Owners Manual
Mounting instruction Öhlins front fork kit
FG 836 for Ducati Monster
Rebound damping
adjuster
Compression
damping adjuster
Öhlins front fork 43
Your Öhlins front fork 43 is an upside down type
front fork featuring the following adjusters.
Compression damping adjuster
Adjustments are made at the bottom of the front
fork leg. Use a 3 mm allen key.
Rebound damping adjuster
Adjustments are made at the top of the fork leg.
Use a 3 mm allen key.
Spring preload adjuster
Adjustments are made by turning the nut at the
top of the fork leg. Clockwise for harder adjust-
ment, counter clockwise too release the preload.
Use a 17 mm wrench.
NOTE!
When delivered the Öhlins front fork is dialed to
recommended settings for the specific brand and
make of the motorcycle. If you have changed the
setting 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 at page 4.
CAUTION!
Do not use to much force, delicate sealing
surfaces can be damaged.
Spring preload
adjuster
Bike on a stand.
F1
R1
Bike on the ground.
F2
R2
Bike with rider on.
F3
R3
Set-up data:
Lenght 730 mm
Stroke 120 mm
Rebound adjustment 12 clicks
Compression adjustment 10 clicks
Spring pre-load 10 mm
Spring rate 9.5 N/mm
Oil level 85 mm
Checking sag and ride height
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 = ............
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.
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
Part No. FG 836. Issued 02 04 05
Before installation
Öhlins Racing AB can not be held responsible for
any damage whatsoever to front fork or vehicle,
or injury to persons, if the instructions for fitting
and maintenance are not followed exactly.
Similarly, the warranty will become null and void
if the instructions are not adhered to.
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
whatsoever that may occur after fitting the front
fork. Contact an Öhlins dealer or other qualified
person for advice.
2. Please study and make certain that you fully
understand all the mounting instructions and
the owners manuals before handling this front
fork kit. If you have any questions regarding
proper installation procedures, contact an
Öhlins dealer or other qualified person.
3. The vehicle service manual must be referred
to when installing the Öhlins front fork
Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:
The Safety alert symbol means:
Caution! 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 dam-
age to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
Öhlins products are subject to continual improve-
ment 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 and this manual. Please consult your Öhlins
dealer if you have any questions with regard to
the contents of the manual.
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out
inside the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
front fork.
Kit contents
Before installing the front fork, please check the
contents of the kit, listed on the front page of
this instruction. If anything is missing, contact
your Öhlins dealer.
Description Pcs. Part No.
Fork legs (pair) 1 01676-02
Bolt MC6S 4x14 4 01046-10
Bolt MC6S 5x16 4 01046-18
Caliper bracket 1 01677-07
Caliper bracket 1 01677-08
Fender bracket 1 01682-11
Fender bracket 1 01682-12
Fender bracket 2 01686-02
Shaft sleeve M18x1.5/30 1 01680-04
Shaft sleeve 25/30/44 1 01687-01
Boss 1 01688-01
Sticker Öhlins 2 00194-10
Owners manual 1
Notes
6
WARNING!
1. It´s advisable to have an Öhlins dealer or other
qualified person to fit your shock absorber.
2. Instructions in the vehicle service manual are
to be followed when changing the shock ab-
sorber.
3. When working on a lifted vehicle it must be
securely supported to prevent it from falling.
Mounting instruction
1
Lift up the motorcycle so that the front wheel is
free. This can be done by inserting a piece of
pipe or bar through a suitable aperture in the
bracket in front of the front fork. Ensure that the
motorcycle is properly secured and cannot fall
over.
2
Release the brake caliper on each side and let
them hang by the brake leads.
3
Remove the front wheel.
4
Remove the front fender.
5
Release the fasteners of the fork legs in the lower
triple clamps. Release the upper triple clamps.
6
Pull the fork legs out downwards and fit Öhlins
fork legs to the triple clamps. Put back the screws
in the fork crowns and the clip-on handles. Do
not tighten fully until you have adjusted the fork
legs in correct position.
NOTE !
The Öhlins front fork is 10 mm longer than the
original front fork. It is important that fork legs
are mounted so the top nuts are not in contact
with the handlebar.
Distance to
handlebar
7
Fit the circlip model flexible fender bracket by
first pressing it over lower fork leg.
8
Then open it slightly so it can be slided to the
fork bottom.
9
Fit the sticker to the fender bracket.
7
8
9
Notes
10
Fit the brake caliper brackets and the fender
brackets. Refit the front fender.
NOTE!
As the fender brackets are tilted a bit forwards
compared to the original brackets the fender will
be positioned slightly forwards.
Former bracket
position
New bracket
position
NOTE!
New fender position will be slightly forward
10
10
11
Fit the sleeve with the two fastening screws on
the left fork bottom and the bushing to the right
front bottom. Put the wheel and the wheel axle
back in position. Do not tighten until the machine
is standing on the ground.
12
Fit the brake calipers.
WARNING!
It might be necessary to fit slightly longer brake
hoses. To avoid malfunction this should be car-
ried out by a skilled mechanic.
20 Nm
7 Nm
25 Nm
5 Nm
NOTE!
Make sure that all bolts are tightened in correct
torque and that nothing restrains the front fork
when the suspension is being compressed.
Check with the Workshop manual of the motor-
cycle.
15
Continue with adjustments according to the
Owner’s Manual.
13
Lower the motorcycle so that the front suspen-
sion works. Brake the front wheel and push the
front suspension down two or three times. This
will put the fork legs in a parallel position.
14
Tighten the triple clamp screws on the fork legs
so that the fork legs are fixed in position.
NOTE !
Tighten the screws to a maximum torque of 15
Nm. If the screws in the lower triple clamp are
tightened too hard they can deform the fork tube
and impair the spring action.
11
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