© Öhlins Racing AB. All rights reserved. Any
reprinting or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
Printed in Sweden.
Mounting Instruction KA 870 Issued 2008-06-13
These instructions and other documents
can be downloaded from
www.ohlins.com
Mounting Instruction
Kit Contents:
Part no. Pcs.
Shock absorber KA 870 2
C-spanner 00710-01 2
Stop washer 00115-01 2
Spring clip 00116-03 2
Circlip 00131-01 2
Spring platform 00154-02 4
Support sleeve 00417-02 2
Sleeve 03281-01 2
Öhlins Sticker 00197-01 2
Memo Notes Sticker 01180-01 1
Owner’s Manual ATV 07235-01 1
Before installing this product, check
the contents of the kit listed below. If
anything is missing, please contact
your nearest Öhlins dealer.
SHOCK ABSORBER KA 870
for Kawasaki KFX 450R - Front
Read the Öhlins Owner’s Manual before installing this product
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Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00 Fax +46 8 590 025 80
www.ohlins.com
with set-up data
During storage and transportation, espe-
cially at high ambient temperature, some
of the oil and grease used for assembling
may leak and stain the packaging. This is
in no way detrimental to the product, wipe
off the excessive oil/grease with a cloth.
NOTE!
No spring included in this kit. See the
Spring Guide in this folder, or contact an
Öhlins dealer for advice.
ADJUSTMENTS
Rebound damping 20 clicks
Compression damping
Low speed 15 clicks
High speed 1½ turns
Circlip position 2nd groove
Free sag and Ride height
Free sag, front 60±5 mm
2½±¼’’
Free sag, rear 30±5 mm
1¼±¼’’
Ride height, front 80±5 mm
3¼±¼’’
Ride height, rear 105±5 mm
4½±¼’’
Shock absorber data
Length 412 mm
Stroke 119 mm
SET-UP DATA
WARNING!
When delivered, the Öhlins shock absorber is
dialed to the recommended settings for the spe-
cific brand and make of the motorcycle. Before
riding, always ensure that the basic settings
made by Öhlins are intact.
To set the adjuster:
The turn adjusters have a normal right hand
thread. Turn the damping adjusters clock-
wise to fully closed (position zero [0]). Then,
turn counter clockwise to open, and count
the clicks until you reach the recommended
number of clicks. See Set-up data.
Do not use force, delicate sealing surfaces can
be damaged. Handtighten only.
Compression damping adjuster
Adjust on top of the reservoir.
Low speed adjuster: Slotted centre screw.
High speed adjuster: Hexagon screw.
Rebound damping adjuster
Adjust by turning the adjuster wheel
above the end eye.
1
2
3
4
1
2
3
4
Cross
over
Spring preload adjuster
Adjust by moving the upper spring seat
circlip to another groove.
Short spring stroke adjuster
- Cross over
The total spring characteristics can be
adjusted by moving the spring platforms
on the floating sleeve. The spring platform
position decides when the stroke for the
short spring is blocked. At this point, the
total spring stiffness will increase on com-
pression stroke. Lock the spring platforms
using C-spanners.
Spring platform
00154-02
Sleeve
03281-01
Washer
00115-01
Circlip
00131-01
INSTALL THE SHOCK ABSORBER
WARNING!
It is advisable to have an Öhlins dealer install the
shock absorber.
WARNING!
Make sure that all screws are tightened to the
correct torque and that nothing fouls or restricts
movement of the shock absorber when the sus-
pension is fully compressed or extended.
SPRING GUIDE
NOTE!
Before installing the shock absorbers, make
sure that the correct springs are installed.
1
!
4
WARNING!
Make sure the vehicle is securely supported so
that it will not tip.
3
1
Raise the front end of the vehicle so that the
original shock absorbers are in a neutral posi-
tion.
2
Remove the original shock absorbers.
3
Install the Öhlins shock absorbers in the same
positions as the original units. Fasten the up-
per attachment first. The piggy back reservoirs
should be at the top and facing outwards.
4
Fasten the lower attachment. Raise or lower
the wheels slightly to make the attachment fit.
5
Tighten the attachment screws to the correct
torque. Consult your ATV Owners manual.
6
Check sag and ride height according to the
Öhlins owners manual. See also Set-up data
for this specific shock absorber kit on the next
page.
INSTALL THE SPRING
NOTE!
Before installing the shock absorbers on the
vehicle you need to install the correct springs.
See spring guide in this manual.
1
Insert the circlip (00131-01)
in the correct groove.
Circlip 00131-01
Washer 00115-01
Short spring
Spring platform
00154-02
Long spring
Spring clip
00116-03
Sleeve 03281-01
Support sleeve
00417-02
2
Install the short and long springs, the surround-
ing parts but not the spring clip (00116-03).
3
Measure the free length of the springs and sur-
rounding parts (without the spring clip 00116-
03) according to fig. 3 (A).
4
Install the spring clip (00116-03) and, again,
measure the length of the springs and sur-
rounding parts according to fig. 4 (B).
2
3
4
Preload
A
B
A - B = Spring preload
Adjust the total preload by moving the
upper spring seat circlip (00131-01) to
another groove. See Set-up data in this
folder for correct preload.
5
Set the short spring stroke position - “Cross
over” according to the Set-up data in this
folder.
Groove No 1
Groove No 2
and so on...
Rider’s weight A-arm: Standard A-arm: Standard Mount +2’’
75kg /165Lb Long spring 06390-04 Long spring 06390-05
Spring rate Prog 21-30 N/mm Spring rate Prog 24-33 N/mm
Short spring 4060-40 Short spring 4060-40
Spring rate 40 N/mm Spring rate 40 N/mm
85kg /187Lb Long spring 06390-05 Long spring 06390-06
Spring rate Prog 24-33 N/mm Spring rate Prog 27-36 N/mm
Short spring 4060-40 Short spring 4060-40
Spring rate 40 N/mm Spring rate 40 N/mm
95kg /209Lb Long spring 06390-06 Long spring 06390-07
Spring rate Prog 27-36 N/mm Spring rate 30-39 N/mm
Short spring 4060-40 Short spring 4060-40
Spring rate 40 N/mm Spring rate 40 N/mm
Total spring preload: 4 mm Total spring preload: 4 mm
Cross-over 12 mm Cross-over 12 mm
/