Ohlins TTX Owners Guide

MX & Enduro TTX Front Fork

Cartridge Kit

Workshop Manual

2

Safety Precautions

Note!

The front fork is a very important part of the vehicle and
will therefore affect the stability of the vehicle.

Read and make sure that you understand the
information in this manual and the mounting
instructions before you use this product. If you have
any questions regarding installation or maintenance
please contact your nearest Öhlins dealer.

Öhlins Racing AB can not be held responsible for
any damage to the cartridge kit, vehicle, 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 model and should only be
installed on the intended vehicle model in its original
condition as delivered from the vehicle manufacturer.

This product contains pressurized nitrogen gas (N2).
Do not open, service or modify this product without
proper education (authorized Öhlins dealer/distributor)
or proper tools.

After installing this product, take a test ride at low
speed to make sure that your vehicle has maintained
its stability.

Note!

When working on this product, always consult your
Vehicle Service Manual.

This Manual should be considered as a part of the
product and should therefore accompany the product
throughout its life cycle.

Safety Symbols

In this manual, mounting instructions and other
technical documents, important information
concerning safety is distinguished by the
following symbols:

The Safety Alert Symbol means: Warning! Your safety
is involved.

Warning!

The Warning Symbol means: Failure to follow
warning instructions can result in severe or fatal
injury to anyone working with, inspecting or using the
cartridge kit, or
to bystanders.

Caution!

The Caution Symbol means: Special precautions
must be taken to avoid damage to the cartridge kit.

Note!

The Note Symbol indicates information that is
important regarding procedures.

© Öhlins Racing AB. All rights reserved. Any

reprinting or unauthorized use without the written

permission of Öhlins Racing AB is prohibited.

Printed in Sweden.

Service Interval

Rec. service interval for Cartridge kit: every 25 hrs

In This Manual

Page
Safety Precautions 1
Recommended Tools 2
1 Remove Cartridge kit from Fork Leg 3
2 Replace Spring and/or Preload Washer 4
3 Measure Spring Preload 5
4 Disassemble Cartridge Kit 6
5 Assemble Cartridge Kit 8
6 Reinstall Cartridge Kit into Fork Leg 10
7 Reinstall Fork Leg on the Vehicle 10

At 25 hour service, replace the following:

Part no.

- Top-out rubber 15486-01

- 8 mm seal 15428-01

- Piston ring 15409-01

- Separating piston seal
years 2010-2011: part no. 00338-96 (2x)
years 2008-2009: part no. 01027-12 (2x)

1

Recommended Tools

Tool 00727-06
Soft jaws for cartridge tube

Tool 00727-08
Soft jaws

Tool 01761-01
Peg spanner for top-cap

Tool 01820-27
Adapter for oil lling machine

Tool 01781-01
Gas lling device assy

Tool 01890-01
Oil plug tool

Tool 01837-01
Gas Piston Set Tool

2

4

1 Remove Cartridge Kit from Fork Leg

1.1

Put the motorcycle on a workstand so that the front wheel barely
touches the ground and the suspension is unloaded.

Warning!

Make sure that the vehicle is securely supported so that it will not tip.

1.2

Remove the front wheel and the brake caliper. Consult your Vehicle
Service Manual

1.3

Measure the position of the front fork. Measure the distance from
the top of the fork leg to the top of the upper triple clamp according
to the gure.

Note!

Note this dimension as fork height position.

1.4

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

1.5

Use a 50 mm fork top cap tool. Loosen the top cap ½ turn. Do not
remove the top cap yet.

1.6

Loosen the screws that hold the fork legs in the lower triple clamps.

1.7

Remove the front fork legs from the vehicle. Clean the fork legs
thoroughly. Make sure to clean underneath the fork bottoms.

1.8

Remove the security snap-ring at the bottom of the fork with a pair
of pliers.

1.9

Remove the top cap from the fork leg.

1.10

Use a 12 mm socket. Loosen the shaft end of the cartridge kit.
Note, clockwise rotation.

1.11

At the same time when pulling the cartridge assembly out of the
fork leg, install the tool 01890-01 (oil plug) by pushing the plug into
the fork bottom. The plug will keep the oil in the fork while working
with the cartridge kit.

1.12

Remove the cartridge kit from the fork leg.

1.13

Note that spring seat and washer will, depending on cartridge
version, stay in fork tube or come out with cartridge.

1.3

1.4

1.9

1.11

1.5

1.2

1.1

1.8

1.10

To replace spring and/or spacers – go to chapter 2

To disassemble Cartridge Kit – go to chapter 4

1.12

3