Ohlins FGKT481 Mounting Instruction

Brand: Ohlins

Model: FGKT481

Type: Mounting Instruction

Ohlins FGKT481 is an upside-down type front fork featuring the following adjusters: rebound damping adjuster, spring pre-load adjuster, and compression damping adjuster. The rebound damping adjuster is located at the top of the fork leg and can be adjusted by turning the wheel. The spring pre-load adjuster is located inside the fork and can be adjusted by changing pre-load tube. The compression damping adjuster is located at the bottom of the fork leg and can be adjusted by turning the screw.

This front fork is designed to provide a comfortable and controlled ride, even on rough terrain. The rebound damping adjuster allows you to control the speed at which the fork rebounds after it has been compressed. The spring pre-load adjuster allows you to adjust the amount of force required to compress the fork. The compression damping adjuster allows you to control the amount of resistance to compression.

Mounting Instructions

Öhlins front fork kit FG KT 481 for KTM EXC 2004

written permission of Öhlins Racing AB is prohibited. Printed in Sweden.

Öhlins front fork EXF

CAUTION!

The front fork springs are delivered separately and

must be installed before the front fork is mounted

to the bike. See page 4.

Your Öhlins front fork EXF 2004 is an upside down

type front fork featuring the following adjusters.

Compression damping adjuster

The compression adjuster is located at the bottom

of the fork leg.

Adjustments are made by turning the screw.

Rebound damping adjuster

Adjustments are made at the top of the fork leg

by turning the wheel.

Spring pre-load adjuster

Adjustments are made by changing pre-load tube

inside the fork.

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

settings, check like this:

The adjusters have a normal right hand tread. 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 page 8.

CAUTION!

Do not use too much force, delicate sealing sur-

faces can be damaged.

Compression

adjustment

Spring

pre-load

adjuster

Rebound damping

adjuster

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 = ............

Recommended: 30±5 mm

Ride height

F1 - F3 = ............

Recommended: 80±5 mm

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 = ............

Recommended: 30±5 mm

Ride height

R1 - R3 = ............

Recommended: 30% of the total stroke

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 KT 481. Issued 04 03 09

Setup data

Lenght 933 mm

Stroke 300 mm

Rebound adjuster 14 clicks

Compression adjuster 14 clicks

Spring preload 4 mm

Front fork oil level 110 mm

Front fork position 4 mm

Fork position is

measured from

the top of the fork

leg, to the top

surface of the

triple clamp.

x 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.

Bike on a stand.

Bike on the ground.

Bike with rider on.

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, espe-

cially 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 thefront fork.

Kit contents

Before installing the suspension components,

please check the contents of the kit, listed on

the front page of this instruction. If anything is

missing, contact your Öhlins dealer.

Description Part No. Pcs.

Front fork type FG KT 481

Spring (4.1 N/mm) 02428-41 2

Spring (4.3 N/mm)*

Spring (4.5 N/mm) 02428-45 2

Spring HSC (40 N/mm) 04107-03 2

Spring support 02436-04 2

Fork leg cover 02309-80 1 pair

Bolts for cover, M6x12 02314-01 6

Sticker Öhlins 02332-07 2

Sticker Öhlins 00197-01 2

Owners Manual 1

* Use a 4.1 N/mm spring in one leg and

a 4.5 N/mm in the other.

Before installation

Öhlins Racing AB can not be held responsible for

any damage whatsoever to suspension components

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 suspension components, 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 suspension

components. 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

suspension components 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

suspension components

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

precautions must be taken to avoid

damage to the suspension.

NOTE!

This indicates information that is of

importance with regard to procedures.

Notes

WARNING!

1. It’s advisable to have an Öhlins dealer or other

qualified person to fit your front fork.

2. Instructions in the motorcycle workshop manual

are to be followed when removing the front fork.

3. When working on the motorcycle it must be

securely supported to prevent it from falling over.

Mounting Instructions

Put the bike on a stand so the front wheel has

ground clearance. Make sure it’s steadily positioned

and will not fall over.

Remove the front wheel, protecting covers and

the brake caliper. Let the caliper stay fitted to the

brake hose.

Remove the original fork legs and fit 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 page 5 for

correct torques.

NOTE!

The front fork legs must be aligned be-

fore the front wheel axle is tightened.

Upper triple clamp

Lower triple clamp

Front leg cover

Brake

caliper

Caliper

protection

cover

Front fork leg

Front wheel

Tighten the wheel axle and refit the removed pro-

tecting covers. Fit the Öhlins front leg 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

motorcycles workshop manual.

Continue your work with adjustments, see Öhlins

Owners Manual.

NOTE!

Before you continue, make sure that the front

springs are installed. If they are not, proceed with

the instructions at page 4 – Installing springs.

Put the wheel back in position. Reassemble the

brake and fit the hose holder.

NOTE!

Do not tighten the front wheel axle before the

front legs are aligned. (5)

Let the motorcycle stand on the ground and com-

press 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.

Base valve housing

Change of high speed

compression spring

Turn the fork leg upside down and fasten the fork

bottom in a vise with soft jaws

Remove the compression (base) valve. Use a 17

mm socket.

Fasten the valve in a vise with soft jaws.

Use tool (1863-01) or a pair of pointed pliers to

loosen the poppet valve seat and remove it to-

gether with the poppet valve and the spring.

Install the new spring, refit the poppet valve and

the poppet valve seat. Tighten to a torque of 5 Nm.

Refit the valve unit to the fork bottom as de-

scribed above. Tighten to a torque of 65 Nm.

Tool 1863-01

Poppet valve seat

Poppet valve

Spring (4107-03/04)

Front fork leg

Base valve

Shims

Installing springs

Put the bike on a stand and loosen the screws in

the top fork crown that hold the fork legs.

NOTE!

On most MX-bikes you have take of the handle

bar off before you can unscrew the top cap.

Remove the adjustment wheel and the springs

and balls of the adjuster.

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.

Close the compression and the rebound valve

(clockwise).

Slot

screwdriver

Guide sleeve

Adjustment

wheel

Balls and

springs

Unscrew the top cap, use tool (1860-01 or

1761-02). Put a box under the front wheel so

that the springs are visible.

Tool (1860-01)

Top cap

17 mm

wrench

Damper rod

extender

Tool (1761-02)

Tool 1860-01

Remove the top cap from the damper rod

extender. Use a 17mm wrench, and tool (1860-01

or 1761-02).

Damper

rod assy

17 mm wrench

Install the the correct spring. Two pairs of springs

are provided – spring ratio 4.1 N/mm and 4.5 N/

mm, respectively.

NOTE!

A spring ratio of 4.3 N/mm is obtained if a 4.1 N/mm

spring is used in one leg and a 4.5 N/mm spring in

the other leg.

Fit the spring support, the desired pre-load tube

and the top nut.

Install the fork top cap. Tighten (30 Nm) the top

cap and the lock nut against each other, use tool

1860-01 and 17 mm wrench.

Adjust the compression and the rebound valves

according to specification card.

Spring

Top cap

Pre-load tube

Spring support

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.

Fit the legs on the motorcycle.

Tightening torques:

Upper tripple clamp: 20 Nm

Lower triple clamp: 10 Nm

Refit the top cap and tighten. Use top cap tool

1761-02 or 1860-01.

The top cap should not be tightened hard, only

turned in position by hand.

Tool

1761-02

17 mm wrench

Ohlins FGKT481 Mounting Instruction

Ohlins FGKT481 Mounting Instruction

Ohlins FGKT481 Mounting Instruction

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