Ohlins FGKT791 Mounting Instruction

Brand: Ohlins

Model: FGKT791

Category: Car kits

Type: Mounting Instruction

Mounting Instructions

Öhlins front fork kit FGKT791

for KTM 125 SX, 250 SX, 250 SX-F, 450 SX-F 2007

Kit Contents

Before installing this front fork kit, please

check the contents of the kit, listed below.

If any part is missing, please contact your

Öhlins dealer.

Please read before installing

Öhlins Racing AB cannot be held responsible

for any damage to the front fork kit, vehicle or

injury to persons, if the instructions for ﬁ tting

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

FGKT791 - Issued 2006 11 30

unauthorized use without the written permission of Öhlins

Racing AB is prohibited. Printed in Sweden.

Front fork 48MXF FGKT791 (1 pair)

Tool for End Cap 01873-01 (1)

Spring 43.6/467/3.9 02428-39 (2)

Spring 43.6/467/4.5 02428-45 (2)

Preload tube 20 mm MX48 02437-20 (2)

Sticker “ÖHLINS” 00197-01 (2)

Sticker Front Fork 02332-11 (2)

Owner’s manual (1)

SAFETY PRECAUTIONS

1 6

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, that is not ap-

proved 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. Contact an

Öhlins dealer.

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 and

the owner’s manual before handling this

front fork kit. If you have any questions

regarding proper installation procedures,

contact an Öhlins dealer.

NOTE!

During storage and transportation, especially

at high ambient temperature, some of the

oil and grease used for assembling may run

out and stain the packaging. This is in no

way detrimental to the product, wipe off the

excessive oil/grease with a cloth.

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 and this manual.

Please consult your Öhlins dealer if you

have any questions regarding the contents

of this manual.

Including:

Safety

Tun ing the

suspension

Design

features

Function

Basic

adjustments

Fine tuning

Inspection,

maintenance

Owner’s Manual

Öhlins shock absorbers, MX/ENDURO/OFF ROAD

Your vehicle OEM

ADJUSTMENTS

NOTE!

Read more about compression, rebound

and spring pre-load in your Öhlins Owner’s

manual.

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 48MXF 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. Adjust by turning the screw. Use a

slot screw driver.

Rebound damping adjuster

The rebound adjuster is located on the top of

the fork leg. Adjust by turning the screw. Use a

slot screw driver.

Compression

damping

adjustment

Rebound damping

adjuster

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, reset according to the following:

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.

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 tipping.

Put the motorcycle on a workstand to raise the

front wheel off the ground. Ensure the vehicle is

securely supported so that it will not fall over.

Remove the front wheel, front leg covers, caliper

protection covers and brake caliper. Let the

brake caliper stay attached to the brake hose.

Remove the original front fork legs.

MOUNTING INSTRUCTIONS

BEFORE RIDING

SET-UP DATA

IMPORTANT NOTICE!

Before riding your bike, check sag and ride

height according to your Öhlins Owner’s

manual.

To get the most out of your suspension com-

ponent it is of great importance to make proper

settings and to use the correct spring for your

weight - full riding equipment on!

We recommend you to read your Öhlins

Owner’s manual carefully to understand the

different effects of the different settings.

Recommended settings

Rebound adjustment 15 clicks

Compression adjustment 12 clicks

Spring pre-load 0 mm

Front fork position 4 mm

General facts

Front fork length 933 mm

Stroke 300 mm

? kg

? lbs

Align the front fork legs

Put the motorcycle on the ground and compress

the front suspension as hard as possible a few

times. This will align the fork legs.

NOTE!

An alternative way to align the front fork legs

is to rotate the front wheel as fast as possible,

and then bring the wheel to a fast stop, using

the brake.

NOTE!

Before you continue, make sure that the

front fork springs are installed. If they are

not installed, proceed with the instructions

on page 3.

NOTE!

Do not tighten the front wheel axle before the

front fork legs are aligned!

Reattach the front leg covers.

Put the wheel back in position.

NOTE!

Make sure that all bolts are tightened to the

correct torque, and that nothing restrains

the front fork when the suspension is fully

compressed.

Installing the front fork

Recommendations

KTM 125 SX

Spring rate 3.9 N/mm

Oil level 110 mm

KTM 250 SX

Spring rate 4.2 N/mm

Oil level 110 mm

KTM 250 SX-F

Spring rate 4.2 N/mm

Oil level 110 mm

KTM 450 SX-F

Spring rate 4.4 N/mm

Oil level 105 mm

Front leg

cover

Front

wheel

Upper triple

clamp

Lower triple

clamp

Brake

caliper

Caliper

protection cover

Make sure

the front

fork legs are

aligned!

Front wheel

Front fork

legs

View from above

Measure fork position

Measure oil level

Measure from the

top of the fork leg

to the top surface of

the triple clamp.

Measure from the

top of the outer leg,

with the top nut

off, fork fully com-

pressed and no

spring installed.

Attach the Öhlins front fork legs to the motor-

cycle.

Tighten the torques:

Upper triple clamp: 20 Nm

Lower triple clamp: 10 Nm

CAUTION!

Do not overtighten the triple clamps. The fork

leg tubes can be deformed.

NOTE!

All spring rates cannot be achieved with the

provided springs. Please contact your Öhlins

dealer for advice.

NOTE!

When delivered, the oil level is 105 mm. For

some models you need to drain some oil to

achieve the recommended level.

MOUNTING INSTRUCTIONS

3 4

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 tipping.

Unscrew the top cap, using the top cap tool

1873-01.

Installing the springs

Pull out the damper rod until it comes to a

stop.

Install the pre-load tube, spring adjuster and the

top cap on the front fork legs.

Tighten the top cap, 30 Nm. Use a 17 mm

and a 24 mm wrench, tighten the top cap to

the lock nut by holding the wrenches as in the

ﬁ gure below.

Adjust the compression and the rebound valves

according to the sections: Set-up data and Ad-

justments in this manual.

Pull up the fork leg. Attach the top cap to the

fork leg using the top cap tool 1873-01.

NOTE!

The top cap should only be hand tightened!

Close the compression and rebound valves. This

will keep the damper rod extended and make it

easier to install the new spring.

Ohlins FGKT791 Mounting Instruction

Brand: Ohlins

Model: FGKT791

Category: Car kits

Type: Mounting Instruction

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Ohlins FGKT791 Mounting Instruction

Ohlins FGKT791 Mounting Instruction

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