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Summary of Contents for NITRON TVT22
- Page 1 TVT22 FORK CARTRIDGE Installation Instructions...
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Page 2: Installation Instructions
The front fork is a critical part of the motorcycle and improper installation could cause serious injury or death. WARNING Nitron will not be held responsible for any damage or injury caused through incorrect fitment, modification or incorrect application of any TVT Fork Cartridge Kits or related products. - Page 3 Sport machine you can be sure that your fork cartridge kit has been developed specifically for your needs. Nitron TVT Adjustable Fork Cartridge Kits offer the same level of improvements in rider control, performance and comfort that have become the trademark of the Nitron product. The system features a large bore 22mm shimmed piston which provides significant improvements in performance over the OEM set up.
- Page 4 Introduction Tri-Valve Technology (TVT) In addition to the main piston in the compression leg TVT cartridges also employ a third piston which gives a great deal of flexibility when designing the damping curve for a specific application. This piston also utilizes shims in much the same way as the main compression piston but with this design the shim stack is preloaded.
- Page 5 Fork Cartridge Diagram Description Top Cap Preload Cap Spring Spacer Tube Upper Spring Seat Spring Bump Stop Spacer Tube Plastic Spacer Bump Stop Lower Spring Seat Cartridge Tube Adaptor Aluminium Lock Nut M10 Lock Nut M10 Washer Piston Rod Adjuster Rod Gland Top Out Spring Piston...
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Page 6: Installation Preparation
Installation Preparation Installation Preparation Before commencing with the installation you will need to support the motorcycle with suitable front and rear stands, ensuring it is on flat, level ground. The front stand should allow the front wheel to be raised off the floor so it can be removed. NOTE Before removing the fork legs from the yokes loosen the top cap half a turn, this will make disassembly of the cartridge easier. - Page 7 Fork cartridge top cap tool -33,38 or 41mm PCD. NTT050264/ NTT050265. Piston rod holder. NTT050268 NOTE Refer to the Nitron Fork Tooling Application List for full details. Standard Tools Required Description Piston rod holding plate Oil level tool Soft jawed vice...
- Page 8 Damper Rod Removal Damper Rod Removal Before commencing with the cartridge kit installation if your forks are of the ‘damper rod’ type you will need to remove these internals from your forks. Step 1 Undo your OEM top cap and remove the spring and spacer tube if present. WARNING The springs may be under considerable preload so be careful when unscrewing the top cap to avoid injury.
- Page 9 Damper Rod Removal Step 6 Remove the circlip. Step 7 Apply heat around the top of the lower fork tube and then separate the two tubes Step 8 Remove the bushes and seals and then part off the very end of the steel tube in a lathe. Step 9 The OEM damper rod mechanism can then be removed from the fork tube.
- Page 10 Pour approximately half of the bottle of suspension fluid into the fork leg making sure that it easily covers the top of the cartridge body tube. WARNING For the best damping performance it is essential to use Nitron 02 suspension fluid.
- Page 11 Assembly Instructions Step 3 Bleeding Air From The Fork Work the upper fork tube up and down at least fifteen times to bleed any air that may be trapped between the two fork tubes. Step 4 Bleeding Air From The Cartridge Work the piston rod up and down at least fifteen times to bleed the air from the cartridge.
- Page 12 Final Assembly Instructions Step 8a Setting The Lock Nut Set the correct position of the lock nut, refer to the specification sheet for your model specific measurement. The measurement should be taken from the end of the piston rod to the top of the lock nut.
- Page 13 Final Assembly Instructions Step 9 Installation Of The Spring Hardware You are now ready to close the fork. Screw NTT050268 – piston rod holder onto the end of the piston rod. Install the spring, upper spring seat, spring spacer tube and spring preload cap. Pull the piston rod upwards and then insert a 17mm spanner through the window in the spring preload cap.
- Page 14 Assembly Instructions Step 11 Top Cap Tightening Remove the 17mm spanner and then pull the inner fork tube up and screw the top cap into it. Tighten to 10N/m using the top cap specific tool for your model (see specification sheet).
- Page 15 Assembly Instructions Setup Set the compression and rebound damping adjusters to the baseline settings specified in your model specific specification sheet. Adjustment is made by screwing the adjuster clockwise to its full hard position and then counting the clicks backwards from this point. WARNING Do not force the adjuster at either end of its adjustment range as this may damage the internal components.