Öhlins FCX0102 Cartridge Kit Mounting Instructions PDF

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Summary of Content for Öhlins FCX0102 Cartridge Kit Mounting Instructions PDF

STX Cartridge Kit for Yamaha YZ 85

FCX 0102 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 hlins dealer.

Warning! Before you install this product, read the hlins Owners manual. This product is an important part of the vehicle and the vehicle stability.

Kit Contents

Description Part No Pcs

STX Cartridge Kit FCX 0102 1 Cartridge sticker 00191-34 2 Sticker set hlins 1 Owners manual 07298-05 1 Base plug (with o-rings) 15430-09 2 Safety clip 15440-01 2 Spacer 15495-02 6 Hydraulic stop cup 15456-13 2

Note! 1 No springs included in this kit. Use hlins Front Fork springs, part no. 08794-XX. See the Spring guide in this folder or contact hlins for advice.

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MOUNTING INSTRUCTIONS Remove the original fork legs

Warning! We strongly recommend to let an hlins 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 specific procedures and important data.

Note! 1 Before you install this product clean the vehicle.

1 Place the motorcycle on a work stand so that the front wheel barely touches the ground.

2 Remove the front wheel, plastic fork leg protectors and the brake caliper.

3 Measure the distance from the top of the upper triple clamp to the center of the front wheel axle, see figure. Note measure

Fork height position

4 Loosen the upper triple clamp screws.

5 Loosen the top cap turn. Use a 30 mm hexagonal fork cap tool.

6 Loosen the lower triple clamp screws.

7 Remove the fork legs from the vehicle.

8 Clean the fork legs, make sure to clean underneath the fork bottom.

9 Refer to the vehicle service manual to remove the original front fork and spring from the fork leg. Turn the fork legs upside down and pour out all oil.

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Upper triple clamp

Lower triple clamp

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MOUNTING INSTRUCTIONS Install the hlins cartridge kit 10 Use contact cleaner to clean the contact surfaces between the hydraulic stop cup and the fork bottom. Insert the hydraulic stop cup in the original fork leg, insert from the upper end of the fork tube.

Caution! Make sure that the hydraulic stop cup is in correct position before you tighten.

11 Install and tighten the base plug into the fork bottom, tighten to 45 Nm.

Caution! If the hydraulic stop cup rotates when you install and tighten, carefully use an impact machine.

12 Apply grease on the thread of the piston rod end.

13 Insert, if any, the preload washer/s, recommeded spring and the cartridge kit into the original fork leg.

Note! 1 Place the preload washer/s below the spring, at the bottom end of the fork leg.

Base plug

Hydraulic stop cup

Cartridge kit

Preload washer(s)

Fork leg

Spring

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MOUNTING INSTRUCTIONS 14 Use a 12 mm socket to tighten the cartridge shaft end into the base plug, turn counter clockwise and tighten to maximum 18 Nm. Do not over tighten.

15 Install the security snap-ring at the shaft end groove.

16 Pour hlins Front fork fluid in the fork leg, refer to the recommended setup in Setup data.

17 Make sure that the front fork is fully extended. Use a 44 mm octagon fork cap tool to tighten the hlins fork top cap to maximum 10 Nm.

18 Check and set the rebound and compression valves click positions, refer to the recommended setup in Setup data.

19 Install the front fork legs into the triple clamps. Set the fork legs at the same height position as before. Refer to the vehicle service manual for correct tightening torque.

Note! 1 The front fork length might change when installing the hlins cartridge kit. See setup data for front fork length before and after installation of hlins cartridge kit.

20 Install the brake caliper and the front wheel. Make sure that all removed parts are installed in the same positions that they were before.

Note! 1 It is very important to tighten the triple clamps to the correct torque, refer to the vehicle service manual.

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Security snap-ring

Cartridge shaft end/ Base valve plug14

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MOUNTING INSTRUCTIONS

Warning! Before you ride/drive, always make sure that the setup is according to the recommended setup data. Read about adjustments and setting up in the hlins Owners Manual before you make any adjustments. Contact an hlins dealer if you have any questions about setting up.

ADJUSTMENTS

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SETUP DATA

Front fork length (OEM) 831 mm Front fork length (hlins cartridge kit) 837 mm Front fork stroke (hlins cartridge kit) 267 mm hlins cartridge kit length 892 mm Rebound adjustment 15 clicks Compression adjustment 15 clicks Spring preload** 0 mm Total spring installation length 430 mm Fluid volume (each leg) 0,200 litre Fluid volume range 0,180-0,250 litre hlins Front Fork fluid 01330-XX Spring preload range* 0-6 mm

*Can be adjusted by adding/removing washer 15495-XX. **To achieve specified spring preload the total spring installation length can be controlled prior installation into fork leg. See model specific length in setup data.

Total spring installation length

Spring Preload washer(s)

MOUNTING INSTRUCTIONS

hlins cartridge kit length

ReservoirBase plug

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MOUNTING INSTRUCTIONS

Yamaha YZ 85 Riders weight kg/lbs* Spring rate N/mm 40/88 2.8 45/99 3.0 50/110 3.0 55/121 3.2

Available spring rates 08794-series: -28 and -32 To get spring rates between the available rates, combine two springs with different rates. One with a lower and one with a higher spring rate. Example: To get spring rate 3.0: Use spring with 2.8 in one fork leg and 3.2 in the other fork leg.

* Riders weight: Rider wearing proper riding gear. Make sure you know your total weight with riding gear. Riding gear weighs between 5 and 15 kg.

SPRING GUIDE

hlins Racing AB Box 722

S-194 27 Upplands Vsby, Sweden Phone +46 8 590 025 00

fax +46 8 590 025 80

hlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited.

hlins products are subject to continuous improvement and development, therefore, although these instructions include the mo

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