Öhlins Front Fork Kit for Kawasaki KX 450 F
FGKA 1394
Application Specific Mounting Instructions
Issued 2012-12-11
Kit Contents (application specific)
Recommended Tools (application specific)
Seal Platform
Set-Up Data
Spring Recommendation
Part No. Pcs.
Front Fork kit FGKA 1394 1
Base plug (with o-rings) 15430-03 2
Spacer 2 mm 15443-02 6
Seal Platform 15452-04 2
Circlip 15440-01 2
OEM Fork Cap Tool 49 mm, octagon
Socket for Base Plug 17 mm
Socket for Öhlins Base Plug 20 mm
Tool for removal of inner tube, Öhlins p/n 00786-06
We strongly recommend that this modification is performed by an authorized Öhlins service centre.
FGKA 1394 cartridge kit comes with an Öhlins seal platform which shall be installed with it’s O-rings between the 48mm inner
tube and the fork bottom in both fork legs. It is of greatest importance to have a proper 48mm inner tube clamping tool and
grinding tools to remove the damaged (by the lock screw) part of the inner tube thread.
1 Follow step 1 to 9 in your Öhlins Owners Manual-General Mounting Instructions.
2 Remove the lock screw and grind damaged threads in the bottom of lock screw hole.
3 Heat up the fork bottom to approx. 150°C to reduce the effect of any thread locking adhesive.
4 Unthread the inner tube from the fork bottom and remove the oem seal platform.
5 Clean the fork bottom and fork leg thread, install the Öhlins seal platform (with O-rings).
6 Apply thread locking adhesive (Loctite 2701 or similar) to the inner tube thread and reinstall the inner tube into the fork
bottom.
7 Tighten to 200Nm and reinstall the lock screw.
8 Continue from step 11 in your Öhlins Owners Manual-General Mounting instructions.
Rebound Damping 15 clicks
Compression Damping 15 clicks
Spring Preload 2 mm
With a spring length of 467mm, 1pcs of plastic spacers
(15443-02) in each leg will equal 2mm of preload
Fluid Volume (each leg) 0,370 litre
Cartridge Kit FGKA 1394 shall be used together with
Öhlins Front Fork Springs part no. 08765-xx. For rate
recommendations, see Owner’s Manual/ General Mounting
Instructions.
Note!
The fork springs need to be ordered separately depending on the
rider’s choice of spring rate.
Part No. Pcs.
Öhlins Sticker 00192-01 2
TTX Cartridge Sticker 00191-40 2
O-ring 00576-02 2
O-ring 00338-92 2
Owners Manual 07296-90 1
Spring preload range -2 to 8 mm
(can be adjusted by adding/removing washers 15443-02)
Fluid volume range (each leg) 0,300 - 0,400 litre
Öhlins Front Fork uid 01309-01
Hydraulic Stop Cup
FGKA 1394 Has the Hydraulic Stop Cup incorporated in the
previously installed Seal Platform.
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