© Öhlins Racing AB. All rights reserved. Any re-
printing or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
Printed in Sweden.
Mounting Instructions KA794_0 Issued 2006 12 04
These instructions and other documents
can be downloaded from
www.ohlins.com
Mounting Instructions
Kit Contents:
Part no. Pcs.
Shock absorber KA794 1
Spring clip 00629-05 1
Screw M10 00439-20 1
C-spanner single 00710-02 1
Öhlins Sticker 00197-01 2
Memo Notes Sticker 01180-01 1
Öhlins Owner’s Manual 1
Before installing this product, check the con-
tents of the kit listed below. If anything is
missing, please contact your nearest Öhlins
dealer.
SHOCK ABSORBER KA794
for Kawasaki KX 450F 2007
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, especially
at high ambient temperature, some of the oil
and grease used for assembling may leak and
stain the packaging. This is in no way detri-
mental 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
Spring preload
Loosen the screw of the spring platform
clamp. Use the C-spanner provided in
this kit, turn the spring platform to the
desired position. Or, when installed on
the vehicle, turn the spring. Tighten the
screw of the spring platform clamp.
Compression damping
Adjust on top of the reservoir.
Low speed: Turn the slotted centre screw
High speed: Turn the hexagon screw
Turn clockwise to increase damping, turn
counter clockwise to decrease.
Rebound damping
Turn the wheel on the piston shaft above
the end eye/bracket. Turn clockwise to
increase damping, turn counter clock-
wise to decrease.
Set-up data
Spring preload 7 turns (10 mm)
Rebound damping 18 clicks
Compression damping
Low speed 15 clicks
High speed 1.5 turns
Free sag and Ride height
Free sag, rear 30±5 mm
Free sag, front 30±5 mm
Ride height, rear 100-105 mm
Ride height, front 80±5 mm
Shock absorber data
Length 485.5 mm
Stroke 138 mm
A
B
Spring preload is the difference
between A and B;
A Free spring length
B Installed spring length
A-B = Spring preload
preload
1
2
3
1
2
3
WARNING!
When delivered, the Öhlins shock absorber is
dialed to the recommended settings for the spe-
cifi c 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.
Loosen the screw
...and adjust with
a C-spanner
... by turning the spring
or
INSTALL THE SHOCK ABSORBER
1
2
INSTALL THE SPRING
NOTE!
Install the spring to the shock absorber before
installing the shock absorber on the vehicle.
1
Measure the free length of the spring (A).
2
Loosen the screw on the spring platform clamp
so that you can move the spring platform as far
up as needed to install the spring.
3
Put the shock absorber up-side-down in a
vice so that you can install the spring and the
spring clip.
NOTE!
The spring platform and spring are press fi tted.
Push hard to install the spring.
4
Measure the spring length. Adjust the spring
preload to the recommended setting, see sec-
tion Adjustments and Set-up data in this folder.
5
Install the shock absorber to the vehicle ac-
cording to the procedure in this folder.
Check sag and ride height (see the Owner’s
Manual) and adjust the spring preload again if
necessary.
A
Spring clip
Spring
Washer
Spring
platform
clamp
Spring
platform
Bump rubber
1
2
3
NOTE!
Tighten the screw on the spring platform clamp
before riding the motorcycle.
SPRING GUIDE
4
Brand Rider’s weight Spring Spring rate Titanium spring
kg/pounds N/mm
Kawasaki KX 450F 65/143 06310-08 48 06350-08
70/154 06310-09 50 06350-09
75/165 06310-10 52 06350-10
80/176 06310-11 54 06350-11
85/187 06310-12 56 06350-12
90/198 06310-13 58 06350-13
95/209 06310-14 60 06350-14
WARNING!
It is advisable to have an Öhlins dealer install the
shock absorber.
1
Raise the rear end of the vehicle so that the
rear wheel barely touches the ground.
WARNING!
Make sure the vehicle is securely supported to
that it will not tip.
2
Remove the seat.
3
Remove the right side number plate.
4
Loosen the silencer from the subframe. Leave
it attached to the exhaust pipe.
5
Loosen the subframe from the frame. Remove
the hose clamp holding the airbox to the
carburetor. Remove the whole unit with rear
fender, subframe and air box.
6
Loosen the lower and the upper attachment of
the original shock absorber and remove it.
7
Install the Öhlins shock absorber in the same
way as the original unit. Fasten the upper
attachment with the provided screw. See
fi gure. Use the original screw for the lower
attachment.
NOTE!
Insert the screw with the head in a horizontal
position to avoid interference with the top of the
reservoir. Turn the screw head 90° and lock it in
its correct position with the original nut.
NOTE!
Lower the motorcycle so that the shock
absorber is slightly compressed, before tighten-
ing the screws.
8
Put the air box, subframe, rear fender, number
plate and seat back in position and fasten
them. Make sure that all removed parts are
installed in the same way as they were before
the installation.
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 being fully compressed or extended.
3
5
7
7
/