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.

1. Remove the top cap, spring support, and preload tube.

2. Remove cylinder tube assembly from shaft assembly.

3. Apply Loctite 2400 on the adaptor thread. Apply grease on the cylindrical sealing surface of the adaptor. Install cylinder tube assembly in the front fork leg with an extended hex key. Tighten to 60 Nm.
   [Extended hex key 14 mm]

   • [01791-25 Loctite 2400]
   • [00146-01 grease]
   • 4. Fill the gas reservoir with a pressure of approximately 5 bar, according to instructions in the vehicle service manual.

4. Pour approximately 0.5-litre Öof Ohlins suspension fluid into the front fork leg.
   Warning!
   The fluid level must be approximately 50 mm above the top of the cylinder tube assembly.

5. Install the tool on the shaft extension. [01765-03 shaft extension tool]

6. Install the tool on the seal head. [01797-07 seal head tool] Note!
   Make sure teeth are securely connected to the seal head.

7. Compress the top out spring fully and insert the clip. [02810-01 clip] Warning!
   If the top-out spring is not completely compressed, adjust the shaft extension tool to achieve complete compression of top top-out spring.

8. Insert shaft assembly in front fork leg.
   Warning!
   Make sure no air is trapped in the piston by carefully pumping the shaft assembly up and down with the piston below the fluid surface.

9. Install the shaft assembly and tighten it with your hand.

10. Remove the clip and shaft extension tool.

11.  Tighten the seal head to 30 Nm and remove the seal head tool.

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

13. Install the tool on top of the shaft extension. Install preload tube (A), main spring (B), and spring support (C) over the shaft extension tool. Select the main spring according to the chapter “Main Spring Guide”. [01765-03 shaft extension tool]

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

15. Remove the shaft extension tool.

16. Make sure that compression and rebound adjusters are fully open before installing the topcap. Use a hex key to open compression and rebound adjusters. [Hex key 3 mm]

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

    • [00638-11 o-ring]
    • [00146-01 grease]

18. Install top cap on shaft extension. Tighten to 20 Nm. [Socket 14 mm]

19. Remove the wrench from the spring support.

20. Pull up the outer tube. Make sure the front fork leg is in a fully extended position. Use the top cap tool to tighten the top cap to the outer tube. Tighten to 10 Nm. [00797‑08 top cap tool]

SETUP DATA

Recommended setup

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.

Note!

• Only 8790-xx main springs 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.
• 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 Part no. MI_FKR131_0 Issued 2024-02-09

• www.ohlins.com

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