Mounting Instructions
Öhlins Front fork kit FG343
Kawasaki ZRX1200 Gold
Kit Contents
Before installing this Öhlins Front Fork kit,
please check the contents of the kit listed
below. If any part is missing, please contact
your Öhlins dealer.
Öhlins Racing AB cannot be held responsible
for any damage to the front fork kit, vehicle or
injury to persons, if the instructions for install-
ing 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
In this manual
Safety precautions
Mounting instructions
Set-up data
Adjustments
© Öhlins Racing AB. All rights reserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
Spring preload adjuster
Adjust by turning the nut on the top of the
fork leg. Use a 17 mm wrench. Turn clock-
wise for harder adjustment. Turn counter
clockwise to release the spring preload.
Rebound damping adjuster
Adjust by turning the screw with a 3 mm
hexagon screw. Turn clockwise to increase
damping and counter clockwise to de-
crease it.
Compression damping adjuster
Adjust by turning the nut. Use a 3 mm
hexagon screw. Turn clockwise to increase
damping and counter clockwise to de-
crease it.
ADJUSTMENTS
NOTE!
Reset according to the following:
The adjusters have a normal right hand thread.
Turn the damping adjusters clockwise to fully
closed (pos. zero [0]). To open, turn counter
clockwise, and count the clicks until you reach
the recommended number. See Set-up data in
this manual.
1
2
CAUTION!
Do not use force, delicate sealing surfaces
can be damaged.
Mounting Instructions FG343 - Issued 2006 04 20
1
2
SET-UP DATA
Recommended settings:
Rebound damping 12 clicks
Compression damping 12 clicks
Spring preload 5 mm
Spring rate 8.5 N/mm
3
3
Front Fork Legs. 43/770 04794-04 (1 pair)
Screw MC6S 6x20 01046-16 (4)
Caliper Bracket RH 01677-56 (1)
Caliper Bracket LH 01677-57 (1)
Sleeve LH 01680-24 (1)
Fender bracket 01682-43 (2)
Fender bracket 01682-44 (2)
Screw M10x1.25x25 04757-01 (8)
Öhlins Sticker 00194-10 (2)
Öhlins Owners Manual (1)
SAFETY PRECAUTIONS
Read this manual carefully!
Pay special attention to statements pro-
ceded by the following notations:
The Safety alert symbol means: Attention!
Your safety is involved!
Failure to follow these warning instructions
may result in severe or fatal injury to any-
one working with, inspecting or using this
front fork kit, or to bystanders.
Caution indicates that special precautions
must be taken to avoid damage to the
front fork kit.
Indicates information that is of importance
regarding mounting procedures.
!
WARNING
CAUTION!
NOTE!
WARNING!
1. Installing a front fork kit, 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 fi tting the front fork kit.
2. The vehicle service manual must be re-
ferred to when installing this front fork kit.
3. Please study and make certain you fully
understand the mounting instructions be-
fore handling this front fork kit. If you have
any questions regarding proper installation
procedures, contact an Öhlins dealer.
!
!
NOTE!
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 kit and this manual.
Please consult your Öhlins dealer if you have
any questions regarding the contents of this
manual.
MOUNTING INSTRUCTIONS
WARNING!
1. It is advisable to have an Öhlins dealer install the
front fork kit. The installation procedure requires
certain Öhlins tools.
2. Follow the instructions in the vehicle service
manual when changing the front fork kit.
3. When working on a raised vehicle, make sure
that it is securely supported to prevent it from tip-
ping over.
!
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.
3
Measure the position of the front fork. Measure
the distance from the top of the fork leg to the
top of the upper triple clamp.
NOTE!
It is very important that the front fork is reat-
tached at the exact same position.
4
Loosen the upper fork crown by loosening the
screws.
5
Loosen the lower fork crown by loosening the
screws.
6
Remove the front fork legs from the fork
crowns.
7
Install the Öhlins front fork legs to the fork
crowns. Tighten the torque according to the
vehicle service manual.
8
Install the brackets according to the figure
below.
9
Read more about the front fork kit in your Öhlins
Owners Manual.
NOTE!
Make sure that all bolts are tightened to the
correct torque and that nothing restrains the
front fork when the suspension is being com-
pressed or extended. Consult your vehicle
service manual.
Figure:
Install the brackets.
Article numbers and (correct
torque).
1682-44
1677-56
4757-01
(30 Nm)
1682-43
1682-44
1046-16
(10 Nm)
1677-57
4757-01
(30 Nm)
1680-24
(20 Nm)
/