kx250f 2008.pdf

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SPRING GuIDE
Brand
Kawasaki KX 250F
Rider’s weight*
kg/pounds
70/154
75/165
80/176
85/187
90/198
95/209
Spring
08762-44
08762-44
08762-46
08762-46
08762-46
08762-48
Spring rate
N/mm
4,4
4,4
4,6
4,6
4,6
4,8
Owner’s Manual/ Mounting Instruc
tions
Öhlins front fork kit FGKA 893
for Kawasaki KX 250F 2008
Please read before installing
Öhlins Racing AB cannot be held responsible
for any damage to the front fork kit, vehicle or
injury to persons, if the instructions for fitting and
maintenance are not followed exactly. Similarly, the
warranty will become null and void if the instructions
are not adhered to. This kit should only be installed
by an authorized Öhlins dealer. The installation
procedure requires certain tools. Before installing
this front fork kit, please check the contents of the
kit, listed below. If any part is missing, please contact
your Öhlins dealer.
* Rider’s weight: Rider wearing all riding equipment
MAINTENANCE
07296-20_1 FGKA 893 Issued 2008-07-10 Öhlins Racing AB Annette Asph/ Jonas Mossberg
Preventive maintenance and regular inspection
reduces the risk of functional disturbance.
Breather plug
Make sure to ventilate the front fork at regular
intervals:
1. Put the motorcycle on a workstand so that
the front wheel is off the ground.
2. Loosen the breather plug to release the
excess pressure in the front fork.
Breather plug
Kit Contents
Front fork kit FGKA 893
(1)
Sticker “TTX Cartridge”
00191-29 (2)
Sticker “Öhlins”
00197-01 (2)
O-ring
00338-10 (2)
O-ring
00438-12 (2)
Base plug TTX FG
15430-02 (2)
Circlip
15440-01 (2)
Spacer 2 mm
15443-02 (2)
Spacer 3 mm
15443-03 (4)
Owner’s Manual/Mounting Instr.07296-20 (1)
Recommended Service Intervals
Every 25 hours. Make your service and
maintenance according to Öhlins Work shop
manual.
NOTE!
Oil and spring kit need to be ordered separately.
For correct spring rate see spring guide
recommendation.
Use Öhlins fork oil only 01311-xx.
Disposal
Discarded Öhlins products should be handed
over to an authorized Öhlins workshop or
distributor for proper disposal.
In this manual
Recommended tools
Tool STD OEM top-cap tool
Tool 22mm socket (bottom plug)
Tool 12mm socket (shaft end adjuster housing)
Tool Pliers for the security snap-ring
Safety precautions
Mounting instruction
Set-up data
Adjustments/ Diagram: Oil volume - Force
Spring guide/ Maintenance
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00. Fax +46 8 590 025 80.
www.ohlins.com
SAFETY PRE CA uTI O NS
Safety signals
Important information concerning safety is
distinguished in this manual by following
notations:
This Safety alert symbol means: Attention!
Your safety is involved!
A D JuS T M E N T S
Adjustments
Compression damping adjuster
The compression adjuster is located at the top
of the fork leg. Adjust by turning the slotted
screw with a screwdriver.
Rebound damping adjuster
The rebound adjuster is located at the bottom
of the fork leg. Adjust by turning the slotted
screw with a screwdriver.
Reset the adjusters according to following:
The adjusters have a normal right hand thread.
Turn the damping adjusters clockwise to fully
closed (pos. zero [0]). To open, turn counter
clockwise, and count the clicks until you reach
the recommended number. For recommended
clicks see Set-up data. Static sag can only be
changed with softer or harder spring rate.
Compression damping adjuster
WARNING!
1. Installing a front fork kit, that is not approved
by the vehicle manufacturer, may affect the
stability of your vehicle. Öhlins Racing AB
cannot be held responsible for any personal
injury or damage whatsoever that may occur
after fitting the front fork kit. Contact an Öhlins
dealer for advice.
2. Please study and make certain that you
fully understand the contents in the mounting
instructions and the owner´s manual before
handling this front fork kit. If you have any
questions regarding installation procedures,
contact an Öhlins dealer.
3. The vehicle service manual must be referred
to when installing the Öhlins front fork kit.
+
-
WARNING!
Failure to follow warning instructions could
result in severe or fatal injury to anyone
working with, inspecting or using the
suspension, or to bystanders.
Rebound damping adjuster
CAuTION!
Caution indicates that special precautions
must be taken to avoid damage to the
suspension.
NOTE!
Öhlins products are subject to continual
improvement and development. Consequently,
although these instructions include the most
up-to-date information available at the time
of printing, there may be minor differences
between your suspension and this manual.
Please consult your Öhlins dealer if you have
any questions with regard to the contents of
the manual.
CAuTION!
Do not use too much force, delicate
sealing surfaces can be damaged.
+
-
NOTE!
This indicates information that is of
importance with regard to procedures.
NOTE!
The total stroke of the front fork may
differ from the original stroke, so that
more or less of the steel tube will be
visible when the fork is fully compressed.
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out
inside the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
Öhlins product.
Force
D I A GR A M
Oil volume - Force
390cc
370cc
350cc
330cc
© Öhlins Racing AB. All rights reserved.
Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Stroke
6
MO uNTING INS TR uCTI O NS
Changing springs (only)
This can be done on the motorcycle with
Öhlins special tools. Make your service and
maintenance according to the Öhlins work
shop manual.
3
Top cap tool
M OuN T I N G IN ST RuC T I O N S
!
WARNING!
1. It is advisable to have an Öhlins dealer to install the
front fork kit.
2. Refer to the instructions in your vehicle service
manual when changing the front fork.
1
1.
Put the motorcycle on a work stand.
4
Security snap-ring
2.
Loosen the screws that hold the fork legs in
the upper triple clamps.
3. When working on a raised vehicle, make sure that
it is securely supported to prevent it from tipping.
Removing the original front fork
1
Put the motorcycle on a workstand so that the
front wheel is off the ground.
Upper triple clamp
Lower triple clamp
Front leg cover
3.
Open up the top cap on the fork leg. Use a
standard fork top cap tool.
4
6
4.
Remove the security snap-ring in the bottom
of the fork with a pair of pliers.
5
Bottom end
2
Remove the front wheel and the brake caliper.
5.
Loosen the bottom end of the cartridge kit.
3
Measure the position of the front fork.
Measure the distance from the top of the
fork leg to the top of the upper triple clamp
according to figure.
6
2
Front
wheel
2
Brake
caliper
6.
Install the tool 01890-01 (oil plug) by pushing it
into the fork bottom. The plug will keep the oil
in the fork while changing the spring.
4
Loosen the upper triple clamp by loosening
the screws.
Oil plug
7.
Remove the cartridge kit from the fork leg and
change the spring. Note the preload washer
(if any).
5
Loosen (but not remove) the top cap 1/2 turn.
Use a standard tool from the motorcycle
manufacture.
8.
Install the cartridge kit into the fork leg and
push out the oil plug tool 01890-01.
7
3
Top cap
NOTE!
The preload washers must be
below the spring, at the bottom
end of the fork leg.
Preload washer
(optional)
Fork leg
6
Loosen the lower triple clamp by loosening the
screws.
9.
Tighten the shaft end into the fork bottom with
tightening torque 18 Nm.
7
Remove the front fork legs from the
motorcycle.
10.
Install the security snap-ring.
NOTE!
If any oil is needed, use Öhlins Front Fork Oil
01311-xx only.
Spring
Disassembling the original front fork
8
Follow your vehicles service manual to remove
the original front fork kit from the front fork leg.
Turn the fork leg upside down to pour out the
oil. Clean your front fork internally thoroughly.
2
5
CAuTION!
The top cap should only be tightened by hand or
maximum torque of 10 Nm into the fork leg.
Cartridge kit
5
MOuNTING INST R uCTI O NS
Install the Öhlins front fork kit
9
Smear some red grease or similar on the o-
rings and install them according to figure.
O-ring 00438-12
S E T-uP D ATA
Before riding your motorcycle, check sag and ride height according to
Set-up data
and
Adjustments
in this mounting instruction. To get the most out of your suspension component it
is of great importance to make the correct settings for your weight - full riding equipment on.
9
O-ring 00338-10
10
Install and tighten the base valve plug into the
fork bottom, use a 22 mm socket (tightening
torque 45 Nm).
10
Fork bottom
R1
F1
F2
R2
R3
F3
Base valve
plug
Motorcycle on a stand
Fork leg
11
Install the preload washer(s) 15443-xx
(optional - see
Set-up data,
Spring preload),
the recommended Öhlins spring
(see
Spring
guide)
and the cartridge kit into the standard
fork leg.
11
Motorcycle on the ground
Motorcycle with rider on
Front suspension
Rear suspension
R1.
Motorcycle on a stand with the
suspension fully extended = .............
R2.
Motorcycle on the ground without rider = ............
R3.
Motorcycle on the ground with rider = ............
Free sag R1 - R2 = ............
Ride height R1 - R3 = ............
NOTE!
Preload
washer
(optional)
Spring
12
Tighten the cartridge shaft end into the base
valve plug. Use a 12 mm socket (tightening
torque 18 Nm).
The preload washers must
be below the spring, at
the bottom end of the
fork leg.
F1.
Motorcycle on a stand with the
suspension fully extended = ............
F2.
Motorcycle on the ground without rider = ............
F3.
Motorcycle on the ground with rider = ............
Free sag F1 - F2 = ............
Ride height F1 - F3 = ............
13
Install the security snap-ring at the shaft end
groove according to figure.
Cartridge kit
Recommended settings:
Rebound damping
Compression damping
Spring preload
12 click
12 click
-5 to 8 mm
(can be changed with
washers 15443-02
and 15443-03)
0,350 litre
Recommended sag and ride height:
If no other recommendations are given in your
vehicles manual follow the measures below:
14
Pour Öhlins front fork oil
(01311-xx)
into
the fork leg according to the recommended
settings. Oil volume range: 0,335 to 0,395 litre.
12
Cartridge shaft end/
Base valve plug
Without rider:
Rear 30 ±10 mm (R1-R2)
15
Tighten the Öhlins fork top cap gently. Use
the standard top cap tool from the motorcycle
manufacture. Handtighten only!
13
Oil volume for 250F:
With rider:
Front 40 ±10 mm (F1-F3)
Rear 100 ±10 mm (R1-R3)
Use only Öhlins fork oil 01311-xx.
16
Check and set the rebound and compression
valves click positions according to the
recommended settings in
Set-up data.
Security
snap-ring
Spring Preload
Measure the spring length. The springs may differ
in length which will affect the preload. The preload
can be changed with the preload washers 15443-xx
(installed before the spring). A negative preload of up
to – 5 mm is possible, because the top-out spring
then still gives a small compression load on the main
spring.
The preload is calculated as:
Top cap tool
A
Free spring length
B
Preload washer thickness
C
Installed length for spring and preload washer
A + B - C
= Spring preload
The setup for zero (0) preload is calculated below.
An increase of the spring length and/or an increase
of the preload washer thickness give a corresponding
increase of the preload.
Free spring length:
Preload washer (15443-xx):
Preload:
465 mm
15443-03 + 15443-02
(5 mm)
0 mm
17
Install the front fork legs into the triple clamps.
Tightening torque - see your vehicle service
manual.
15
NOTE!
It is very important that the triple clamps are tightened
to the correct torque.
3
4

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