Ohlins FGK131 Mounting Instruction
- Category
- Motorcycles
- Type
- Mounting Instruction
Mounting Instructions
Öhlins Front fork kit FGK 131
for Honda CBR600RR
Kit Contents
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
Check sag and ride height
Set-up data
Adjustments
Diagram: Oil level - Force
© Öhlins Racing AB. All rights reserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
Front fork kit FGK131 (1)
Öhlins Sticker 01196-02 (2)
Öhlins stickers 00192-01 (2)
DIAGRAM: OIL LEVEL - FORCE
Spring preload adjuster
Adjust by turning the nut on the top of the
fork leg. Turn clockwise for harder adjust-
ment. Turn counter clockwise to release the
spring preload.
Rebound damping adjuster
Adjust by turning the screw with a screw-
driver. Turn clockwise to increase damping
and counter clockwise to decrease 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.
Recommended tool
Tool 1797-07
This kit should only be installed
by an Öhlins dealer. The instal-
lation procedure requires certain
Öhlins tools.
!
Mounting Instructions FGK131 - Issued 2006 04 05
1
2
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
0 102030405060708090100110120
Stroke [mm]
Force [N]
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
140mm oil lev
150mm oil lev
160mm oil lev
170mm oil lev
180mm oil lev
190mm oil lev
200mm oil lev
210mm oil lev
220mm oil lev
230mm oil lev
240mm oil lev
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 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.
1
Your vehicle OEM
SET-UP DATA
Recommended settings:
Rebound damping 2
1
/
6
turns
Compression damping 1 turn
Spring preload 10 mm
Oil level 170 mm
CHECK SAG AND RIDE HEIGHT
R1
R2
R3
F1
F2
F3
Bike on a stand Bike on the ground Bike with rider
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 = ............
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 = ............
Before riding your bike, check sag and ride
height according to the procedure above.
To get the most out of your suspension com-
ponent it is of great importance to make the
proper settings. See Set-up data below and
Adjustments on the next page.
Mounting Instructions
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unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
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!
Recommended sag and ride height:
The measures should not differ from the
following recommendations:
Without rider:
Rear 10 - 20 mm (R1-R2)
Front 20 - 30 mm (F1-F2)
With rider:
Rear 25 - 40 mm (R1-R3)
Front 35 - 50 mm (F1-F3)
MOUNTING INSTRUCTIONS
25
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.
!
6
Loosen, but do not remove, the top cap ½ turn.
Use a wratchet with a 32 mm socket.
7
Loosen the lower fork crown by loosening the
screws.
8
Remove the front fork legs from the fork
crowns.
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
Release the spring preload. Use a 22 mm
wrench.
5
Loosen the upper fork crown by loosening the
screws.
1
2
!
Removing the original front fork
3
5
22
Grab the spring support and the nut inside, with
a 19 mm wrench, according to the fi gure. Put
the spacer on top.
23
Open the rebound adjuster fully. Put the original
top cap on the Öhlins cartridge assembly. Tight-
en the top cap. Use a wratchet with a 32 mm
socket. Torque 15 Nm.
24
Pull up the fork leg. Make sure the fork leg is
in a fully extended position. Tighten the torque
to 10 Nm.
25
Set the spring preload. Use a 22 mm wrench.
Set rebound and compression according to the
Set-up data in this manual. See sections Set-up
and Adjustments in this manual.
26
Install the front fork legs into the fork crowns.
NOTE!
It is very important that the front forks are in the
same position as they were before changing the
fork kit. See step 3 on page 2.
27
Tighten the torque:
Upper fork crown 20 Nm
Lower fork crown 10 Nm
23
4
6
24
22
26
25
8
NOTE!
Wider opening at the
bottom.
MOUNTING INSTRUCTIONS
3 4
NOTE!
When disassembling the original front fork, con-
sult your vehicle service manual for advice.
9
Remove the original cartridge from the fork
leg.
10
Remove the top cap from the original car-
tridge.
11
Remove the original rebound adjuster screw by
screwing it through the top cap.
12
Install the Öhlins rebound adjuster article
no. 3336-01 and the o-ring provided in this kit.
Disassembling the original front fork
Installing the Öhlins front fork kit
14
Remove the spring support, spring
and the preload tube of the Öhlins kit.
15
Put the cartridge assembly into the fork leg.
16
Tighten the cartridge with tool 1797-07 and use
a wratchet with a 8 mm allen key. Put Loctite 243
on the threads. Tighten the torque: 20 Nm.
15
14
16
170 mm
17
18
20
9
13
Turn the fork leg upside down to pour out all
oil.
17
Pour approximately 0.5 litre Öhlins oil article
no. 01311-01 into the fork leg.
18
Put the top cap directly to the cartridge (no
spring or preload tube). Pull up the fork leg
and screw it to the top cap. Handtighten only.
Pump out all the air from the fork leg by pull-
ing the fork up and down 10-15 times.
19
Remove the top cap from the fork leg.
20
Make sure the cartridge is in the bottom of the
fork leg. Make sure the fork leg is in the bottom
position. Measure the oil level with a scale.
21
Put the preload tube and the spring on top of
the cartridge.
21
11
12
Loctite
o-ring
Rebound adjuster
03336-02
-
1
-
2
-
3
-
4
Ohlins FGK131 Mounting Instruction
- Category
- Motorcycles
- Type
- Mounting Instruction
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