Tenere (2012 models on) Ohlins fork spring fitting issues resolved
 

To the people that have replaced their fork springs with the Ohlins 60 Nm, did you have to shorten the spacer to achieve the correct sag.
I was under the impression that it was just a straight spring swap.
I really struggled to replace the fork cap and now have no sag, so I assume I will have to shorten spacer to achieve this.

Did you not get some shorter spacers in the box with the springs? I did (supplied by OTR).

If I remember right, they were about half the length of the original spacers, but I can't be sure without taking my springs out. You definitely will end up with little or no sag with the stock spacers. With the Ohlins supplied spacers the fork caps (with preload wound right out) fit with only the slightest amount of spring compression, a gentle push is all that is required to catch the first thread.

No spacer supplied, only springs.
I thought it didn't feel right with the amount of effort to put caps on.
I might have to sent an email to OTR on spacer length, unless anybody here can help me out.
Thanks

Just measured my stock spacers and they are 52mm. The Ohlins 60N spring free length is 590mm and the stock spring free length is 580mm, so by my reckoning the Ohlins spacers are/should be 42mm. This sounds about right, as far as I can remember, they were about 20% shorter.

mmmmmmm, my stock spring is 440mm long, not sure on spacers length, will pull out tomorrow, but I think about 130mm.
Bike is brand new and oem springs are fixed rate springs.

Ah, now it sounds like yours is either the "Touring" model with reduced travel suspension, or an ABS model with the low suspension.

Do your springs and spacers look like the ones in this video (ignore the language - you'll get the idea! ;) )

Spring length difference looks the same, mine is a brand new aussie version, non abs. At the 6:51 minute mark of video, looks to be shorter spacers.
When I pull the springs out tomorrow, I will see what the fork travel is.
I have sent an email to OTR for info on the spacers

Been doing a bit of digging. You find out something new everyday! ;)

It would appear that from mid 2012 the fork internals changed from Paioli to Kayaba/KYB (both Paioli and KYB parts are listed for the 2012 model year). The KYB ones have the raised hex head adjusters, rather than the recessed type on early forks. The part numbers for the springs and spacers are different between the two types.

I had no idea that the internals had changed, although I did know the preload adjusters had, but thought that was it. The measurements I gave earlier were from my 2008 model with Paioli internals.

However, if you've been supplied with Ohlins 08716-60 springs, they are exactly the same as mine, so the spacer dimension required is going to be somewhere around the 40mm mark (depending on how deep the new type preload adjuster is?) What's the Ohlins part number on the box?

Interestingly Ohlins only list fork springs for up to 2010/2011 bikes. Technically, they don't exist for 2012 KYB equipped bikes?

Try the different years in the search: https://www.ohlins.eu/en/motorcycle/search/?Brand=35&Model=XT+660+Z+T%E9n%E9r%E9&Year=2008

Best contact OTR, maybe Ohlins too. Could be some useful information to be gained here worth sharing with others with post 2011 bikes...

Looks like your on the money, will have a look tomorrow and take some measurements.
Thanks for the help

My 2011 forks have much shorter spacers than the ones in that video. Mine are probably about 50mm (from memory).

Pre-2012 bikes have Paioli 52mm spacers, 580mm springs and recessed preload adjusters, post 2012 have a completely different KYB arrangement of long spacer/short spring and raised preload adjuster nuts.

OTR replied with "no spacer required".
So I will fit reduced sized spaces as required to suit weight.
Thanks for everones input.

Just a follow up, pulled the spacers out and cut them to 50mm.
Checked fork travel and is 200mm.
Reinstalled and now have 30mm static sag and 60mm rider sag.
To sum up - Factory spring 440mm and 195mm spacer, Ohlins 08716-60 spring 590mm and have used a 50mm spacer.
Mind you I am a fat b@stard at 130 kg.

:023: Well done. Good work and useful info for all post 2012 Tenere owners wanting to change to Ohlins fork springs.

So useful I've moved the relevent bits to create a new thread so the info is easier to find in future, rather than buried in an old more general Ohlins thread.

All I'd add is that, for someone of a lighter frame (say 75 -100Kg), the Ohlins recommended spacer length or 42mm would probably do the job.