Kit Contents
Shock absorber KA872 1
C-spanner 00710-02 1
Spring clip 00629-01 1
Öhlins Sticker 00197-01 2
Memo Notes Sticker 01180-01 1
Owner’s Manual ATV 07235-01 1
NOTE!
No spring included in this kit! See
spring recommendation in this
manual. Consult your Öhlins dealer.
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
© 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
ADJUSTMENTS
SET-UP DATA
Rebound damping 18 clicks
Compression damping
Low speed 15 clicks
High speed 1½ turn
Spring pre-load 2 mm
Shock absorber data
Shock absorber length 435.5 mm
Stroke 128 mm
Free sag and Ride height
Free sag, front 60 ± 5 mm
2½ ± ¼ “
Free sag, rear 30 ± 5 mm
1 ¼ ± ¼ “
Ride height, front 80 ± 5 mm
3 ¼ ± ¼ “
Ride height, rear 105 ± 5 mm
4½ ± ¼ “
Öhlins shock absorber kit KA872
for Kawasaki KFX 450R - Rear
with set-up data
Before installing this product, check the
contents of the kit listed below.
If anything is missing, please contact
your nearest Öhlins dealer.
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
detrimental to the product, wipe off the
excessive oil/grease with a cloth.
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Spring guide
Rider’s weight Spring part no. Spring rate
75kg/ 165 lbs Standard swingarm 00698-03 38 N/mm
85kg/ 187 lbs Standard swingarm 00698-05 42 N/mm
95kg/ 209 lbs Standard swingarm 00698-07 46 N/mm
Read the Öhlins Owner’s Manual before installing this product
Mounting Instruction KA872_2 Issued 2008-11-19.
These instructions and other documents can be
downloaded from www.ohlins.com
1
2
3
1
WARNING!
When delivered, the Öhlins shock absorber is
dialed to the recommended settings for the
specific brand and make of the motorcycle.
Before riding, always ensure that the basic set-
tings 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.
Spring pre-load
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 by hand.
Tighten the screw of the spring platform
clamp when done with the adjustment.
2
3
Compression damping:
Adjustments are made on top of the
reservoir.
Low speed: Slotted centre screw.
High speed: Hexagon screw.
Rebound damping:
Adjust by turning the wheel on the piston
shaft above the end bracket.
INSTALL THE SPRING
1
Remove the seat.
2
Raise the rear end of the vehicle so that the
original shock absorber is in an unloaded
position.
CAUTION!
Do not apply lifting force to the swing arm.
Make sure the vehicle is securely supported
so that it will not fall over.
3
Remove the original shock absorber.
NOTE!
Remove the lower bolt of the triangle link so
that the lower bolt of the shock absorber can
be removed.
4
Install the Öhlins shock absorber in the
same position as the original unit. Fasten
the upper attachment first. You may need to
loosen the mounts for the fuel pump when
fitting the shock absorber. When mounting is
completed, make sure to reattach these fit-
tings and that the fuel pump and its lines and
electrical wires do not interfere with any part
of the shock absorber. If they do, secure them
carefully with appropriate straps.
NOTE!
Before installing the shock absorber, make sure
that the correct spring is installed.
3
Remove
bolt
Fold out
the arm
Triangle link
Lower shock
absorber bolt
!
2
CAUTION!
1
4
3
5
NOTE!
The piggy back reservoir should be at the top,
towards the front and slightly to the left.
5
Fasten the lower attachment. Raise the
wheels slightly to make the attachment fit.
Reattach the triangle link!
6
Tighten the attachment screws to the correct
torque. Consult your ATV Owners manual.
7
Check sag and ride height according to the
Öhlins Owner’s manual. See also Set-up data
in this manual.
NOTE!
Make sure that all bolts are tightened to
the correct torque and that nothing fouls or
restricts movement of the shock absorber
when the suspension is being fully com-
pressed or extended.
INSTALL THE SHOCK ABSORBER
Spring
Spring clip
A
1
2
Spring
platform
clamp
Spring
platform
Spring Preload = A - B
A Free spring length
B Installed spring length
A
B
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 plat-
form 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 fitted.
Push hard to install the spring.
4
Measure the spring length. Adjust the spring
preload to the recommended setting, see
section 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 Own-
er’s Manual) and adjust the spring preload
again if necessary.
NOTE!
Tighten the screw on the spring platform clamp
before riding the motorcycle.
3
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