Ohlins FKS 503 Manuale utente

Front Fork Kit for Yamaha TMAX

FKS 503

Mounting Instructions

Note!1

Please note that there can be small differences

between your product and the images in

these instructions.

Note!1

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.

Note!1

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.

Kit Contents

Description Part No Pcs

Front fork kit FKS 503 1

O-ring 00576-02 2

Sticker set Öhlins - -

Owner’s manual 07284-01 1

Warning!⚠

This kit should only be installed by an authorized

Öhlins dealer. The installation procedure

requires certain tools.

MOUNTING INSTRUCTIONS

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

Tool Part no Applies Size

Vehicle service manual

Torque wrench

Wrench Shaft extension

19 mm

Hex key Compression and

rebound bleed

adjusters

3 mm

Socket Preload adjuster 14 mm

Ruler Suspension uid level

Öhlins tool 01765-03 Shaft extension

Wrench Top cap 46 mm

Öhlins tool 01797-07 Seal head

Suspension uid 01309-xx

Grease 00146-01 100 g

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!1

When you work with this product, see the

vehicle service manual for vehicle specic

procedures and important data.

Note!1

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.

MOUNTING INSTRUCTIONS

1 Remove the original front fork

Note!1

The following procedure applies to both front

fork legs.

1.1

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.

1.2

Remove front fender, brake calipers, speed

sensor (if present), front wheel and front cover.

1.3

Note front fork leg position.

1.4

Loosen upper triple clamp.

1.5

Loosen lower triple clamp.

1.6

Remove front fork legs from triple clamps.

Front fork

leg position

Front cover

MOUNTING INSTRUCTIONS

2 Disassemble original front fork

Remove original

2.1

Loosen top cap from outer tube.

2.2

Slide outer tube down until it stops.

2.3

Loosen and remove top cap from shaft

according to vehicle service manual.

2.4

Remove main spring and surrounding parts

from front fork leg.

2.5

Drain front fork leg of suspension uid.

2.6

Loosen cartridge according to vehicle service

manual.

2.7

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.

2.8

Remove top cap (A), spring support (B) and

preload tube and guide ring (C).

2.9

Insert the cartridge in the front fork leg.

2.10

Install bottom screw according to instructions in

the vehicle service manual.

MOUNTING INSTRUCTIONS

2.11

Pour approximately 0.5 litre Öhlins suspension

uid in front fork leg.

Warning!⚠

Fluid level must be approximately 50 mm above

top of cylinder tube assembly.

2.12

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]

2.13

Pull outer tube up and down 10-15 times to

pump out all air from the cartridge.

2.14

Remove top cap from front fork leg.

2.15

Make sure that shaft assembly and outer tube

are in their bottom positions.

Set suspension uid level according to chapter

“Setup Data”.

2.16

Install shaft extension tool on top of shaft

extension.

Install main spring with the marking up (A),

preload tube and guide ring (B) and spring

support (C) over shaft extension tool.

[01765-03 shaft extension tool]

2.17

Pull up shaft assembly and grab spring support

with a wrench tool.

[Wrench 19 mm]

MOUNTING INSTRUCTIONS

2.18

Install o-ring on top cap. Apply grease on o-ring

and thread.

[00576-02 o-ring]

[00146-01 grease]

2.19

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]

2.20

Remove wrench from spring support.

2.21

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 46 mm]

2.22

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]

MOUNTING INSTRUCTIONS

4 Install the front fork in the vehicle

Note!1

The following procedure applies to both front

fork legs.

4.1

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!1

Measure the front fork leg position from the

upper triple clamp to the top of the outer tube.

4.2

Remaining installation, instructions according

to vehicle service manual.

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00

fax +46 8 590 025 80

reserved. Any reprinting or

unauthorized use without the written

permission of Öhlins Racing AB

is prohibited.

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 nd the latest information

contact an Öhlins distributor.

Please contact Öhlins if you have

any questions regarding the

contents in this document.

SETUP DATA

MAIN SPRING GUIDE

Part no. MI_FKS503_0

Issued 2017-06-20

Compression 12 clicks

Rebound 12 clicks

Suspension uid level 150 mm

Front leg position Standard position

Suspension uid 01309-xx

Make sure you choose the correct main spring for your rider weight, driving style and

preferences. Below you nd a general recommendation of main spring rate for your

weight. Contact an authorized Öhlins service center for advice.

Rider weight [kg] 50 60 70 80 90 100 110

Spring rate [N/mm] 8.5 8.5 9 9 9.5 9.5 10

Preload [turns] 9 11 10 12 11 13 12

Spring part number 08790-85 08790-85 08790-90 08790-90 08790-95 08790-95 08790-10

Spring are packed in pairs.

100

150

200

250

300

350

400

450

010 20 30 40 50 60 70 80 90 100 110 120 130

Force [N]

Stroke [mm]

Force vs Stroke

110

120

130

140

150

160

170

180

190

200

210

220

230

Level

[mm]

Indice

Altri manuali Ohlins Accessori per motociclette

Manuali Accessori per motociclette popolari di altre marche

SRC

SRC B-TRK502-01-01-SL Manuale utente

3M Speedglas 9100 MP Manuale utente

hepco & becker

hepco & becker 6307520 00 01 Manuale utente

HOMCOM

HOMCOM AA0-077 Manuale utente

hepco & becker

hepco & becker 6307558 00 01 Manuale utente

Wunderkind Custom

Wunderkind Custom 106503-F15 Guida utente

Dräger

Dräger HPS 3500 Manuale utente

M-WAVE

M-WAVE SKI Manuale utente

Kuryakyn

Kuryakyn 6212 Manuale utente

hepco & becker

hepco & becker 6507504 00 01 Manuale utente

Tool it

Tool it PROMAX LCD 9.13G Manuale utente

Custom Dynamics

Custom Dynamics TruWrapz Manuale utente

Roof

Roof RO200 CARBON Manuale utente

Kabuto

Kabuto Japan IBUKI Manuale utente

PUIG

PUIG 5051 Manuale utente

rizoma

rizoma ZTH050 Manuale utente

Joubert

Joubert 10001711 Manuale utente

Sperian

Sperian Optrel p420 Manuale utente