Spring preload adjustment
Use a 14 mm wrench to turn the upper adjustment screw. Maximum
adjustment range is 10 mm. One turn of the adjustment screw will
cause 1 mm change in spring preload. The spring has a minimum
spring preload of 2 mm, giving an adjustment range of 2-12 mm.
Adjust according to the procedure in chapter Set-up.
Rebound adjustment
Adjust the rebound damping on the adjustment screw positioned at
the top centre of the fork leg. Use a 3 mm allen key. Adjustment range
is + - 5 click from recommended setting. Please check Set-up data
for recommended setting.
Compression adjustment
Adjust the compression damping on the fork bottom (compression
valve). Use a 3 mm allen key. Adjustment range is + - 5 click from
recommended setting. Please check Set-up data for recommended
setting.
Oil level [mm]
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Stroke [mm]
Force [N]
140
150
160
170
180
190
200
210
220
230
240
+
-
+-
Öhlins Racing AB cannot be held responsible
for any damage to the front fork, vehicle or injury
to persons, if the instructions for installing and
maintenance are not followed exactly.
Similarly, the warranty will become null and void if
the instructions are not adhered to.
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
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
DIAGRAM: OIL LEVEL - FORCE
CAUTION!
Do not use force, delicate sealing surfaces can be damaged.
ADJUSTMENTS
Mounting instruction FGRT804_1 Issued 20081027 Öhlins Racing AB
1
2
3
Öhlins products are subject to continuous
improvement and development. Therefore,
although these instructions include the most
up-to-date information available at the time of
printing, there may be minor differences between
your front fork and this mounting instruction.
Please consult your Öhlins dealer if you have any
questions regarding the contents of this mounting
instruction.
Other available documents for this product is the
Öhlins Owner’s manual, spare part list and work
shop manual.
Enjoy your Öhlins product!
2
1
+
-
3
AIR SPRING FOR
BOTH LEGS
Front fork total length and stroke:
The total lenght of the front fork can be extended by 10 mm to obtain a
130 mm stroke. See the Owners manual for a correct procedure.
Contents
Front fork FGRT 804 (1)
Screw MF6S 5x12 01046-34 (4)
Fender bracket front 21628-06 (2)
Sticker “Öhlins” 01196-02 (1)
Owners manual 07282-05 (1)
Mounting instruction
Öhlins Front fork FGRT 804
for Kawasaki ZX-10R
90°
Vehicle
direction
Outside
machining
surface
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 = ..............
SAFETY PRECAUTIONS
Read this manual carefully!
Pay special attention to statements proceeded by the
following notations:
Failure to follow these warning instructions may result in
severe or fatal injury to anyone working with, inspecting or
using this front fork, or to bystanders.
Caution indicates that special precautions must be taken
to avoid damage to the front fork.
Indicates information that is of importance regarding
mounting procedures.
WARNING
CAUTION!
NOTE!
WARNING!
1. Installing a front fork, that is not approved
by the vehicle manufacturer, may affect the
vehicle’s stability. Öhlins Racing AB cannot be
held responsible for any personal injury or damage
that may occur after fitting the front fork.
2. The vehicle’s service manual must be referred
to when installing this front fork.
3. Please study and make certain you fully
understand the mounting instructions before
handling this front fork. If you have any questions
regarding proper installation procedures, contact an
Öhlins dealer.
MOUNTING INSTRUCTIONS
WARNING!
1. It is advisable to have an Öhlins dealer install the front
fork.
2. Follow the instructions in the vehicle service manual
when changing the front fork.
3. When working on a raised vehicle, make sure that it is
securely supported to prevent it from falling.
1
Put the motorcycle on a workstand so that the
front wheel is off the ground.
2
Remove the front fender, brake caliper and the
front wheel.
SET-UP DATA
Recommended sag and ride height:
The measures should not differ from the following
recommendations:
Without rider (Free sag):
Rear 10 - 20 mm (R1-R2)
Front 20 - 30 mm (F1-F2)
With rider (Ride height):
Rear 25 - 40 mm (R1-R3)
Front 35 - 50 mm (F1-F3)
Recommended settings:
Rebound adjustment 12 clicks
Compression adjustment 11 clicks
Spring preload 7 mm (5 turns)
Oil level 150 mm
Öhlins oil 01309
CHECK SAG AND RIDE HEIGHT
Bike on a stand
Bike on the ground Bike with rider
Before riding your bike, check sag and ride height according to gure below. To get the most out of your suspension
component it is of great importance to make the proper settings. See Set-up data and Adjustments.
R1
R2
R3
F1
F2
F3
9
Tighten the fork crowns
with the following torque:
Upper front fork 20 Nm and
lower front fork 10 Nm.
10
Reinstall the front fender,
front wheel and the brake
calipers. Do not tighten
yet.
11
Put the bike on the ground,
apply the front brake and
compress the front fork
distinct 3-4 times. This will
put the legs in an exact
parallell position.
3
3
Measure the distance from the top of the outer
fork leg to the top of the upper triple clamp.
NOTE!
It is very important that the front fork is reattached at the
exact same position.
4
Loosen the upper and lower fork crowns by
loosening the screws.
5
Remove the fork legs from the fork crowns.
6
Install the caliper spacers from the original fork
into the Öhlins fork bottom.
7
Install the supplied fender brackets to the fork
legs according to gure. Apply Loctite 243 or
similar to the screws.
8
Install the fork legs into the fork crowns at the
same height as measured in gure 3. Turn the
handle bars fully from side to side to make sure
that nothing restricts the movement, and that the
throttle cable and wire harness runs in smooth
bends.
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 = ..............
Screw
10 mm
Loctite
6
Fender
bracket
Caliper
spacers
1
4
Springs:
04744-95 (standard) 9,5 N/mm
04744-90 (optional) 9,0 N/mm
04744-10 (optional) 10 N/mm
04744-05 (optional) 10,5 N/mm
04744-11 (optional) 11 N/mm
12
Tighten the front wheel, brake calipers and the
front fender. Consult your vehicle service manual
for the correct tightening torques.
13
Make sure nothing restricts the fork movement
when fully compressed. Read more in Öhlins
Owners manual - Chapter Setting up your front
fork, Extended stroke.
8
2
WARNING
The surface of the outer
machining must be
90° from the vehicles
direction.
7
/
