Ohlins FGHO681 Mounting Instruction

Brand: Ohlins

Model: FGHO681

Category: Car kits

Type: Mounting Instruction

Mounting Instructions

Öhlins front fork kit FGHO 681

for HONDA CRF/ CR 2006

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.

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

FGHO 681 - Issued 2005 12 15

unauthorized use without the written permission of Öhlins

Racing AB is prohibited. Printed in Sweden.

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.

The Öhlins front fork is an upside down type

featuring the following adjusters:

Compression damping adjuster

The adjuster is located at the bottom of the fork

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

driver.

Rebound damping adjuster

The adjuster is located on the top of the fork leg.

Turn the adjuster knob to adjust the rebound

damping.

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 recom-

mended number of clicks. See Setup data in

this manual.

CAUTION!

Do not use too much force, delicate sealing

surfaces can be damaged.

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.

In this manual

Safety precautions

Mounting instructions

Before riding

Set-up data

Adjustments

Front fork 48 EXF FGHO681(1 pair)

Tool 01860-01 (1)

Spring 43.6/467/4.1 02428-41 (2)

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

Spring support 4mm 02436-04 (2)

Triple clamp, lower 02443-01 (1)

Triple clamp, upper 02443-02 (1)

Screw M8-6g 35 8.8 02456-03 (8)

Screw MC6S 01046-45 (2)

Handlebar clamp lower 04315-01 (2)

Sticker Front Fork 02332-09 (2)

Sticker “ÖHLINS” 00197-01 (2)

Owners manual front fork (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

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. Contact

an Öhlins dealer or other qualiﬁ ed person

for advice.

2. The vehicle service manual must

be referred 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 or other quali-

ﬁ ed person.

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 the

front fork kit.

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

esign

features

Function

Basic

adjustments

Fine tuning

Inspection,

aintenance

Owner’s Manual

Öhlins shock absorbers, M

/ENDU

O/O

OAD

Your vehicle OEM

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 14 clicks

Compression adjustment 14 clicks

Spring pre-load 4 mm

Front fork position 4 mm

General facts

Front fork length 940 mm

Stroke 300 mm

? kg

? lbs

Recommendations

CRF 250X

Spring rate 4.1 N/mm

Oil level 100 mm

CRF 450X

Spring rate 4.3 N/mm

Oil level 100 mm

CR 125/ 250

Spring rate 4.1 N/mm

Oil level 100 mm

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.

NOTE!

All spring rates above cannot be achieved

with the provided springs. Please contact

your Öhlins dealer for advice.

NOTE!

When delivered, the oil level is 100 mm. For

some models you need to drain some oil to

achieve the recommended level.

WARNING!

1. It is advisable to have an Öhlins dealer or other

qualiﬁ ed person 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.

Put the motorcycle on a workstand to raise the

front wheel off the ground.

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 from the

triple clamps.

Remove the handlebar brackets. Loosen the

stem nut and remove it.

Remove the upper triple clamp. Remove the

nut that holds the steering stem and the lower

triple clamp.

MOUNTING INSTRUCTIONS

Removing the original front fork and triple clamps

Front leg

cover

Front

wheel

Upper triple

clamp

Lower triple

clamp

Brake

caliper

Caliper

protection cover

WARNING!

Replacing the steering stem is a demanding

task and must be carried out by an authorized

dealer or other qualiﬁ ed workshop.

Replacing the lower triple clamp

This front fork is provided with specially de-

signed triple clamps. Replacing triple clamps

is an operation that requires high mechanic

competence. To perform this task you will

need a hydraulic press.

steering stem

Upper triple

clamp

Lower triple

clamp

WARNING!

Faulty handling when reattaching the steering

stem can cause damage to the triple clamps

and may affect the riding characteristics of

the motorcycle.

Install the the correct springs. In this kit, there

are two pairs of springs provided.

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.

Install 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.

Reattach the top cap and tighten. Use top cap

tool 1761-02 or 1860-01.

The top cap should only be hand tightened!

Continue your work according to page 3, step

10 Installing the Öhlins front fork.

Spring support

Top cap

17 mm wrench

Tool (1761-02)

Tool (1860-01)

MOUNTING INSTRUCTIONS

3 4

WARNING!

1. It is advisable to have an Öhlins dealer or other

qualiﬁ ed person 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.

Installing the springs

CAUTION!

Do not overtighten the triple clamps. The fork

leg tubes can be deformed.

Reattach the brake caliper, caliper protection

and 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.

Make sure

the front

fork legs are

aligned!

Front wheel

Front fork

legs

View from above

NOTE!

Do not tighten the front wheel axle before the

front fork legs are aligned!

Installing the Öhlins front fork

Attach the Öhlins front fork legs to the tri-

ple clamps, make sure the triple clamps are

aligned.

Tighten the torques:

Upper triple clamp: 20 Nm

Lower triple clamp: 10 Nm

When the triple clamps are installed, reattach

the stem nut.

Attach the lower handlebar bracket, provided in

this kit.Use the original upper handlebar bracket.

Put the handlebar in place before tightening

the screws holding the handlebar brackets.

NOTE!

Before you continue, make sure that the

front fork springs are installed. If they are

not installed, proceed with the instructions

on page 4.

Alter between

these two

positions on

the upper

triple clamp.

Rotate the

bracket to alter

position.

Align the front fork legs. Put the motorcycle on

the ground and compress the front suspension

as hard as possible a few times.

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!

You can alter the position of the handlebar

by using the different available positions on

the triple clamp and by rotating the handlebar

brackets. See ﬁ gure below.

When you have decided on position for the

handlebar, tighten the screws holding the han-

dlebar brackets.

Put the motorcycle on a workstand to raise the

front wheel off the ground. Make sure that the

vehicle is securely supported so that it will

not fall over.

Remove the handlebar.

Loosen the screws that hold the triple clamps.

Remove the adjustment wheel, the adjuster

springs and balls.

Close the compression and rebound valves. This

will keep the damper rod extended and make it

easier to install the new spring.

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

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

that the springs are visible.

Remove the top cap from the damper rod

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

or 1761-02).

Adjustment

wheel

Springs and

balls

Tool (1761-02)

Tool (1860-01)

Tool 1860-01

17 mm wrench

Top cap

17 mm wrench

Bump rubber

Damper rod

assembly

Ohlins FGHO681 Mounting Instruction

Brand: Ohlins

Model: FGHO681

Category: Car kits

Type: Mounting Instruction

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Ohlins FGHO681 Mounting Instruction

Ohlins FGHO681 Mounting Instruction

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