Motocross 85/150cc

Front Fork Cartridge Kit

Owner’s Manual
INTRODUCTION

Öhlins Racing AB - The Story

It was the 1970’s, a young man named Kenth Öh- Congratulations! You are now the owner of an
lin spent most of his spare time pursuing his fa- Öhlins Shock Absorber. More than two hundred
vourite sport: motocross. World Championships and other major world ti-
A careful observer, Kenth’s attention tles are definitive proof that Öhlins shock absorb-
was continually drawn to one specific de- ers offer outstanding performance and reliability.
tail - motocross bikes had more engine pow- Every product has gone through rigorous
er than their suspension could handle. testing and engineers have spent thousands of
It was not long before Kenth realised that bet- hours, doing their very best to use every possi-
ter performance could be achieved by improved ble experience from our 40 years within the rac-
wheel suspension. ing sport.
Öhlins Racing was established in 1976, and The product that you now have in your pos-
just two years later the company won its first session is pure racing breed that is built to with-
World Championship title. Despite being in the stand.
business for 40 years, the search for perfection By installing this shock absorber on your ve-
and new functions is still the main focus of the hicle you have made a clear statement… you are
company. a serious rider with a focus on getting the max-
imal handling ability and outstanding feedback
from your vehicle. Along comes the fact that your
shock absorber will be a long lasting friend, de-
livering the very best of comfort and performance
every time you go for a ride. Go explore!

1
 SAFETY PRECAUTIONS
General Warnings SAFETY SYMBOLS
Note! In this manual, mounting instructions and
The shock absorber/front fork/steering damper is other technical documents, important infor-
an important part of the vehicle and will affect the mation concerning safety is distinguished
stability. by the following symbols:

Note!
Read and ensure you understand the informa- The Safety Alert Symbol means: Warning!
tion in this manual and other technical documents Your safety is involved.
provided by Öhlins, before using the product.
Warning!
Note! The Warning Symbol means: Failure to fol-
Öhlins Racing AB can not be held responsible low warning instructions can result in se-
for any damage to the shock absorber/front fork/ vere or fatal injury to anyone working with,
steering damper, vehicle, other property or injury inspecting or using the shock absorber, or
to persons, if the instructions for mounting, usage to bystanders.
and maintenance are not followed exactly.
Caution!
Warning! The Caution Symbol means: Special pre-
After installing the Öhlins product, take a test ride cautions must be taken to avoid damage to
at low speed to ensure your vehicle has main- the shock absorber.
tained stability.
Note!
Warning! The Note Symbol indicates information that
If the suspension makes an abnormal noise, or is important regarding procedures.
the function is irregular, or if you notice any leak-
age from the product, stop the vehicle immediate-
ly and return the product to an Öhlins dealer.
Product Specific Warnings
Warning!
The product warranty shall only apply if the prod- Warning!
uct has been operated and maintained in accord- This product was developed and designed exclu-
ance with recommendations in this manual. If you sively for a specific vehicle model and shall only
have any questions regarding usage, service, be installed on the intended vehicle model in its
inspection and/or maintenance please contact original condition as delivered from the vehicle
Öhlins. manufacturer.

Note! Warning!
When working with the Öhlins product, always This product contains pressurized nitrogen
read the vehicle service manual. gas (N2). Do not open, service or modify this
product without proper education (authorized Öh-
Note! lins dealer) and proper tools.
This Manual shall be considered a part of the
product and shall therefore accompany the prod-
uct throughout its life cycle.

© Öhlins Racing AB. All rights reserved. Any

reprinting or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.

2
ÖHLINS CARTRIDGE KIT
Congratulations on your excellent choice of pur-
chasing this high performance Öhlins front fork
cartridge kit.
This product is designed for the upcoming,
next generation of stars and has been
developed by Öhlins’ off-road racing department
in Sweden, with their experience from the world
stars of today.
We recommend you to read this manual
thouroughly for proper bike set up to get the best
possible performance out of your suspension
components.

TABLE OF CONTENTS
1 - How it works.................................4
2 - How to install................................5
2.1 - Remove fork legs....................6
2.2 - Install the front fork kit............7
2.3 - Replace spring.......................9
4 - Set-up.........................................10
5 - Measure spring preload.............. 11
6 - Recommended set-up................. 11
7 - Oil level vs. damping force..........12
8 - Adjusters.....................................13
9 - Inspection and maintenance........14

3
 1 - HOW IT WORKS
To get a front fork work properly, the front fork
and shock absorber must be in balance. To
obtain this, it is highly important to have sag
and ride height correctly installed on the shock
absorber. (see chapter 4 - Set-up)
A front fork can roughly be divided into three
different systems working in parallel;
Spring
The main purpose of the spring is to keep the
weight of the rider and bike up in the stroke and
push it back up after the fork has traveled down
in the stroke. The spring will also help to break
an upcoming motion as forces are applied to the
front wheel or chassis.
Hydraulic damping
The main purpose is to slow down upcom-
ing motions, both when the fork is going down
and when it is coming back up again. Hydraulic
damping is absorbing energy from upcoming
motions. Adjust the hydraulic damping charac-
ter with the adjustment clickers (compression
and rebound).
Oil level
The main purpose is to create a progressive
damping curve in the lower part of the stroke.
Remember that each system in the front
fork is depending on the shock absorber being
correctly set up.

4
2 - HOW TO INSTALL
In this chapter we describe how to install the
Öhlins Front Fork Cartridge Kit into the fork legs
and how to replace the spring.
It is very important that these procedures are
performed accurately. If you have any insecuri-
ties regarding the procedure or anything regard-
ing the product, please contact an authorized
Öhlins dealer.

Warning!
We recommend to have an Öhlins dealer install
the front fork cartridge kit.

Warning!
Before installing this product, read the Öhlins
Owner’s Manual thouroughly. The front fork is
an important part of your vehicle and will affect
the stability.

Chapter overview
2.1 Remove Fork legs
2.2 Install Öhlins Front Fork Cartridge Kit
2.3 Replace Spring

Tools

Part No Description Notes

01309-XX Öhlins Front fork fluid
01890-01 Plug Oil plug
01892-01 Wrench 44 Top cap
Contact cleaner
Pliers (for security snapring)
Screwdriver (remove/install triple clamps)
Socket 21 mm (Bottom plug)
Socket 12 mm (Shaft end Adjuster housing)
Soft jaws
Torque wrench
Vise

5
 2.1 - REMOVE FORK LEGS
Warning!
It is advisable to have an Öhlins dealer install the 1
front fork cartridge kit. When installing, see the
vehicle service manual.
1
Put the motorcycle on a workstand so that the
front wheel barely touches the ground.

Warning!
When working on a raised vehicle, ensure that
the vehicle is securely supported so that it will
not tip. Upper triple clamp
2
Lower triple clamp 4
Remove the front wheel and the brake caliper.
3 Front leg cover 6
Measure the distance from the top of the fork leg
to the top of the upper triple clamp according to
the figure. 2
Note! Front wheel Brake
Note this dimension as fork height position. caliper

Fork height position..............

4
Loosen the upper triple clamp by loosening the
screws.
5
Top cap
Loosen (but do not remove) the top cap 1/2 turn. 3
6
Loosen the lower triple clamp by loosening the
screws.
7
Remove the front fork legs from the motorcycle.
8
Clean the fork legs thoroughly. Make sure to
clean underneath the fork bottoms.
5

6
2.2 - INSTALL THE FRONT FORK KIT
Disassemble the original front fork
10
9
Follow the vehicle service manual to remove the
original front fork kit and spring from the fork leg.
Turn the fork leg upside down to pour out the oil.
Clean the fork legs thoroughly before installing
the Öhlins front fork cartridge kit.
Install Öhlins front fork cartridge kit
10
Base plug Hydraulic
Clean the contact surfaces between the hydrau-
stop cup
lic stop cup and fork bottom with contact clean-
er. It is important to clean so that the friction 11
makes the surfaces attach correctly.
11
Install the hydraulic stop cup, into the original
fork leg, from the upper end of the fork tube.

Caution!
Make sure that the hydraulic stop cup is well
seated before tightening.
13
11
Install and tighten the base plug into the
fork bottom. Use a 21 mm socket, tightening
torque 45 Nm.
Cartridge kit
12
See chapter Measure Spring Preload. Spring
Install preload washer(s) 15482-xx, the rec-
ommended Öhlins spring (see Spring guide)
and the cartridge kit into the original fork leg.
Minimum one preload washer must be installed
for spring support. Preload washer(s)

Note! Fork leg

The preload washers shall be below the spring,
at the bottom end of the fork leg.
Cartridge shaft end/
13 14 Base valve plug
Tighten the cartridge shaft end into the base
plug by turning counter clockwise. Use a 12 mm
socket, tightening torque 18 Nm.

7
2.2 - INSTALL THE FRONT FORK KIT
14
Install the security snapring at the shaft end 15
groove according to figure.
15
Pour Öhlins Front fork fluid in the fork leg
according to the recommended settings. Security
snapring
16
Make sure the front fork is fully extend-
ed and tighten the Öhlins fork top cap. Use
Wrench (01892‑01).
Tightening torque maximum 10 Nm.
17
Check and set the rebound and compression
valves click positions according to the recom-
mended settings in Set-up data. 17
18
Install the front fork legs into the triple clamps.
Use, to begin with, the same height position as
before. Tightening torque - see the vehicle ser-
vice manual.
19
Reinstall the brake caliper and front wheel.
Make sure that all removed parts are reinstalled
as they were before the installation of the Öhlins
Front Fork Cartridge Kit.

Note!
It is very important that the triple clamps are tight-
ened to the correct torque. See the vehicle ser-
vice manual.

8
2.3 - REPLACE SPRING
1
Follow steps 1-8 in Chapter Remove Fork Legs. 2
2
Remove the security snapring in the bottom of
the fork with a pair of pliers.
3 Security
snapring
Loosen the bottom end of the cartridge kit, turn
clockwise, according to image.
4
Install the Plug (01890-01) by pushing it into the
fork bottom. The plug will keep the oil in the fork
while replacing the spring.
5
Remove the cartridge kit from the fork leg,
replace the spring. Note the plastic preload 3
washer(s).

Note!
The preload washers must be below the spring,
at the bottom end of the fork leg.
6
Install the cartridge kit into the fork leg and push
5
out the Plug (01890-01).
7 4 6
Tighten the shaft end (counter clockwise) into
the fork bottom, tightening torque 18 Nm.
Cartridge
8 kit
Install the security snapring.
9 Oil plug
Make sure the front fork is fully extended and
tighten the Öhlins fork top cap. Use Wrench
(01892-01), tightening torque maximum 10 Nm.

Caution! Spring
Do not tighten to more than 10Nm.
10
Install the front fork legs into the triple clamps.
Use, to begin with, the same height position as
before. Tightening torque - see the vehicle ser-
vice manual. Preload
washer (s)
11
Reinstall the brake caliper and front wheel - Fork leg
make sure that all removed parts are reinstalled
as they were before installing the Öhlins Kit.
9
 4 - SET-UP
Warning!
Before riding, always ensure that the basic set-
tings set by Öhlins are intact. Take notes, adjust in
small steps, make only one adjustment at a time.

Step 1 - Check Sag and Ride Height

1. Put the motorcycle on a workstand so that
both wheels are off the ground and the sus-
pension is unloaded. Ensure you are working
on a flat surface.
2. Mark, for example with a piece of tape, a point
immediately above the rear wheel axle.
3. Measure the distance from the marked point
to a fixed point, for example the wheel axle.
(See figure: R1)
4. Put the motorcycle on the ground so that the
front and the rear suspensions are slightly
compressed. Repeat the measuring proce-
dures. (R2)
5. Sit on the motorcycle in normal riding position,
properly outfitted in your riding gear. Repeat
the measuring procedures. (R3)

Recommended sag and ride height;

If no other recommendations are given in the
Vehicle Manual follow the measures below:
R1 - R2 20±10 mm
R1 - R3 85±10 mm

Step 2 - Adjust spring preload

1. If your measurements differ significantly from
the recommendations from the table above,
adjust the spring preload. (See section
Spring Preload in this manual).
2. If the ride height still differs from the reco- Note measures
mendations, you may need to change spring. R1
Contact an Öhlins dealer for advise.
R2
Warning! R3
Incorrect spring rate may produce a fork angle
that is too steep or too flat. This in turn can lead
to a tendency for over- och understeering, which
could seriously affect the handling characteristics
of the motorcycle.

10
5 - MEASURE SPRING PRELOAD
Fork springs may differ in length. Therefore we Measure the spring preload according to the fol-
recommend to check the preload on each fork lowing steps;
leg and install the required preload washers to 1. Measure A. Fork outer tube slid down to stop
get the correct value. 2. Measure B.
A negative preload of up to minus 1 mm is 3. Measure C.
possible, since the top-out spring still gives a
Note measure
small compression on the main spring.
Preload less than -1 mm will make the fork A
spring loose when the front wheel is off the B
ground, which increases wear inside the fork. C

Caution! Preload ((B-A-C)-2=

Preload washers must be placed below the 4. Calculate preload:
spring, otherwise they will restrict oil flow and the Preload = (B - A - C) - 2
fork may break. 5. Adjust preload according to the desired val-
ue according to set-up data below, by adding/
removing preload washers below the spring.

Measure Spring Preload

6 - RECOMMENDED SET-UP
Rebound damping 15 click Note!
Compression damping 15 click Öhlins products are subject to continuous im-
provement and development, therefore, although
Spring preload 0 mm
these instructions include the most up-to-date in-
Oil volume 0,200 litre formation available at the time of printing, minor
Spring preload range 0-4 mm* updates may occur. To find the latest information
Oil volume range 0,180-0,240 litre contact an Öhlins dealer. Please contact Öhlins if
Öhlins Front Fork fluid 01309-xx you have any questions.
*can be adjusted by adding/ removing
washers 15482-xx

11
7 - OIL LEVEL VS. DAMPING FORCE
To set the oil level
Proper oil level is a balance between sufficient might appreciate the additional damping from a
bottoming resistance and comfort. Higher oil higher oil level on all parts of the track, as this
level will give better bottoming resistance, but keeps the fork running higher in the stroke,
might reduce comfort over smaller bumps. withstanding their additional forces due to their
higher velocities.
Bottoming issues
Increase oil level in 10ml steps until unpleasant Note!
bottoming no longer occurs, or until comfort on Since small amounts of oil have great influence
rest of the track becomes too harsh. on the performance, make sure to service a leak-
ing fork immediately. We highly recommend to
Harsh fork
have an Öhlins dealer service the fork.When
Try to decrease oil level in steps of 10ml to gain draining a fork, it is very important to let all oil
comfort until harshness no longer occurs or bot- drain out to obtain a proper oil level in the fork af-
toming resistance gets too low. ter service.
Additionally, lower oil level will let the fork
dive longer into the stroke during braking before
additional damping effect stiffens up the stroke
(see figure below, position C). Very fast riders

B C
A

more oil
less oil

12
8 - ADJUSTERS
Compression damping adjuster Compression damping adjuster
The compression adjuster is located at the top
close
of the fork leg. Adjust by turning the adjuster (position zero [0])
screw with a 3 mm Allen key.
Rebound damping adjuster
The rebound adjuster is located at the bottom
of the fork leg. Adjust by turning the adjuster open
screw with a 3 mm Allen key.
To Set
The adjusters have a normal right hand
thread. Turn the damping adjusters gently
clockwise to fully closed (pos. zero [0]). To
open, turn counter clockwise, and count the
clicks until you reach the recommended num-
ber. For recommended clicks see Set-up data.
Static sag can only be changed with softer or
harder spring rate.

Caution!
When adjusting, turn carefully not to damage
Rebound damping adjuster
delicate sealing surfaces.

Note!
The total front fork stroke may differ from the
original stroke, so that more or less of the
closed
steel tube will be visible when the fork is fully
(position zero [0])
compressed.

open

13
9 - INSPECTION AND MAINTENANCE
Preventive maintenance and regular inspection
reduces the risk of functional disturbance. If there
is any need for additional service, please contact Breather plug
an Öhlins dealer.
After every ride
1. Put the motorcycle on a workstand so that the
wheels barely touch the ground (suspension
unloaded).
2. Let the bike cool off.
3. Aerate the front fork; Loosen the Breather
plug to release excessive pressure in the front
fork. Make sure to tighten the Breather plug
after aerating.
Recommended Service Intervals
Rec.service every 20 hours

Contact an authorized Öhlins dealer for service.

Disposal
Discarded Öhlins products shall be handed over
to an Öhlins dealerfor proper disposal.

14
 Öhlins Owner’s Manual Front Fork Cartridge Kit MX | Part No. 07298-01_0 | Issued 2013-04-09 | © Öhlins Racing AB

Your Öhlins retailer:

Öhlins Racing AB
Box 722 Phone: +46 (0)8 590 025 00
SE-194 27, Upplands Väsby Fax: +46 (0)8 590 025 80
Sweden www.ohlins.com