Ohlins FKS 503 User manual

Front Fork Kit for Yamaha TMAX
FKS 503
Mounting Instructions
Note!1
Please note that there can be small differences
between your product and the images in
these instructions.
Note!1
Please note that during storage and transport,
especially at high ambient temperature, some
of the oil and grease used for assembly may
leak and stain the packaging. This will not cause
damage to the product, wipe off the excessive
oil or grease with a cloth.
Note!1
Before you install this product, check the kit
contents. If anything is missing, please contact
an Öhlins dealer.
Warning!⚠
Before you install this product, read the Öhlins
Owner’s manual and this document. This
product is an important part of the vehicle and
the vehicle stability.
Kit Contents
Description Part No Pcs
Front fork kit FKS 503 1
O-ring 00576-02 2
Sticker set Öhlins - -
Owner’s manual 07284-01 1
Warning!⚠
This kit should only be installed by an authorized
Öhlins dealer. The installation procedure
requires certain tools.

2
MOUNTING INSTRUCTIONS
TOOLS, GREASE AND FLUID
Tools needed for the original front fork
• Refer to the vehicle service manual for tools
needed for removing/installing the front fork
from the vehicle.
• Refer to the vehicle service manual for tools
needed for removing the cartridge from the
front fork.
Tools needed for the Öhlins cartridge kit
Tool Part no Applies Size
Vehicle service manual
Torque wrench
Wrench Shaft extension
19 mm
Hex key Compression and
rebound bleed
adjusters
3 mm
Socket Preload adjuster 14 mm
Ruler Suspension uid level
Öhlins tool 01765-03 Shaft extension
Wrench Top cap 46 mm
Öhlins tool 01797-07 Seal head
Suspension uid 01309-xx
Grease 00146-01 100 g
Warning!⚠
We strongly recommend to let an Öhlins dealer
install this product.
Warning!⚠
If you work with a lifted vehicle, make sure that it
is safely supported to prevent it from tipping over.
Note!1
When you work with this product, see the
vehicle service manual for vehicle specic
procedures and important data.
Note!1
Before you install this product clean the vehicle.
Warning!⚠
Spring compression creates a potential danger
because of the violent force that loaded springs
are capable of. Beware of this when you work
with the front fork.

3
MOUNTING INSTRUCTIONS
1 Remove the original front fork
Note!1
The following procedure applies to both front
fork legs.
1.1
Put the motorcycle on a workstand so that the
front wheel barely touches the ground.
Warning!⚠
Make sure the vehicle is securely supported so
that it will not fall over.
1.2
Remove front fender, brake calipers, speed
sensor (if present), front wheel and front cover.
1.3
Note front fork leg position.
1.4
Loosen upper triple clamp.
1.5
Loosen lower triple clamp.
1.6
Remove front fork legs from triple clamps.
3
Front fork
leg position
2
Front cover

4
MOUNTING INSTRUCTIONS
2 Disassemble original front fork
Remove original
2.1
Loosen top cap from outer tube.
2.2
Slide outer tube down until it stops.
2.3
Loosen and remove top cap from shaft
according to vehicle service manual.
2.4
Remove main spring and surrounding parts
from front fork leg.
2.5
Drain front fork leg of suspension uid.
2.6
Loosen cartridge according to vehicle service
manual.
2.7
Remove cartridge from front fork leg.
Install the Öhlins cartridge kit
Caution!✋
The cartridge kit is divided into compression and
rebound cartridges.
Install compression cartridge marked “COMP” in
left hand side front fork leg.
Install rebound cartridge marked “REB” in right
hand side front fork leg.
2.8
Remove top cap (A), spring support (B) and
preload tube and guide ring (C).
2.9
Insert the cartridge in the front fork leg.
2.10
Install bottom screw according to instructions in
the vehicle service manual.
9
10
B
A
8
C

5
MOUNTING INSTRUCTIONS
2.11
Pour approximately 0.5 litre Öhlins suspension
uid in front fork leg.
Warning!⚠
Fluid level must be approximately 50 mm above
top of cylinder tube assembly.
2.12
Use a hex key to open compression and
rebound bleed adjusters fully. Install top cap
directly to shaft extension (no main spring or
preload tube). Pull up outer tube and tighten it
to the top cap with your hand.
[Hex key 3 mm]
2.13
Pull outer tube up and down 10-15 times to
pump out all air from the cartridge.
2.14
Remove top cap from front fork leg.
2.15
Make sure that shaft assembly and outer tube
are in their bottom positions.
Set suspension uid level according to chapter
“Setup Data”.
2.16
Install shaft extension tool on top of shaft
extension.
Install main spring with the marking up (A),
preload tube and guide ring (B) and spring
support (C) over shaft extension tool.
[01765-03 shaft extension tool]
2.17
Pull up shaft assembly and grab spring support
with a wrench tool.
[Wrench 19 mm]
15
16
17
13
B
C
A

6
MOUNTING INSTRUCTIONS
2.18
Install o-ring on top cap. Apply grease on o-ring
and thread.
[00576-02 o-ring]
[00146-01 grease]
2.19
Make sure that compression and rebound
adjusters are fully open before installing top
cap.
Use a hex key to open compression and
rebound adjusters.
Remove pull-up tool and install top cap to the
shaft extension. Tighten to 20 Nm.
[Hex key 3 mm]
[Socket 14 mm]
2.20
Remove wrench from spring support.
2.21
Pull up outer tube. Make sure front fork leg is
in a fully extended position. Tighten top cap to
outer tube. Tighten to 10 Nm.
[Wrench 46 mm]
2.22
Set main spring preload, compression and
rebound adjusters according to chapter “Setup
Data”.
Use a hex key for compression and rebound
adjusters.
Use a socket for the preload adjuster.
[Hex key 3 mm]
[Socket 14 mm]
19

7
MOUNTING INSTRUCTIONS
4 Install the front fork in the vehicle
Note!1
The following procedure applies to both front
fork legs.
4.1
Install the front fork legs into the triple clamps
at the position recommended in setup data
(Front leg position). See the vehicle service
manual for correct procedure and tightening
torque.
Note!1
Measure the front fork leg position from the
upper triple clamp to the top of the outer tube.
4.2
Remaining installation, instructions according
to vehicle service manual.
1

Öhlins Racing AB
Box 722
S-194 27 Upplands Väsby, Sweden
Phone [phone]
fax [phone]
© Öhlins Racing AB. All rights
reserved. Any reprinting or
unauthorized use without the written
permission of Öhlins Racing AB
is prohibited.
Öhlins products are subject to
continuous improvement and
development, therefore, although
these instructions include the most
up-to-date information available at
the time of printing, minor updates
may occur.
To nd the latest information
contact an Öhlins distributor.
Please contact Öhlins if you have
any questions regarding the
contents in this document.
SETUP DATA
MAIN SPRING GUIDE
Part no. MI_FKS503_0
Issued 2017-06-20
Compression 12 clicks
Rebound 12 clicks
Suspension uid level 150 mm
Front leg position Standard position
Suspension uid 01309-xx
Make sure you choose the correct main spring for your rider weight, driving style and
preferences. Below you nd a general recommendation of main spring rate for your
weight. Contact an authorized Öhlins service center for advice.
Rider weight [kg] 50 60 70 80 90 100 110
Spring rate [N/mm] 8.5 8.5 9 9 9.5 9.5 10
Preload [turns] 9 11 10 12 11 13 12
Spring part number 08790-85 08790-85 08790-90 08790-90 08790-95 08790-95 08790-10
Spring are packed in pairs.
0
50
100
150
200
250
300
350
400
450
010 20 30 40 50 60 70 80 90 100 110 120 130
Force [N]
Stroke [mm]
Force vs Stroke
110
120
130
140
150
160
170
180
190
200
210
220
230
Level
[mm]