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TTX25 Pressurized Front Fork Cartridge Kit

Workshop Manual

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Summary of Contents for TTX25

Page 1: ...TTX25 Pressurized Front Fork Cartridge Kit Workshop Manual...

Page 2: ...cle other property or injury to persons if the instructions for installing and maintenance are not followed exactly Warning This product was developed and designed exclusively for a specific vehicle m...

Page 3: ...01765 03 Pull up tool length 300 mm 9 01781 01 Gas filling device assy gas needle housing 01779 02 10 01797 05 Seal head tool 33 5 compress top out spring 11 01797 07 Seal head tool 36 tighten with to...

Page 4: ...rom being pushed out by the spring force 1 5 Remove tool 04705 03 1 6 Remove the Spring support and the Spring Use a wire with a hook and carefully pull up the Preload tube 1 7 Check the oil level acc...

Page 5: ...crews that hold the fork legs in the lower triple clamp 2 5 Remove the front fork from the motorcycle 2 6 Fasten the fork leg in a vice 2 7 Use appropriate tool on the Top cap preload adjuster and too...

Page 6: ...the front fork Note Ensure that the Shim between the Adaptor and fork bottom follows when removing the Cartridge 2 12B Front Fork with Bottom Screw Connection 2 12 1B Use tool 01797 07 to loosen the S...

Page 7: ...service until gas pressure is completely released 3 1 2 Use tool 01781 01 Release gas pressure 3 1 3 Use tool 00727 09 and fasten the Cartridge in a vice in a vertical position 3 1 4 Use tool 01797 0...

Page 8: ...priate tool to remove the Piston holder from the Shaft 3 2 6 Remove the Shaft from the vice 3 2 7 Use the Adjustment rod to push out the Needle from the Shaft 3 2 8 Pull off the Top out spring Sleeve...

Page 9: ...ad and Bushing 3 4 1 3 4 2 3 4 3 approx 50 mm 3 4 Disassemble Dividing Piston 3 4 1 Use tool 00727 09 Fasten the Cylinder tube assembly in a vice approximately 50 mm from the Adaptor 3 4 2 Use heat gu...

Page 10: ...tube push it as far in the Outer cylinder tube as possible Caution Be careful not to damage the O ring and the Piston ring on the Outer cylinder tube s thread 4 2 Assemble Seal Head 4 2 1 Use Assembly...

Page 11: ...tension 4 3 4 Remove the Shaft from the vice 4 3 5 Mount the Guide sleeve on the Shaft Ensure that the Guide sleeve connects to the Shaft extension You will hear a noticeable click 4 3 6 Mount the Spa...

Page 12: ...e at removal Tightening torque 7 Nm Loctite 243 4 3 12 Connect the Top out spring onto the Piston holder You will hear a noticeable click 4 3 13 Mount the Piston ring on the Piston 4 Assemble Cartridg...

Page 13: ...ividing piston Use Adaptor without O ring as a stop by screwing it all the way into the Cylinder tube Handtighten only Note O ring shall not be installed on the Adaptor 5 4 Remove the Fill screw Check...

Page 14: ...Use Assembly lubricant on the O ring Clean the thread and apply Loctite Tightening torque 40 Nm Loctite 243 5 10 Remove tool 02810 01 01797 05 and 01765 03 5 11 Use tool 01781 01 Fill gas to 6 Bar 5 1...

Page 15: ...15 6 reinstall cartridge into fork leg 6 Mount the Cartridge Kit into the front fork See Mounting Instructions for correct procedure...

Page 16: ...ler hlins Workshop Manual TTX25 Pressurized Cartridge Kit_0 Issued 20111 04 11 2011 hlins Racing AB Phone 46 0 8 590 025 00 Fax 46 0 8 590 025 80 www ohlins com hlins Racing AB Box 722 SE 194 27 Uppla...

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