Mounting Instructions
Öhlins front fork kit FGKA791
for Kawasaki KX250F 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.
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
FGKA791_0 - Issued 2007 02 09
© Öhlins Racing AB. All rights reserved. Any reprinting or
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 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.
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.
Front fork 48MXF FGKA791 (2)
Screw M12x25 01046-45 (2)
Tool for End Cap 01873-01 (1)
Bolt M8x25 02314-02 (4)
Spring.Fr.fork 43.6/467/4.1 02428-41 (2)
Spring.Fr.fork 43.6/467/4.3 02428-43 (2)
Preload tube 20 mm 02437-20 (2)
Upper Triple clamp 02448-02 (1)
Lower Triple clamp, assy 02449-03 (1)
Screw M8-6g 02456-03 (8)
Upper Handlebar clamp 04316-22 (2)
Lower Handlebar clamp 04317-35 (2)
Öhlins Sticker 00197-01 (2)
Front Fork Sticker 02332-11 (2)
Owner’s Manual FF 07295-27 (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 installing the front fork. Con-
tact an Öhlins dealer 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.
!
!
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.
1
Including:
Safety
Tun ing the
suspension
D
esign
features
Function
Basic
adjustments
Fine tuning
Inspection,
m
aintenance
Owner’s Manual
Öhlins shock absorbers, M
X
/ENDU
R
O/O
F
F
R
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 15 clicks
Compression adjustment 12 clicks
Spring pre-load 0 mm
Front fork position 4 mm
Spring rate 4.2 N/mm
Oil level 110 mm
General facts
Front fork length 940 mm
Stroke 300 mm
?
?
? kg
? lbs
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.
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.
1
Put the motorcycle on a workstand to raise the
front wheel off the ground.
2
Remove the front wheel, front leg covers, caliper
protection covers and brake caliper. Let the
brake caliper stay attached to the brake hose.
3
Remove the original front fork legs from the
triple clamps.
4
Remove the original handlebar brackets. Loosen
the stem nut and remove it.
5
Remove the upper triple clamp. Remove the
nut that holds the steering stem and the lower
triple clamp.
MOUNTING INSTRUCTIONS
25
!
Removing the original front fork and triple clamps
Front leg
cover
Front
wheel
Upper triple
clamp
Lower triple
clamp
Brake
caliper
Caliper
protection cover
3
2
2
6
Install the pre-load tube, spring adjuster and the
top cap on the front fork legs.
7
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 seen in the
fi gure below.
8
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!
9
Adjust the compression and the rebound valves
according to the sections: Set-up data and Ad-
justments in this manual.
Top cap
Pre-load
tube
Spring
adjuster
17 mm
wrench
24 mm
wrench
8
7
Top cap tool
1873-01
7
6
10
Continue your work according to page 3,step
10 Installing the Öhlins front fork.
Replacing the lower triple clamp
6
This front fork is provided with specially de-
signed triple clamps. Removing the bearing
is an operation that requires high mechanic
competence. Preferably, use a hydraulic
press to perform this task.
Install the parts provided in this kit as indi-
cated in the fi gure. Use the original bearing, stem
nut and nut that holds the steering stem.
steering stem
Upper triple
clamp
Lower triple
clamp
5
!
!
02314-02
04316-22
04317-35
original bearing
see NOTE!
original
stem
nut
original
nut
6
NOTE!
We recommend you to buy a new bearing
from your nearest dealer.
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.
!
1
Unscrew the top cap, using the top cap tool
1873-01.
Installing the springs
Read more about rebound and compression on
the last page of this manual.
4
Pull out the damper rod until it comes to a
stop.
3
Close the compression and rebound valves. This
will keep the damper rod extended and make it
easier to install the new spring.
Top cap tool
1873-01
Top cap
Fork leg
1
2
5
5
Install the correct springs. In this kit, there are
two pairs of springs provided.
NOTE!
A spring ratio of 4.2 N/mm is obtained by
using a 4.1 N/mm in one leg and a 4.3 N/mm
in the other.
Rebound adjuster
Compression adjuster
4
2
Pull down the fork leg.
CAUTION!
Do not overtighten the triple clamps. The fork
leg tubes can be deformed.
11
Reattach the brake caliper, caliper protection
and front leg covers.
12
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
10
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
7
When the triple clamps are installed, make sure
you have reattached the nut that holds the steer-
ing stem and the stem nut.
8
Reattach the handlebar brackets. Put the han-
dlebar in place before tightening the screws
holding the handlebar brackets.
13
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!
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.
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.
9
When you have decided on position for the
handlebar, tighten the screws holding the han-
dlebar brackets.
/