Ohlins FGK127 Mounting Instruction

Category
Motorcycles
Type
Mounting Instruction

Ohlins FGK127 is a high-performance front fork kit designed to enhance the handling and performance of your Yamaha R6. With its advanced features and adjustable settings, the Ohlins FGK127 empowers you to tailor your suspension setup to suit your riding style and specific track conditions.

The Ohlins FGK127 features a rebound damping adjuster that allows you to fine-tune the fork's rebound speed for optimal control and stability. Additionally, the spring preload adjuster provides the ability to adjust the fork's spring tension, ensuring proper sag and ride height for your weight and riding conditions.

Ohlins FGK127 is a high-performance front fork kit designed to enhance the handling and performance of your Yamaha R6. With its advanced features and adjustable settings, the Ohlins FGK127 empowers you to tailor your suspension setup to suit your riding style and specific track conditions.

The Ohlins FGK127 features a rebound damping adjuster that allows you to fine-tune the fork's rebound speed for optimal control and stability. Additionally, the spring preload adjuster provides the ability to adjust the fork's spring tension, ensuring proper sag and ride height for your weight and riding conditions.

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0 102030405060708090100110120
Stroke [mm]
Force [N]
0
25
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125
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200
225
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275
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325
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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
Mounting Instructions
Öhlins Front fork kit FGK 127
for Yamaha R6
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 FGK127 (1)
Öhlins stickers 47x125 00192-01 (2)
Öhlins stickers 28x74 01196-02 (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 hex key
with a spherical head.
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 tools
Tool 0797-01Tool 1765-03
Tool 1797-07
1
2
2
This kit should only be installed
by an Öhlins dealer. The instal-
lation procedure requires certain
Öhlins tools.
!
Mounting Instructions FGK127_6 - Issued 2007 02 14
Tool 4702-04
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’s service manual must
be referred 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 adjustment 13 clicks
Low speed compression 4 clicks
High speed compression 1.5 turns
Spring preload 6 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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Front fork kit FG
K
127
for Yam
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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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!
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 falling.
!
6
Loosen, but do not remove, the top
nut ½ turn.
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 pre-load. Use a 14 mm
wrench.
5
Loosen the upper fork crown by loosening the
screws.
1
2
!
Removing the original front fork
3
5
8
24
23
Put the pre-load tube and the spring on top of
the cartridge.
24
Use tool 1765-03 and screw it on top of the
piston rod. Install the spring support by lead-
ing it on the tool and screwing it on top of the
piston rod (24a).
25
Pull up the top cap holder and grab the spring
support with a 19 mm wrench.
26
Open the rebound adjuster fully. Put the
top cap on the fork. Tighten the top nut.
Torque 15 Nm.
27
Pull up the fork leg. Make sure the fork leg is in a
fully extended position. Use tool 0797-01 (27a).
Tighten the torque to 10 Nm.
28
Set the spring pre-load. Use a 14 mm wrench.
Set rebound and compression according to the
Set-up data in this manual. See sections Set-up
and Adjustments in this manual.
29
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.
30
Tighten the torque:
Upper fork crown 20 Nm
Lower fork crown 10 Nm
23
26
24a
4
6
27
27a
25
29
28
MOUNTING INSTRUCTIONS
3 4
9
Remove the top nut from the fork leg.
10
Pull down the fork leg.
11
Remove the pre-load tube.
12
Remove the spring.
13
Loosen the cartridge. Use tool 4702-04. Take out
the whole cartridge unit from the fork leg.
14
Turn the fork leg upside down to pour out all
oil.
Disassembling the original front fork
15
Remove the top cap.
16
Remove the spring support, spring and the
pre-load tube.
Installing the Öhlins front fork kit
17
Put the cartridge assembly into the fork leg.
18
Tighten the cartridge with tool 1797-07.
Torque: 20 Nm.
19
Pour approximately 0.5 litre Öhlins oil article
no. 01311-01 oil into the fork leg.
17
15
16
18
CAUTION!
170 mm
19
20
22
20
Put the top cap directly to the cartridge (no
spring or pre-load 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.
21
Remove the top cap from the fork leg.
22
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.
15
Loctite 270
NOTE!
1 / 1

Ohlins FGK127 Mounting Instruction

Category
Motorcycles
Type
Mounting Instruction

Ohlins FGK127 is a high-performance front fork kit designed to enhance the handling and performance of your Yamaha R6. With its advanced features and adjustable settings, the Ohlins FGK127 empowers you to tailor your suspension setup to suit your riding style and specific track conditions.

The Ohlins FGK127 features a rebound damping adjuster that allows you to fine-tune the fork's rebound speed for optimal control and stability. Additionally, the spring preload adjuster provides the ability to adjust the fork's spring tension, ensuring proper sag and ride height for your weight and riding conditions.

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