FGSU 590, Issued 06 05 05
Mounting Instructions
Öhlins front fork kit FGSU 590
for Suzuki RM 85
Kit Contents
Before installing the front fork, please check
the contents of the kit. If anything is missing,
please contact your Öhlins dealer.
Description Pcs. Part No.
Front fork 1 FGSU590
Spring (3.1 N/mm) 2 02468-31
Spring (3.5 N/mm) 2 02468-35
Spring HSC (30 N/mm) 2 04107-03
Spring support 2 02471-01
Washer 2 02470-01
Bump rubber 2 02476-01
Sticker Öhlins 2 00197-01
Owner’s Manual 1
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out in-
side the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
front fork.
Before installing
Öhlins Racing AB cannot be held responsible
for any damage to suspension components or
vehicle, or injury to persons, if the instructions
for fi tting and main tenance are not followed
exactly.
Similarly, the warranty will become null and
void if the instructions are not adhered to.
Öhlins products are subject to continuous
improvement and development.
Consequently, although these instructions
include the most up-to-date information
available at the time of printing, there may
be minor differences between your suspen-
sion components and this manual. Please
consult your Öhlins dealer if you have any
questions with regard to the contents of
the manual.
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
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
WARNING!
1. Installing a front fork, that is not
approved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage that may
occur after fi tting the front fork.
2. Please study and make certain that you
fully understand all the mounting instruc-
tions and the Owner’s Manual before
handling this front fork kit. If you have any
questions regarding proper installation
procedures, contact an Öhlins dealer or
other qualifi ed person.
3. The vehicle service manual must be
referred to when installing the Öhlins
front fork kit.
Safety Signals
Important information concerning safety is
distinguished in this manual by the following
notations:
The Safety alert symbol means:
Attention! Your safety is involved.
WARNING!
Failure to follow warning instructions
could result in severe or fatal injury to
anyone working with, inspecting or using
the suspension, or to bystanders.
CAUTION!
Caution indicates that special pre-
cautions must be taken to avoid damage
to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
!
!
!
CAUTION!
The front fork springs are delivered separately
and must be installed before the front fork is
mounted to the bike. See section “Installing
springs” in this manual.
Your Öhlins front fork MX 38 is an upside
down type front fork featuring the following
adjusters.
Compression damping adjuster
The compression adjuster is located at the bot-
tom of the fork leg. Adjustments are made by
turning the screw. Use a slot screw driver.
Rebound damping adjuster
Adjustments are made at the top of the fork
leg by turning the adjuster wheel.
Compression
damping
adjustment
Rebound damping
adjuster
Adjustments
NOTE!
When delivered the Öhlins front fork is dialed
to recommended settings for the specifi c
brand and make of the vehicle. If you have
changed the settings, check like this:
The adjusters have a normal right hand thread.
Turn the damping adjusters clockwise to
fully closed (pos. zero [0]). Turn counter
clockwise to open and count the clicks
until you reach the recommended number
of clicks. See Setup data on the last page
of this manual.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
Base valve
housing
1
Turn the fork leg upside down and fasten the
fork bottom in a vice with soft jaws
2
Remove the compression (base) valve. Use a
23 mm socket.
3
Fasten the valve in a vice with soft jaws.
4
Use tool (1863-01) or a pair of pointed pliers
to loosen the poppet valve seat and remove it
together with the poppet valve and the spring.
Tool 1863-01
Poppet valve
seat
Poppet valve
Spring
(4107-02/03/04)
Shims
Base valve
Front
fork leg
5
Install the new spring, refi t the poppet valve and
the poppet valve seat.
Tighten to a torque of 5 Nm.
6
Refi t the valve unit to the fork bottom as de-
scribed above.
Tighten to a torque of 60 Nm.
Changing the high speed compression spring
Installing springs
1
Fasten the front fork leg in a vice with soft
jaws.
2
Remove the adjustment wheel and the springs
and balls of the adjuster.
2
3
Unscrew the top cap, use tool (1860-01).
Tool (1860-01)
Adjustment
wheel
Balls and
springs
4
4
Remove the top cap from the damper rod extender.
Use a 17mm wrench and tool (1860-01).
Top cap
17 mm
wrench
Damper
rod assy
Damper rod
extender
Tool 1860-01
5
NOTE!
Closing the compression and the rebound valves
will keep the damper rod extended making it
easier to install the new spring.
Pull out the damper rod as far as possible and
then close the compression and the rebound
valve (clockwise).
17 mm
wrench
6
Install the correct spring. Two pairs of springs
are provided – with spring ratio 3.1 N/mm and
3.5 N/mm.
NOTE!
A spring ratio of 3.3 N/mm is obtained if a 3.1
N/mm spring is used in one leg and a 3.5 N/mm
spring in the other leg.
Spring
6
Bike on a stand. Bike on the ground. Bike with rider on.
R1
R2
R3
F1
F2
F3
Front suspension
F1. Bike on a stand with the
suspension fully extended = ............
F2. Bike on the ground without rider = ............
F3. Bike on the ground with rider = ............
Free sag F1 - F2 = ............
Ride height F1 - F3 = ............
Rear suspension
R1. Bike on a stand with the
suspension fully extended = .............
R2. Bike on the ground without rider = ............
R3. Bike on the ground with rider = ............
Free sag R1 - R2 = ............
Ride height R1 - R3 = ............
Checking Sag and Ride Height
Setup data
Shock absorber length 840 mm
Shock absorber stroke 280 mm
Rebound damping adjuster 14 clicks
Compression damping adj. 15 clicks
Spring pre-load 3.5 mm
Front fork oil level 105 mm
Front fork position 10 mm
Fork position is
measured from the
top of the fork leg,
to the top surface
of the triple clamp.
10 mm
Oil level
Oil level is
measured from the
top of the outer
leg, with the top
nut off, the fork
fully compressed
and no spring
installed.
NOTE!
If ride height is higher than recommended,
softer spring/springs must be used.
If ride height is lower than recommended,
harder spring/springs must be used.
Contact your Öhlins dealer for advice.
Recommended Free sag
Front 25 + 5 mm
Rear 25 + 5 mm
Recommended Ride height
Front 60 + 5 mm
Rear 80 + 5 mm
(30% of the total stroke)
9
Refi t the top cap to the fork leg and tighten. Use
tool 1860-01. The top cap should not be tight-
ened hard, only turned in position by hand.
NOTE!
The top nut only has to be tightened by hand,
without extending tool.
10
Fit the legs on the motorcycle.
Tightening torques:
Upper tripple clamp: 20 Nm
Lower triple clamp: 10 Nm
CAUTION!
Do not overtighten the clamps. There is a risk of
deforming the fork leg tubes. See the motorcycle’s
Workshop manual for correct torques.
Tool (1860-01)
7
17 mm
wrench
Tool 1860-01
17 mm
wrench
7
Adjustment
wheel
Top cap
Spring support
8
7
Fit the spring support. Install the fork top cap.
Tighten (30 Nm) the top cap and the lock nut
against each other. Use a 17 mm and 24 mm
wrench.
CAUTION!
The piston shaft must bottom in the top cap
before the lock nut is tightened.
8
Refi t the adjustment wheel. Adjust the compres-
sion and rebound valves according to specifi cation
card.
1
Put the bike on a stand so the front wheel has
ground clearance. Make sure it is steadily
positioned and will not fall over.
2
Remove the front wheel, the protecting covers
and the brake caliper. Let the caliper stay fi tted
to the brake hose.
3
Remove the original fork legs and fi t the Öhlins
fork legs to the triple clamps.
CAUTION!
Do not overtighten the clamps. There is a risk
of deforming the fork leg tubes. See section
“Installing springs” in this manual for correct
torques.
2
3
2
Upper triple clamp
Lower triple clamp
Front leg cover
Brake
caliper
Caliper
protection
cover
Front fork leg
Front wheel
WARNING!
!
It is advisable to have an Öhlins dealer to fi t
your front fork.
Instructions in the vehicle service manual are
to be followed when changing the front fork.
When working on a lifted vehicle make sure
it is securely supported to prevent it from
tipping over.
Mounting Instructions
NOTE!
Before you continue, make sure that the front
springs are installed. If they are not, proceed
with the instructions under section: “Installing
springs”.
4
Put the wheel back in position. Reassemble the
brake and fi t the hose holder.
NOTE!
The front fork legs must be aligned before the front
wheel axle is tightened.
5
Let the motorcycle stand on the ground and
compress the front suspension as hard as
possible a couple of times. This will align the
fork legs.
NOTE!
Another way to align the front legs is to rotate
the front wheel as fast as possible and bring it
to a fast stop by braking.
6
Tighten the wheel axle and refi t the removed
protecting covers.
NOTE!
Make sure that all bolts are tightened to the correct
torque and that nothing restrains the front fork
when the suspension is been fully compressed.
See the motorcycle’s workshop manual.
7
Continue your work according to the Öhlins
Owner’s Manual.
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