Ohlins KA 590 User manual

Mounting Instructions
Öhlins shock absorber kit KA 590
for Kawasaki KX 85
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone [phone]. Fax [phone].
www.ohlins.com
KA 590_1, issued 07 02 07
Kit Contents
Before installing the shock absorber, please
check the contents of the kit. If anything is
missing, please contact your Öhlins dealer.
Description Pcs. Part No.
Shock absorber 1 KA 590
Spring clip 1 00516-01
Screw 1 00439-19
Washer 1 00153-06
C-spanner 1 00710-02
Sticker Öhlins 2 00197-01
Sticker memo notes 1 01180-01
Owner’s manual 1
Before Installing
Öhlins Racing AB cannot be held responsible
for any damage to shock absorber or vehicle,
or injury to persons, if the instructions for fitting
and maintenance are not followed exactly.
Similarly, the warranty will become null and
void if the instructions are not adhered to.
Öhlins products are subject to continuous im-
provement and development. Consequently,
although these instructions include the most
up-to-date information available at the time
of printing, there may be minor differences
between your shock absorber and this manual.
Please consult your Öhlins dealer if you have
any questions regarding the contents of this
manual.

WARNING!
1. Installing a shock absorber, that is not
approved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage that may occur
after fitting the shock absorber. Contact an
Öhlins dealer for advice.
2. Please study and make certain that you
fully understand all the mounting instructions
and the owner’s manual before handling this
shock absorber kit. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer.
3. The vehicle service manual must be
referred to when installing the Öhlins shock
absorber.
Safety Signals
Important information concerning safety is
distinguished in this manual by the following
notations:
The Safety alert symbol means:
Attention! Your safety is involved.
WARNING!
Failure to follow warning instructions
could result in severe or fatal injury to
anyone working with, inspecting or using
the shock absorber, or to bystanders.
CAUTION!
Caution indicates that special pre-
cautions must be taken to avoid damage
to the shock absorber.
NOTE!
Indicates information that is of importance
regarding mounting procedures.
!
!
!
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out in-
side the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
shock absorber.
NOTE!
If ride height is higher than recommended,
softer spring/springs must be used.
If ride height is lower than recommended,
harder spring/springs must be used.
Contact your Öhlins dealer for advice.
Setup data
Length 380 mm
Stroke 111 mm
Rebound adjustment 18 clicks
Low speed comp. adj. 15 clicks
High speed comp. adj 1½ turns
Free sag, rear 25±5 mm
Free sag, front 25±5 mm
Ride height, rear 70±5 mm
Ride height, front 60±5 mm
Front fork adjustment std.
Bike on a stand. Bike on the ground. Bike with rider on.
NOTE!
Make notes when the correct spring is mounted
and sag and ride height is adjusted.
Spring pre-load mm
R1
R2 R3
F1
F2 F3
Checking sag and ride height
Front suspension
F1. Bike on a stand with the
suspension fully extended = ............
F2. Bike on the ground without rider = ............
F3. Bike on the ground with rider = ............
Free sag F1 - F2 = ............
Ride height F1 - F3 = ............
Rear suspension
R1.Bike on a stand with the
suspension fully extended =.............
R2.Bike on the ground without rider = ............
R3.Bike on the ground with rider = ............
Free sag R1 - R2 = ............
Ride height R1 - R3 = ............

Mounting Instructions - Step 1
Assembly of Öhlins Shock Absorber with spring separately supplied
WARNING!
!
1. It is advisable to have an Öhlins dealer installl
your shock absorber.
2. Instructions in the vehicle service manual
are to be followed when changing the shock
absorber.
3. When working on a lifted vehicle make
sure it is securely supported to prevent it
from tipping.
1
Make sure that all components listed on the
front page of this manual under “Kit contents”
are included.
2
Measure the free length of the spring.
3
Fit the spring clip, turn the shock absorber so the
spring rests against the spring platform and turn
the rings (lock nut and spring platform) so they
touch the upper surface of the spring.
4
With a C-spanner, turn the upper spring platform
approximately 8 laps (10 mm) clockwise to pre-
load the spring before fitting the shock absorber
to the motorcycle.
A
A-B=Pre-load
B
Lock nut
Spring
platform
Washer
Spring
Spring clip
Spring guide
Rider's weight Spring Spring rate
Kg/pounds Part no. N/mm
Kawasaki 35/77 698-05 42
KX 85cc 40/88 698-06 44
45/99 698-07 46
50/110 698-08 48
55/121 698-09 50

Your Öhlins shock absorber type 46 PRXW
features the following adjusters:
Spring pre-load adjuster
Adjust spring pre-load by turning the rings on
the cylinder house. Use a C-spanner.
Rebound
adjustment
Spring pre-load
adjustment
Low speed
compression
adjustment
High speed
compression
adjustment
NOTE!
Make sure that all bolts are tightened to the
correct torque and that nothing fouls or restricts
movement of the shock absorber when the
suspension is being fully compressed or ex-
tended.
1
Put the motorcycle on a stand so the rear wheel
is off the ground. Make sure that the vehicle is
securely positioned so that it will not fall over.
2
Remove the seat by loosening the rear attach-
ment screws.
3
Remove the left side panel and the remov-
able part of the left sub-frame. Loosen the
hose clamp from the air box and remove the
air box.
6
Place the seat support and seat back in position
and fasten them.
4
Loosen the lower and the upper attachment of
the original shock absorber and remove it.
5
Attach the Öhlins shock absorber in the same
way as the original unit. Fasten it by using the
chamfered screw and washer provided in this
kit for the upper attachment. Use the original
screw for the lower linkage.
7
Continue your work according to the Owner’s
Manual.
Adjustments
NOTE!
When delivered the Öhlins shock absorber is
dialed to recommended settings for the specific
brand and make of the motorcycle. If you have
changed the settings, reset according to the
following:
The adjusters have a normal right hand thread.
Turn the damping adjusters clockwise to fully
closed (pos. zero [0]). Turn counter clockwise
to open and count the clicks until you reach the
recommended number. See Set-up data on the
last page of this manual.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
Compression damping adjuster
Adjustments are made on top of the reservoir.
Low speed adjustments: Slotted centre screw.
High speed adjustments: Hexagon screw.
Rebound damping adjuster
Adjuster wheel on the piston shaft above the
end bracket.
WARNING!
!
Mounting Instructions - step 2
Installing the Shock Absorber
Fig.
Removing seat, side panel, left side
sub-frame and air box.
1. It is advisable to have an Öhlins dealer
or other qualified person installl your shock
absorber.
2. Instructions in the vehicle service manual
are to be followed when changing the shock
absorber.
3. When working on a lifted vehicle make
sure it is securely supported to prevent it
from falling.