Ohlins TTX25 Workshop Manual - 1 Replace Spring

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5

1 rePlace SPring

1 replace Spring

note!

You can replace the Spring with the front fork still mounted on the 

motorcycle. 

1.1 

Use appropriate tool to release the spring preload completely. Turn 

the Preload adjuster counter clockwise as far as possible. 

caution!

Do not use the Preload adjuster to tighten or loosen the Top cap from 

the fork leg.

1.2 

Loosen the screws that hold the fork legs in the upper triple clamp.

1.3 

Use tool 00797-08 together with appropriate tool. Loosen the Top 

cap from the outer fork leg.

1.4 

Use appropriate tool on the Top cap preload adjuster and tool 

04705-03 on the Shaft extension. Remove the Top cap from the 

Shaft extension. 

note!

When removing tool 04705-03 hold your hand against the Spring 

support and Spring to prevent them from being pushed out by the 

spring force.

1.5

Remove tool 04705-03.

1.6 

Remove the Spring support and the Spring. Use a wire with a hook 

and carefully pull up the Preload tube. 

1.7 

Check the oil level according to Mounting Instructions.

note!

Use Öhlins Front Fork fluid 01309-01 only.

1.8 

Mount the Preload tube, the new Spring and the Spring support in 

the front fork.

note!

Mount the Spring with the marking facing up.

1.9 

Mount the Top cap to the Shaft extension. 

Tightening torque 15 Nm

1.10 

Apply Assembly lubricant to the Top cap thread and O-ring. Use 

tool 00797-08. Mount the Top cap into the outer fork leg, with the 

fork leg fully extended. 

Tightening torque 10 Nm

note!

It is important that the fork leg is fully extended.

1.11

Tighten the upper triple clamp.

Tightening torque according to vehicle service manual

1.12

Adjust the spring preload according to recommendations in the 

Mounting Instructions.

1.1

1.2

1.3

Spring 

support

Spring

Preload 

tube

1.6

1.4

1.8