Mounting Instructions
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
© Öhlins Racing AB. All rights reserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
Part no. Pcs.
Spring 4.7 N/mm 02490-47 (2)
Spring 5.1 N/mm 02490-51 (2)
Washer 02528-05 (2)
Recommended tools
Tool 0727-02
Tool 1797-06
Mounting Instructions FGK660 - Issued 2006 04 05
Tool 1873-01
Tool 1761-02
Öhlins Super Motard Conversion kit FGK 660
for Öhlins Front forks MXF o 48 2006
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!
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 12 clicks
Compression damping 14 clicks
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 = ............
Recommended free sag 30±5 mm
Ride height F1 - F3 = ............
Recommended ride height 50-70 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 free sag 30±5 mm
Ride height R1 - R3 = ............
Recommended ride height 80-90 mm
Before riding your bike, check sag and ride
height according to the procedure above.
Mounting Instructions
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© Öhlins Racing AB. All r
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unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
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!
To get the most out of your suspension com-
ponent it is of great importance to make the
proper settings. See sections: Set-up data and
Adjustments in this manual.
Basevalve Rebound Compression
184-22 (14x) 184-21 (3x) 520-22
185-12 185-12 188-12 (2x)
184-21 184-20 1149-01 (2x)
184-20 184-18 184-20 (2x)
184-19 184-16 184-18
184-18 184-15 184-16
184-17 184-14 184-14
184-16 184-13 184-12
184-15 184-12
184-14 184-51
184-13
184-12
Recommended shims stack
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
tipping over.
!
Installing spacer and spring
1
Put the motorcycle on a workstand so that the
front wheel is off the ground.
2
Remove the front fork legs by loosening the
screws in the top fork crown.
3
Unscrew the top cap. Use tool 1761-02.
4
Remove the top cap from the damper rod ex-
tender, use a 17 mm and a 24 mm wrench.
5
Remove the top cap, pre-load tube and the
spring.
3
4
5
6
Loosen the cylinder tube cap on top of the cyl-
inder tube. Use tool 1797-06. Lift up the damper
rod assembly. Drain the oil.
NOTE!
If the fork leg is fi xed in an upright position during
the whole operation it is not necessary to drain
the fork leg.
6
ADJUSTMENTS
Top cap
Pre-load tube
Spring
Tool 1761-02
17 mm wrench
24 mm wrench
Compress the
spring to get the
wrench in its
correct position
Compression damping
adjuster
Rebound damping adjuster
Measure from the top
of the outer leg, with
the top nut off, fork
fully compressed and
no spring installed.
Measure from the
top of the fork leg
to the top surface
of the triple clamp.
Measure fork position Measure oil level
Setting spring preload
MOUNTING INSTRUCTIONS
3 4
7
Fasten the damper rod assembly in a vice with
soft jaws.
CAUTION!
Fasten the damper rod carefully into the vice.
Do not tighten hard! The piston rod is easily
damaged!
8
Remove the piston holder together with the
spring. Remove the original washer.
9
Clean all parts thouroughly and inspect them for
wear and damage. Replace if needed.
10
Reassemble the damper rod assembly. Install
the washer provided in this kit, spring and
piston holder.
CAUTION!
The part of the washer with a groove should be
directed downwards, facing the piston holder.
Assembly
1
Install the damper rod assembly into the cylinder
tube. Use Loctite 542 on the cylinder tube cap.
tighten with tool 1797-06 to 65 Nm torque.
2
Pump the damper rod up and down a few times
to make sure all air is out.
3
Measure the correct amount of oil according to
the Setup data in this manual.
4
Pull out the damper rod as far as possible and
close the compression and rebound valves.
5
Install the spring, spring support and the pre-
load tube. In this kit there are two pairs of springs
provided.
NOTE!
A spring ratio of 4.9 N/mm is obtained if a
5.1 N/ mm spring is used in one leg and a
4.7 N/ mm in the other leg.
6
Install the fork top cap and the lock nut. tighten
the top cap and the lock nut against each other.
use a 17 mm and a 24 mm wrench. Tighten to
30Nm torque.
7
Reinstall the top cap and tighten. The top cap
should only be handtightened!
8
Install the fork legs to the motorcycle.
Tighten the torques:
Upper triple clamp 20 Nm
Lower triple clamp 10 Nm
9
7
Tool 0727-02
Hydraulic stop
close to the
soft jaws
Washer (02528-02)
Piston holder
Cylinder tube cap
Cylinder tube
65 Nm
Damper rod assembly
1
17 mm wrench
24 mm wrench
Tool 1761-02
6
7
-
1
-
2
-
3
-
4
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