K-Tech DDS APRILIA RSV4 User manual

APRILIA RSV4
155-011-010-025
21/06/2017 ISSUE 1
OWNER’S MANUAL

2
1
1
CONTENTS
K-Tech Suspension Ltd products are manufactured to fit specific
brands and models. Under no circumstances should any K-Tech Sus-
pension Ltd products be fitted to an application other than that for
which it has been designed, tested and manufactured.
RECOMMENDED SETTINGS
Fork stroke
Preload
Air gap
Fork oil
Spring rate
Comp damping L/H leg
Reb damping R/H leg
Fork position
RECOMMENDED SETTINGS
DDS CLOSED CARTRIDGE DAMPING SYSTEM
Page 2
Page 3
Page 4
Page 5
Page 6-10
Page 11
Recomended Settings
Introduction
Adjustment
Setting the fork
Changing the fork springs/ Service
Notes
125mm
8-10mm
190mm
5wt.
10N
-16 Clicks out
-18 Clicks out
Manufacturer specs

3
INTRODUCTION
***This product is not designed or intended for highway use.***
DDS CLOSED CARTRIDGE DAMPING SYSTEM
The DDS Front Fork Cartridges have been designed to fit original
equipment front forks to use at the highest levels of competition, these high
quality replacement cartridges are designed and manufactured in the UK
using the highest quality materials and processes available. The closed car-
tridge pressurised Direct Damping System uses 20mm dia displacing pistons
with an 8mm piston rod and 31mm dia control
pistons giving a high flow of fluid for precise damping control. This unique
damping system uses one leg for compression damping and one leg for re-
bound damping making each circuit independent for adjustment.
These procedures should only be carried out by a qualified motorcycle tech-
nician. K-Tech Suspension Ltd will not be liable for any damages caused in
any way to/by the product and any injuries sustained if the product is fitted
by someone who is neither an authorised dealer of K-Tech Suspension Ltd
or have the relevant qualifications in motorcycle technology. K-Tech Suspen-
sion Ltd will also not be liable if the correct tools are not used throughout
the process of fitting and adjustment of a K-Tech suspension Ltd product.
Please refer to the manufacturer’s workshop manual before attempting this
procedure. This procedure will require two people, you will need to remove all
relevant bodywork and any other parts that may restrict you from carrying out
this task.

4
1
DDS CLOSED CARTRIDGE DAMPING SYSTEM
ADJUSTMENT
The K-Tech DDS cartridge kits are adjustable by the following
external adjusters.
Spring Preload:- 14mm hex nut in
centre of the fork caps.
Spring preload has 18mm of
adjustment, 1 turn on hex nut equals
1mm of preload on spring.
Spring preload should be set from the
fully open (anti-clockwise) position.
Compression Damping:- 3mm allen
key in centre of the BLACK LEFT hand
fork cap.
Adjustment range is 30 clicks.
All settings should be made from fully
closed (clockwise) position.
Rebound Damping:- 3mm allen key
in centre of the NATURAL RIGHT hand
fork cap.
Adjustment range is 30 clicks.
All settings should be made from fully
closed (clockwise) position.

5
DDS CLOSED CARTRIDGE DAMPING SYSTEM
The K-Tech DDS cartridge kits are adjustable by the following
external adjusters.
SETTING THE FORK
When the fork is fitted to the bike there is some basic geometry you
should check with the preload adjustment, to do this you need to sup-
port your bike so the front wheel is lifted off the ground.
To set the preload on your forks you need a 14mm socket or
spanner, preload is very important as it effects the attitude of the motor-
cycle and the angle of the forks.
To check the preload on your forks support the motorcycle on a stand
so the front wheel is fully off the ground, make sure the fork is fully
extended by pushing down on the wheel and measure the amount of
chrome tube there is extending from below the seal to the axle bracket
at the bottom of the fork. Make a note of this. (A)
Take the bike off of the stand and push down on the handlebars a few
times allowing the bike to settle. Measure the same points as before
and make a note of it. (B)
Subtract the second measurement -See Fig (B) from the first
measurement - See Fig (A), this measurement should be between
25-35mm. If you do not have this measurement you need to adjust the
preload with the 14mm hex on the top cap until you achieve this figure.
AB

6
1
DDS CLOSED CARTRIDGE DAMPING SYSTEM
CHANGING THE FORK SPRINGS
Before changing fork springs make a note of the spring preload, com-
pression and rebound damping settings.
1. Remove all the preload from both
forks using the 14mm hex in the
centre of the top cap.
Loosen the clamping screws in the up-
per clamp.
With the bike supported under the
bottom fork clamp unscrew both
fork caps with either the spanner
provided or a top cap socket
- Tool No. 113-020-000.
With one person on each handle bar
remove the stand from under the
bottom fork clamp and slowly lower
the bike.
3.
2.
Before performing step 3
please make sure the
persons holding the handle bars are
strong and in good health as the
motorcycle maybe very heavy when
lowered.

7
DDS CLOSED CARTRIDGE DAMPING SYSTEM
CHANGING THE FORK SPRINGS
Loosen the clamping screws in the up-
per clamp.
Remove the top cap nut
assembly from the piston rod
joiner using a 14mm spanner and
the 17mm steel spanner provided
-Tool No. 113-010-020.
4.
Remove the nylon spring pusher
and the main spring slowly,
keeping as much oil in the fork leg
as possible.
5.
If a large amount of oil has been
lost removing the spring it is nec-
essary to check the
oil level. To do this you will need
to remove the spring
preload spacer from under the
main spring using a wire hook.
6.
CHANGING THE FORK SPRINGS

8
DDS CLOSED CARTRIDGE DAMPING SYSTEM
To check the oil level in the fork is
to the recommended level
use - Tool No. 113-030-500.
To do this add approximately
100cc of oil to the fork, insert the
oil level tool to the preset stop (see
recommended settings on page 2) and
suck out any excess oil. The pis-
ton rod should be fully
compressed downwards when per-
forming this procedure.
7.
Refit the preload tube with nylon
seats, with the holes facing
downwards along with the
optional spring you are
choosing to use and the nylon
spring pusher.
8.
Using the pull up rod supplied
- Tool No. 113-030-015 screw
this onto the piston rod joiner.
9.
CHANGING THE FORK SPRINGS
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
OIL
LEVEL
mm
K-Tech recommend 5wt.

9
DDS CLOSED CARTRIDGE DAMPING SYSTEM
Pull the piston rod up and locate
the 17mm steel spanner
provided Tool No. 113-010-020
through the nylon spring pusher
onto the 17mm hex on the piston
rod joiner.
10.
11.
Fit the correct top cap onto the
piston rod joiner using the17mm
steel spanner
provided and a 14mm socket.
Tighten the top cap to the
piston rod joiner torque load to
20N/M (14.75Ib - ft ).
12.
CHANGING THE FORK SPRINGS
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
B
C
D
1 2
A
3 2 1 4
B
A
5 6
DRAWN
CHK'D
APPV'D
MFG
Q.A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
NAME
SIGNATURE
DATE
MATERIAL:
DO NOT SCALE DRAWING
REVISION
TITLE:
DWG NO.
SCALE:1:20 SHEET 1 OF 1
A4
C
WEIGHT:
13 put spring and stuff back in
Remove the piston rod pull
up tool.
Fork cap with black adj in
left hand fork.
Fork cap with natural adj
in right hand fork leg.
K-Tech recommend 5wt.

10
DDS CLOSED CARTRIDGE DAMPING SYSTEM
With one person on each
handlebar slowly lift the bike and
support the bike under the
bottom fork clamp so the wheel
is off the ground. Refit the top
caps to the fork legs and torque
load to 10N/M (7.35 Ib-ft)
- using Tool No. 113-020-000.
13.
CHANGING THE FORK SPRINGS
Tighten the upper fork clamp
bolt to manufacturer’s
specification and adjust
preload and damping
settings to previous or
recommended settings.
(Located at the front of document)
14.
K-Tech Suspension Ltd recommend that this product is serviced every 20
hours of use. It is very important that this product is serviced by an authorised
dealer, as there are special tools required to guarantee correct performance
of this product. K-Tech Suspension Ltd cannot be held responsible for any
damage caused to/by the product if a service is overdue or was not conduct-
ed by an authorised dealer.
www.ktechsuspension.com/service-centres-and-partners
SERVICE