Mounting Instructions
Öhlins Super Motard Conversion Kit FGK 460
for Öhlins front forks MXF and EXF ø48
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Öhlins Conversion Kit MXF/EXF
Öhlins Super Motard conversion kit is designed
to convert an Öhlins front fork MXF and front fork
EXF into Super Motard forks. It shortens the total
length by 31 mm and makes the high speed com-
pression damping harder.
The kit consists of main springs, internal spacers
and base valve springs.
Main spring, 4,9 N/mm –
shorter than MXF and
EXF springs.
Spacer – replaces the
internal washer to
shorten the front fork.
Base valve spring –
replaces original
spring to make the
high speed
compression
damping harder.
Checking sag and ride height
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 = 30±5 mm
Ride height
F1 - F3 = 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 = 30±5 mm
Ride height
R1 - R3 = 80-90 mm
NOTE!
If ride height is higher than recommended,
softer spring/springs must be used.
If ride height is lower than recommended,
harder spring/springs must be used.
Contact your Öhlins dealer for advice.
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
Part No. FGK 460. Issued 04 04 29
Setup data
Here you can note your personal settings.
Lenght _____ mm
Stroke _____ mm
Rebound adjuster _____ clicks
Compression adjuster
High speed _____ clicks
Low speed _____ clicks
Spring pre-load _____ mm
Front fork oil level _____ mm
Front fork position _____ mm
Bike on a stand. Bike on the ground. Bike with rider on.
F1
R1
F2
R2
F3
R3
Fork position is
measured from
the top of the fork
leg, to the top
surface of the
triple clamp.
x mm
Oil level
Oil level is
measured from
the top of the
outer leg, with the
top nut off, the
fork fully
compressed and
no spring
installed.
Tools
0727-02: Soft jaws
1761-02: Top cap releasing tool
1797-03: Cartridge tool
1860-01: Top cap releasing tool
1863-01: Base valve tool
1873-01: Top cap releasing tool
Öhlins products are subject to continual improve-
ment and development. Consequently, although
these instructions include the most up-to-date
information available at the time of printing, there
may be minor differences between your suspen-
sion and this manual. Please consult your Öhlins
dealer if you have any questions with regard to
the contents of the manual.
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.
Kit contents
Before installing the suspension components,
please check the contents of the kit, listed on
the front page of this instruction. If anything is
missing, contact your Öhlins dealer.
Before installation
Öhlins Racing AB can not be held responsible for
any damage whatsoever to suspension components
or vehicle, or injury to persons, if the instructions for
fitting and maintenance are not followed exactly.
Similarly, the warranty will become null and void if
the instructions are not adhered to.
WARNING!
1. Installing suspension components, that is
not approved by the vehicle manufacturer,
may affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage whatsoever
that may occur after fitting the suspension
components. Contact an Öhlins dealer or
other qualified person for advice.
2. Please study and make certain that you
fully understand all the mounting instructions
and the owners manuals before handling this
suspension components kit. If you have any
questions regarding proper installation
procedures, contact an Öhlins dealer or other
qualified person.
3. The vehicle service manual must be
referred to when installing the Öhlins
suspension components
Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:
The Safety alert symbol means:
Caution! Your safety is involved.
WARNING!
Failure to follow warning instructions
could result in severe or fatal injury
to anyone working with, inspecting or
using the suspension, or to bystanders.
CAUTION!
Caution indicates that special
precautions must be taken to avoid
damage to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
Tools needed
1873-01
1860-01
1761-02
1863-01
1797-03
0727-02
Description Part No. Pcs.
Spring, front fork (4.7 N/mm) 02490-47 2
Spring, front fork (5.1 N/mm) 02490-51 2
Spring, base valve (60 N/mm) 04107-06 2
Spring, base valve (40 N/mm) 04107-04 2
Washer 02528-05 2
Alternative tools
EXF only:
Refit the adjustment wheel together with the balls
and springs.
Balls and springs
Adjust the compression and the rebound
valves according to specification card.
Fork bottom
Flat screwdriver
Fork top
Compression
adjuster
Adjustment wheel
Fit the fork legs on the motorcycle.
Tightening torques:
Upper triple clamp: 20 Nm
Lower tripple clamp: 10 Nm
MXF and EXF
Recommended settings
Recommended shims stacks:
Compression Rebound Midvalve
0186-14 (7x) 0184-21 (5x) 0530-22
0520-23 0184-20 1149-01 (5x)
4105-02 0184-19 0530-18 (4x)
0530-18 (2x) 0184-18
0184-17
0184-16
0184-14
Compression adjustment:
Low speed: 14 clicks
High speed: 1 turn ( MXF only)
Rebound adjustment: 12 clicks
High speed
compression
adjuster
(MXF only)
12 mm
socket
Fork bottom
Base valve
housing
Tool
(1863-01)
Poppet
valve seat
Poppet valve
Spring
(04107-xx)
Base valve
17 mm/23 mm
Shims
Front fork leg
Change of high speed compression spring
1
Put the bike on a stand and loosen the
screws in the fork top crown that hold the
fork legs.
2
Turn the fork leg upside down and fasten
the fork bottom in a vise with soft jaws.
3
Remove the compression valve assembly
from the fork bottom using a 23 mm socket
(MXF) and a 17 mm socket (EXF).
Fasten the valve assembly with soft jaws
in a vice.
NOTE!
This operation must be carried out with help
of a pneumatic impact driver
4
Fasten the valve in a vise with soft jaws.
5
Use tool (1863-01) or a pair of pointed pliers to loosen
the poppet valve seat and remove it together with the
poppet valve and the spring.
6
Install the new spring, refit the poppet valve and the
poppet valve seat. Tighten to a torque of 5 Nm.
7
Refit the valve unit to the fork bottom as described
above. Tighten to a torque of 65 Nm.
65 N/mm
MXF
23 mm
Hexagon
Key Grip
EXF
17 mm
Hexagon
Key Grip
Assembly
1
Install the damper rod assembly into the cylin-
der tube. Use Loctite 542 on the cylinder tube cap.
Tighten with tool 1797-01to a torque 65 Nm.
2
Pump the damper rod up and down a few times
to check that there is no air trapped.
3
Measure the correct amount of oil according to
the specification card.
4
Pull out the damper rod as far as possible and
close the compression and the rebound valves.
5
Install the spring and the spring support, (EXF)
and the pre-load tube. (MXF)
NOTE!
A spring ratio of 4.9 N/mm is obtained if a 4.7 N/
mm spring is used in one leg and a 5.1 N/mm
spring is used in the other.
6
Install the fork top cap and the lock nut. Tighten the
top cap and the lock nut against each other, use
a 17 and 24 mm wrench. Tighten to 30 Nm.
7
Refit the top cap and thighten. The top cap should
not be thightened hard, only turned in position
by hand.
65 Nm
Damper rod assy
Cylinder
tube
Cylinder
tube cap
17 mm wrench
24 mm wrench
17 mm wrench
24 mm wrench
MXF
EXF
Tool 1761-02
MXF
Tool
(1860-01)
Tool
(1761-02)
Mounting Instructions - Spacers and Springs
Tool 1761-02
Top cap
Fork leg
17 mm
wrench
24 mm
wrench
Top cap
Pre-load tube
Spring
Top cap
17 mm
wrench
Damper
rod assy
Damper rod
extender
Tool 1860-01
EXF
Remove the adjustment wheel and the springs
and balls of the adjuster.
Unscrew the top cap, use tool (1860-01 or
1761-02).
Remove the top cap from the damper rod
extender. Use a 17mm wrench, and tool (1860-01
or 1761-02).
Adjustment wheel
Balls and
springs
Original
spring
support
Remove the original spring support and the
original spring.
1
Put the bike on a stand and loosen the screws in
the fork top crown that hold the fork legs.
NOTE!
On most MX and Enduro-bikes you have to take
the handle bar off before you can unscrew the
top cap.
2
Unscrew the top cap, using top cap tool 1761-02.
MXF
Remove the top cap from the damper rod ex-
tender, use a 17 and 24 mm wrench.
Remove the spring support , the pre-load tube
and the spring.
Compress the
spring to get the
24 mm correct in
position.
Compress the
spring to get the
24 mm correct
in position.
Original
spring
Tool
(1873-01)
Alternative tools
MXF and EXF
3
Loosen the cylinder tube cap, on top of the cylin-
der tube, with tool 1797-01. Lift up the damper
rod assembly and drain the oil.
NOTE!
If the fork leg is fixed in upright position during
the whole operation it is not necessery to drain
the fork leg.
Tool (1797-01)
Cylinder tube
Damper
rod assy
Cylinder
tube cap
Hydraulic stop
close to soft
jaws
MXF front fork
EXF front fork
How to fasten the damper rod assembly
Guide sleeve
close to the
jaws
CAUTION !
Fasten the damper rod assembly in a vice.
Be careful not to tighten too hard. The piston
rod is very delicate.
Washer
Washer
(02340-02)
Piston
holder
4
Fasten the damper rod assembly in a vice with
soft jaws.
5
Remove the piston holder and the spring, so the
original washer can be removed.
6
Clean all parts thoroughly and inspect all parts for
wear and damage, replace if necessary. Assemble
the damper rod assy by fitting the washer provided,
the spring and the piston holder.
CAUTION!
The part of the washer with a groove on should
be directed downwards, facing the piston holder.
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