OHLINS FKS 527 Front Forks Cartridge Kit Instruction Manual

OHLINS FKS 527 Front Forks Cartridge Kit

Product Specifications

• Part No: FKS 527
• Components Included: 1 Front Fork Kit for Harley-Davidson CVO Road Glide
• Tools Required: Torque wrench, Wrench, Hex key

Product Usage Instructions

Mounting Instructions

1. Remove original front fork:
   • Note: Procedure applies to both front fork legs.
   • Place the motorcycle on a workstand with the front wheel barely touching the ground.
2. Disassemble original front fork:
   • Loosen and remove top cap from outer tube.
   • Slide outer tube down until it stops.
   • Loosen and remove top cap from shaft according to vehicle service manual.
   • Remove main spring and surrounding parts from front fork leg.
   • Drain front fork leg of suspension fluid.
   • Loosen cartridge according to vehicle service manual.
   • Remove cartridge from front fork leg.
3. Install new components:
   • Install compression cartridge marked COMP in left front fork leg and rebound cartridge marked REB in right front fork leg.
   • Remove top cap, spring support, and preload tube.
   • Insert the cartridge into the front fork leg.
   • Install bottom screw as per vehicle service manual instructions.
   • Fill fluid in front fork leg ensuring proper level above the cylinder tube assembly.
   • Open compression and rebound bleed adjusters fully using a hex key.
   • Pump out air from the cartridge by moving the outer tube up and down 10-15 times.
   • Set suspension fluid level according to the manual.

Frequently Asked Questions (FAQ)

• Q: Are there any specific precautions to take during installation?
  A: Yes, ensure that the vehicle is safely supported to prevent tipping over, and be cautious of the potential danger posed by spring compression force.

• Q: What tools are required for installation?
  A: You will need a torque wrench, wrench, and hex key as specified in the manual.

• Q: Is it necessary to clean the vehicle before installing the product?
  A: Yes, it is recommended to clean the vehicle before installation.

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.

Kit Contents

Description| Part No| Pcs
Front fork kit| FKS 527| 1
O-ring| 00338-65| 2
Öhlins sticker white| 00191-32| 2
Öhlins sticker blue| 00191-33| 2
Owner’s manual| 07284-01| 1

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.

Front Fork Kit for Harley-Davidson CVO Road Glide

FKS 527

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

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

4. Note 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 original front fork

Remove original

1. Loosen top cap from outer tube.

2. Slide outer tube down until it stops.

3. Loosen and remove top cap from shaft according to vehicle service manual.

4. Remove main spring and surrounding parts from front fork leg.

5. Drain front fork leg of suspension fluid.

6. Loosen cartridge according to vehicle service manual.

7. Remove cartridge from front fork leg.
   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.

8. Remove top cap (A), spring support (B) and preload tube (C).

9. Insert the cartridge in the front fork leg.

10. Install bottom screw according to instructions in the vehicle service manual.

Caution!
Make sure that the cylinder tube adapter connects to the fork bottom properly.

1. Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg.
   Warning!
   Fluid level must be approximately 50 mm above top of cylinder tube assembly.

2. 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]

3. Pull outer tube up and down 10-15 times to pump out all air from the cartridge.

4. Remove top cap from front fork leg.

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

6. Install shaft extension tool on top of shaft extension.
   Install preload tube (A), main spring (B) and spring support (C) over shaft extension tool.
   [01765-03 shaft extension tool]

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

8. Install o-ring on top cap. Apply grease on o-ring and thread.
   [00438-26 o-ring] [00146-01 grease]

9. Make sure that compression and rebound adjusters are 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]

10. Remove wrench from spring support.

11. 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 50 mm]

12. 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.

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

2. Remaining installation, instructions according to vehicle service manual.

SETUP DATA

MAIN SPRING GUIDE
Make sure you choose the correct main spring for your rider weight, driving style and preferences. Below you find a general recommendation of main spring rate for your weight. Contact an authorized Öhlins service center for advice.

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.
© 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_FKS527_0 Issued 2024-04-23

www.ohlins.com

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