Öhlins Racing AB
Box 722
S-194 27 Upplands Väsby, Sweden
Phone +46 8 590 025 00
fax +46 8 590 025 80
© Öhlins Racing AB. All rights
reserved. Any reprinting or
unauthorized use without the written
permission of Öhlins Racing AB
is prohibited.
www.ohlins.com
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, minor updates
may occur.
To find the latest information contact
your Öhlins distributor. Please
consult your Öhlins dealer if you
have any questions regarding the
contents in this document.
Front Fork Kit for Kawasaki ZX-6R
FGK 144
Mounting Instructions
Part No. Pcs.
Front fork kit FGK144 1
Öhlins Sticker (60x23) white 00191-32 2
Öhlins Sticker (60x23) blue 00191-33 2
Warning!
This kit should only be installed by an Öhlins
dealer. The installation procedure requires
certain Öhlins tools.
Before installing this product, check the
contents of the kit. If anything is missing, please
contact your nearest Öhlins dealer.
Kit Contents
7 - Diagram: Oil Level - Force
Please note that during storage and
transportation, especially at high ambient
temperature, some of the oil and grease used for
assembling may leak and stain the packaging.
This is in no way detrimental to the product,
wipe off the excessive oil/grease with a cloth.
Part no. FGK144_3
Issued 2009-03-31
Warning!
Before installing this product, read the Öhlins
Owner’s Manual. The front fork is an important
part of your vehicle and may affect the stability.
Oil level
[mm]
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Stroke [mm]
Force [N]
110
120
130
140
150
160
170
180
190
200
6 - Set-up Data
Recommended sag and ride height:
The measures should not differ from the
following recommendations:
Without rider:
Rear 5 - 15 mm (R1-R2)
Front 20 - 30 mm (F1-F2)
With rider:
Rear 25 - 35 mm (R1-R3)
Front 30 - 40 mm (F1-F3)
Recommended set-up:
Rebound adjustment 12 clicks
Compression adjustment 12 clicks
Spring preload 12 mm
Oil level 150 mm
Öhlins Front Fork uid Part No. 01309-01
1 10
Safety Precautions
Safety Symbols
In this manual, mounting instructions and
other technical documents, important
information concerning safety is
distinguished by the following symbols:
The Safety Alert Symbol means: Warning!
Your safety is involved.
Warning!
The Warning Symbol means: Failure to
follow warning instructions can result in
severe or fatal injury to anyone working with,
inspecting or using the front fork, or
to bystanders.
Caution!
The Caution Symbol means: Special
precautions must be taken to avoid damage
to the front fork.
Note!
The Note Symbol indicates information that
is important regarding procedures.
Note!
The front fork is a very important part of the
vehicle and will therefore affect the stability.
Read and make sure that you understand the
information in this manual and the mounting
instructions before you use this product. If you
have any questions regarding installation or
maintenance please contact your nearest Öhlins
dealer.
Öhlins Racing AB can not be held
responsible for any damage to the front fork,
vehicle, other property or injury to persons, if the
instructions for installing and maintenance are
not followed exactly.
Warning!
This product was developed and designed
exclusively for a specific vehicle model and
should only be installed on the intended vehicle
model in its original condition as delivered from
the vehicle manufacturer.
This product contains pressurized nitrogen
gas (N
2
). Do not open, service or modify this
product without proper education (authorized
Öhlins dealer/distributor) and proper tools.
After installing this product, take a test ride
at low speed to make sure that your vehicle has
maintained its stability.
Note!
When working on this product, always consult
your Vehicle Service Manual.
This Folder should be considered as a part of
the product and should therefore accompany
the product throughout its life cycle.
5 - Adjustments
1. Spring Preload Adjuster. Adjust by
turning the nut on the top of the fork leg. Turn
clockwise to increase and counter clockwise
to decrease the spring preload.
2. Rebound Damping Adjuster. Adjust by
turning the screw with an allen key.
3. Compression Damping Adjuster. Adjust
by turning the screw, use proper tool.
To Reset
The adjusters have a normal right hand
thread. Turn the damping adjuster clockwise
to fully close (pos. zero [0]). To open, turn the
damping adjuster counter clockwise - count
the clicks or turns from fully closed until you
reach the recommended setting. See Set-up
data in this manual.
Caution!
Do not use force, delicate sealing surfaces can
be damaged.
Decrease
Increase
Warning!
Before riding, always make sure that the basic
settings made by Öhlins are according to
recommended Set-up Data. Contact an Öhlins
dealer if you have any questions about setting
up the front fork.
1
2
3
9 2
4 - Setting up
Warning!
Before riding, always ensure that the basic
settings made by Öhlins are intact. Take notes,
adjust in small steps and make only one
adjustment at a time.
Step 1
Spring Preload - Free Sag - Ride Height
Spring preload is a crucial part of setting your
motorcycle since it affects the height of the
motorcycle and the fork angle.
Note!
The following procedure should be performed on
a flat surface.
Put the motorcycle on a workstand so that
both wheels are off the ground and the
suspension is unloaded.
Mark, for example with a piece of tape, a
point immediately above the rear wheel
axle.
Measure the distance from the marked
point to a xed point, for example the
wheel axle (R1).
Measure the distance from the bottom of
the outer tube to a xed point, for example
the front wheel axle (F1).
Put the motorcycle on the ground so
that the front and the rear suspensions
are slightly compressed. Repeat the
measuring procedures (R2 and F2).
Sit on the motorcycle in normal riding
position, properly outtted in your riding
gear. Repeat the measuring procedure (R3
and F3).
1.
2.
3.
4.
5.
6.
Recommended Measures
Recommended measures for Free Sag and
Ride Height; see Set-up Data.
Note!
Always check on the Öhlins web site
www.ohlins.com or with your Öhlins
dealer/ distributor for the latest information.
Step 2
Adjust spring preload
If your measures differ signicantly from
the recommendations in section “Set-up
Data”, adjust the spring preload. (See
section Spring Preload in this manual).
If the ride height still differs from the
recommendations, you may need to
change to softer/harder spring. Contact
your Öhlins dealer for advise.
Warning!
Incorrect spring rate may result in a front
geometry that is either too steep or too flat.
This can result in a tendency of under or over
steering, that could seriously affect the handling
characteristics of the motorcycle.
1.
2.
Safety Precautions 1
Recommended Tools 2
1 Remove Original Front Fork 3
2 Disassemble Original Front Fork 4
3 Install Öhlins Front Fork Kit 6
4 Setting up 9
5 Adjustments 10
6 Set-up Data 11
7 Diagram: Oil Level - Force 11
Tool 00797-01Tool 01765-03
Tool 01797-07
In This Manual
Recommended Tools
Tool 00786-08 (Ø41)
3 8
1 - Remove Original Front Fork
1
Warning!
It is advisable to have an Öhlins dealer install the
front fork.
When installing, consult your Vehicle Service
Manual.
1.1
Put the motorcycle on a workstand so that
the front wheel barely touches the ground.
Warning!
Make sure the vehicle is securely supported so
that it will not tip.
1.2
Remove the front fender, brake caliper and
the front wheel.
1.3
Measure the position of the front fork:
Measure the distance from the top of the fork
leg to the top of the upper fork crown.
Note!
It is very important that the front fork is
reinstalled at the exact same position.
1.4
Release the spring preload.
1.5
Loosen the upper fork crown by loosening the
screws.
1.6
Loosen (do not remove) the top cap ½ turn.
1.7
Loosen the lower fork crown by loosening the
screws.
1.8
Remove the front fork legs from the fork
crowns.
Screw
1/2 turn
2
3
5
4
6
3.15
Put the preload tube and the spring on top of
the cartridge.
3.16
Fasten tool 01765-03 on the top of the piston
shaft. Install the spring support by leading it
over the tool.
3.17
Pull up the piston shaft and grab the spring
support with a 19 mm wrench.
3.18
Open the rebound adjuster fully. Remove
the pull-up tool and install the top cap to the
piston rod. Tighten with torque 15 Nm.
3.19
Pull up the outer fork tube. Make sure the fork
leg is in a fully extended position. Use tool
00797‑01 to tighten the top cap. Tighten the
top cap with torque 10 Nm.
3.20
Set the spring preload, rebound and
compression adjusters according to
Adjustments and Set-up data in this
manual.
3.21
Install the front fork legs into the fork crowns.
Tighten the upper fork crown with torque
20 Nm, and the lower fork crown with
torque 10 Nm.
Note!
It is very important that the front forks are in the
same position as they were before changing the
fork kit!
15 Nm
19 mm
wrench
10 Nm
Spring
support
Top cap
Spring
Preload
tube
Tool
1765-03
Spring
support
15
16
17
18
19
3 - Install Öhlins Front fork kit
7 4
3 - Install Öhlins Front fork Kit
2 - Disassemble Original Front Fork
2.1
Loosen the top cap from the outer tube.
2.2
Loosen the top cap from the shaft.
2.3
Use appropriate tool according to your
Vehicle Manual. Loosen the seal head
from the steel tube to remove the standard
cartridge.
2.4
Drain the fork leg from oil.
Caution!
Make sure that the lose parts will not fall out
when draining the fork leg.
2.5
Remove the spring and surrounding parts
from the fork leg.
2.6
Loosen the steel tube lock screw at the fork
bottom.
Caution!
If the lock nut is not removed the steel tube will
be damaged.
Note!
Use a heat gun to soften the Loctite between
the lock screw and the fork bottom.
2.7
Push the outer tube as far up as possible.
Use tool 00786-08, install it close to the outer
tube. Loosen the steel tube from the fork
bottom.
Note!
Use a heat gun to soften the Loctite between
the steel tube and the fork bottom.
Note!
Do not remove tool 00786-08 from the steel
tube. You will need it to reinstall the steel tube.
1 2
3
5
6
4
7
3.7
Remove the Öhlins top cap.
3.8
Remove the spring support, spring and the
preload tube.
3.9
Put red grease on the thread. Put the
cartridge carefully into the fork leg.
3.10
Tighten the cartridge with tool 01797-07 to
torque 20 Nm.
3.11
Remove tool 01797-07 and pour
approximately 0,5 litre Öhlins oil into the fork
leg.
3.12
Install the top cap directly to the cartridge
(no spring or preload tube). Pull up the outer
front fork tube and screw it to the top cap.
Handtighten only. Pump out all air from the
cartridge by pulling the fork tube up and
down 10-15 times.
3.13
Remove the top cap from the outer fork tube.
3.14
Make sure the piston shaft is in the bottom of
the fork leg and that the outer fork tube is in
the bottom position. Measure the oil level with
a scale. Recommended setting according to
chapter Set-up data.
Red
grease
Spring
support
Spring
Preload
tube
20 Nm
Top cap
Top cap
7
8
9
10
11
12
XXX mm
14
5 6
3 - Install Öhlins Front fork Kit
2.8
Loosen the spring preload adjuster from the
fork bottom. Use appropriate tool according
to your vehicle service manual.
2.9
Remove the o-ring and the steel washer from
the fork bottom.
Note!
The steel washer will not be used for the Öhlins
kit and should therefore not be reinstalled.
2.10
Remove all spring preload adjuster parts from
the inside of the fork bottom.
3.1
Loosen the adaptor from the Öhlins Fork kit.
Note!
Do not remove the coupling from the adaptor.
3.2
Put some red grease on the original o-ring
and install it into the fork bottom.
3.3
Install the Adaptor and make sure that the
coupling is directed towards the preload
adjuster hole.
Note!
The original steel washer (removed in step 2.8)
should not be reinstalled.
3.4
Install the bleed valve housing. Tightening
torque 12 Nm.
Note!
Make sure that the bleed valve housing and the
coupling connect. Put some red grease on the
o-ring.
3.5
Reinstall the steel tube.
Torque 130 Nm. Loctite 2701.
3.6
Reinstall the steel tube lock screw.
Torque 3 Nm. Loctite 2701.
9
8
10
2 - Disassemble Original Front Fork
6
5
1
2
3
4
3
Adaptor
Coupling
/
