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Cartridge kit for BMW S1000RR, BMW HP4

FKR 104

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. This product is an important

part of the vehicle and the vehicle stability.

Kit Contents

Description Part No Pcs

Cartridge kit FKR 104 1

O-ring (44.04x3.53) 00438-26 2

O-ring (23.52x1.78) 00438-02 2

Plug 21652-06 2

Main spring 9.5 N/mm 04744-95 2

Main spring 10.0 N/mm 04744-10 2

Main spring 10.5 N/mm 04744-05 2

Sticker 00191-32 2

Sticker 00191-33 2

Owner’s manual 07291-01 1

Summary of content (8 pages)

PAGE 1
Kit Contents 11 Note! Please note that there can be small differences between your product and the images in these instructions. 11 Note! 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. Description Part No Pcs Cartridge kit FKR 104 1 O-ring (44.04x3.53) 00438-26 2 O-ring (23.52x1.
PAGE 2
MOUNTING INSTRUCTIONS ⚠⚠ Warning! ⚠⚠ Warning! We strongly recommend to let an Öhlins dealer install this product. 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. ⚠⚠ Warning! If you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over.
PAGE 3
MOUNTING INSTRUCTIONS 1 Remove original front fork 4 11 Note! The following procedure applies to both front fork legs. 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. 2 Remove front fender, brake calipers, speed sensor (if present) and front wheel. 3 Release main spring preload fully (if present). 4 Note front fork leg position. 5 Loosen upper triple clamp.
PAGE 4
MOUNTING INSTRUCTIONS 2 Disassemble original front fork 4 11 Note! The following procedure applies to both front fork legs. A 1 Remove top cap from outer tube. 2 Slide outer tube down until it stops. 3 Remove top cap from shaft according to instructions in the vehicle service manual. 4 Remove main spring and associated parts according to instructions in the vehicle service manual. ⚠⚠ Warning! The two plastic tubes (A) inside outer tube shall not be removed.
PAGE 5
MOUNTING INSTRUCTIONS 3 Install Öhlins cartridge kit 1 11 Note! The following procedure applies to both front fork legs. ✋✋ 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. 1 Remove top cap, spring support and preload tube. 2 Remove cylinder tube assembly from shaft assembly.
PAGE 6
MOUNTING INSTRUCTIONS 7 Pour approximately 0.5 litre Öhlins suspension 10 fluid in front fork leg. ⚠⚠ Warning! Fluid level must be approximately 50 mm above top of cylinder tube assembly. 8 Install tool on shaft extension. [01765-03 shaft extension tool] 9 Install tool on seal head. [01797-07 seal head tool] 11 Note! Make sure teeth are securely connected to seal head. 10 Compress top out spring fully and insert clip.
PAGE 7
MOUNTING INSTRUCTIONS 16 24 Install tool on shaft extension. Set compression, rebound and main spring Install preload tube (A), main spring (B) and adjusters according to chapter “Setup Data”. spring support (C) over shaft extension Use a hex key for compression and rebound tool. Select main spring according to chapter adjusters. Use a socket for main spring preload “Main spring guide”. adjuster.
PAGE 8
SETUP DATA MAIN SPRING GUIDE Recommended setup Make sure you choose the correct main spring for your rider weight, driving style and preferences. Below you find a general recommendation of main spring rate for your weight. Contact an authorized Öhlins service center for advice.