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2 reMove cartridge froM front fork

2 remove cartridge from front fork

2.1 

Use appropriate tool to release the spring preload completely. Turn 
the Preload adjuster counter clockwise as far as possible. 

caution!

Do not use the Preload adjuster to tighten or loosen the Top cap from 
the fork leg.

2.2 

Loosen the screws that hold the fork legs in the upper triple clamp.

2.3 

Use tool 00797-08 together with appropriate tool. Loosen the Top 
cap from the outer fork leg, approximately ½ turn.

2.4

Loosen the screws 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 tool 
04705-03 on the Shaft extension. Remove the Top cap from the 
Shaft extension. 

note!

When removing tool 04705-03 hold your hand against the Spring 
support and Spring to prevent them from being pushed out by the 
spring force.

2.8

Remove tool 04705-03.

2.9 

Remove the Spring support and the Spring. Use a wire with a hook 
and carefully pull up the Preload tube. 

2.10

Remove the front fork from the vice.

2.11

Pour out all oil from the front fork.

2.1

2.2

2.3

2.6

Spring 

support

Spring

Preload 

tube

2.9

2.7

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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