Mounting Instructions
Öhlins front fork kit FG 318
for Ducati 748/916
Rebound damping
adjuster
Compression
damping adjuster
Öhlins front fork 43
Your Öhlins front fork 43 is an upside down type
front fork featuring the following adjusters.
Compression damping adjuster
Adjustments are made at the bottom of the front
fork leg. Use a 3 mm allen key.
Rebound damping adjuster
Adjustments are made at the top of the fork leg.
Use a 3 mm allen key.
Spring preload adjuster
Adjustments are made by turning the nut at the
top of the fork leg. Clockwise for harder adjust-
ment, counter clockwise too release the preload.
Use a 17 mm wrench.
NOTE!
When delivered the Öhlins front fork is dialed to
recommended settings for the specific brand and
make of the motorcycle. If you have changed the
setting check like this:
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 at page 4.
CAUTION!
Do not use to much force, delicate sealing
surfaces can be damaged.
Spring preload
adjuster
Bike on a stand.
F1
R1
Bike on the ground.
F2
R2
Bike with rider on.
F3
R3
Set-up data:
Length 730 mm
Stroke 120 mm
Rebound adjustment 12 clicks
Compression adjustment 12 clicks
Spring pre-load 10 mm
Spring rate 9.5 N/mm
Oil level 170 mm
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 = ............
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 = ............
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. FG 318. Issued 04 11 02
Before installation
Öhlins Racing AB can not be held responsible for
any damage whatsoever to front fork 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 a front fork, 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 front
fork. 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 front
fork 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 front fork
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 pre-
cautions must be taken to avoid dam-
age to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
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, especially
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 contents
Before installing the front fork, please check the
contents of the kit, listed on the front page of
this instruction. If anything is missing, contact
your Öhlins dealer.
Description Pcs. Part No.
Front fork Ducati 999 1 04790-02
Caliper bracket RH 1 01677-30
Caliper bracket LH 1 01677-31
Fender bracket LH 1 01678-11
Fender bracket RH 1 01678-12
Fork crown lower 1 01690-01
Clamp tool 2 03179-01
Shaft sleeve 1 01687-04
Shaft sleeve 1 01687-05
Nut 1 01691-01
Bolt MC6S 5x12 4 01046-34
Sticker 1 00194-10
Owners Manual 1
Notes
3
WARNING!
1. It´s advisable to have an Öhlins dealer or other
qualified person to fit your suspension.
2. Instructions in the vehicle service manual are
to be followed when changing the suspension.
3. When working on a lifted vehicle it must be
securely supported to prevent it from falling.
Mounting instructions
1
Lift up the motorcycle so that the front wheel is
free. This can be done by inserting a piece of
pipe or bar through a suitable aperture in the
frame behind the front fork. Ensure that the mo-
torcycle is properly secured and cannot fall over.
2
Remove the steering damper.
3
Remove the front fender by loosening the four
screws.
4
Release the brake caliper on each side and let
them hang by the brake leads.
5
Remove the wheel axle, by loosening the clamp-
ing screw on the left side and then screw out the
wheel axle. Lift out the front wheel.
6
Release the fasteners of the fork legs in the triple
clamps and loosen the screws on the clip-on
handles. Pull the fork legs out downwards. Re-
lease the screw, remove it and lift the upper tri-
ple clamp off.
7
Remove the nut holding the lower triple clamp
and release the triple camp together with the fork
column downwards.
6
1
7
NOTE!
Make sure that all bolts are tightened to the cor-
rect torque and that nothing fouls or restricts
movement of the suspension when it´s being fully
compressed or extended. Check with the Work-
shop manual for the motorcycle.
15
Fit the brackets for the brake calipers on the right
and left sides and for the front fender. Fit the
calipers and the fender.
16
Lower the motorcycle so that the front suspen-
sion works. Brake the front wheel and push the
front suspension down two or three times. This
will put the fork legs in a parallel position.
17
Tighten the clamp bolts on the RH fork bottom
to 20 Nm.
18
Continue with adjustments according to the
Owner’s Manual.
20 Nm
5 Nm
25 Nm
10 Nm
15
8
Fix the steering column in a vice by using the
tool provided.
10
Apply some Loctite 270 or equivalent to the
thread and fit the Öhlins triple clamp to the origi-
nal column.
9
Use a hot air gun to heat the triple clamp close
to the column attachment and release the clamp
from the column by unscrewing it. It can be nec-
essary to give the clamp a beat with a soft head
hammer.
11
Refit the fork column and the triple clamps to the
motorcycle and attach the screw to the upper
triple clamp.
8
9
10
12
Fit the fork legs to the triple clamps. Tighten the
triple clamps and the clip-on handles.
NOTE!
The fork legs are to be mounted so that the fourth
groove is just visible above the top, side edge of
the fork crown. This corresponds to a height of
about 16 mm.
NOTE!
Tighten the screws to a maximum torque of 15
Nm. If screws in the lower fork crown are tight-
ened too hard they can deform the fork tube and
impair the spring action.
12
13
13
IInsert the sleeve (1687-04) into the LH fork bot-
tom and the thinner flanged sleeve (1607-05) in
the RH fork bottom. Both sleeves shall have the
slot downwards. Put the wheel in position and
insert the wheel shaft from the right side. Turn
the speedometer drive so the speedometer ca-
ble not interferes anywhere.
14
Use the wheel nut (1691-01) supplied and tighten
to a torque of 45 – 50 Nm. Tighten the LH fork
bottom clamp bolts to 20 Nm.
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Ohlins FG320 Mounting Instruction
- Type
- Mounting Instruction
- This manual is also suitable for
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