Mounting Instructions
Öhlins front fork kit FGSU 681
for Suzuki RM-Z 250, Kawasaki KX 125/ 250 2006
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
FGSU 681 - Issued 2005 12 29
© Öhlins Racing AB. All rights reserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
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.
In this manual
Safety precautions
Mounting instructions
Before riding
Set-up data
Adjustments
Front fork FGSU681 (1 pair)
Tool 01860-01 (1)
Spring 43.6/467/3.9 02428-39 (2)
Spring 43.6/467/4.3 02428-43 (2)
Spring support 4mm 02436-04 (2)
Sticker Front Fork 02332-09 (2)
Sticker “ÖHLINS” 00197-01 (2)
Owners manual front fork (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 fi tting the front fork. Contact
an Öhlins dealer or other qualifi ed person
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 or other quali-
fi ed person.
!
!
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
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. Turn the adjuster knob to adjust the
rebound damping.
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 recom-
mended number of clicks. See Setup data in
this manual.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
WARNING!
1. It is advisable to have an Öhlins dealer or other
qualifi ed person 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 falling.
MOUNTING INSTRUCTIONS
25
!
Front leg
cover
Front
wheel
Upper triple
clamp
Lower triple
clamp
Brake
caliper
Caliper
protection cover
3
2
2
1
Put the motorcycle on a workstand to raise the
front wheel off the ground. Ensure the vehicle is
securely supported so that it will not fall over.
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.
7
Align the front fork legs
Put the motorcycle on the ground and compress
the front suspension as hard as possible a few
times. This will align the fork legs.
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!
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!
5
Reattach the front leg covers.
6
Put the wheel back in position.
4
Attach the Öhlins front fork legs to the motor-
cycle.
Tighten the torques:
Upper triple clamp: 20 Nm
Lower triple clamp: 10 Nm
CAUTION!
Do not overtighten the triple clamps. The fork
leg tubes can be deformed.
NOTE!
Before you continue, make sure that the
front fork springs are installed. If they are
not installed, proceed with the instructions
on page 3.
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 14 clicks
Compression adjustment 14 clicks
Spring pre-load 4 mm
Front fork position 8 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.
NOTE!
All spring rates above cannot be achieved
with the provided springs. Please contact
your Öhlins dealer for advice.
NOTE!
When delivered, the oil level is 100 mm. For
some models you need to drain some oil to
achieve the recommended level.
Recommendations
RM-Z 250
Spring rate 4.1 N/mm
Oil level 100 mm
KX 125/ 250
Spring rate 4.1 N/mm
Oil level 100 mm
Installing the Öhlins front fork
MOUNTING INSTRUCTIONS
3 4
WARNING!
1. It is advisable to have an Öhlins dealer or other
qualifi ed person 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 falling.
!
Installing the springs
1
Put the motorcycle on a workstand to raise the
front wheel off the ground. Make sure that the
vehicle is securely supported so that it will
not fall over.
2
Remove the handlebar.
3
Loosen the screws that hold the triple clamps.
4
Remove the adjustment wheel, the adjuster
springs and balls.
7
Close the compression and rebound valves. This
will keep the damper rod extended and make it
easier to install the new spring.
5
Unscrew the top cap, use tool (1860-01 or
1761-02). Put a box under the front wheel so
that the springs are visible.
6
Remove the top cap from the damper rod
extender. Use a 17 mm wrench, and tool (1860-
01 or 1761-02).
Adjustment
wheel
Springs and
balls
or
Tool (1761-02)
Tool (1860-01)
Tool 1860-01
17 mm wrench
Top cap
17 mm wrench
Bump rubber
Damper rod
assembly
5
6
8
Install the the correct springs. In this kit, there
are two pairs of springs provided.
NOTE!
A spring ratio of 4.1 N/ mm is obtained if a
3.9 N/ mm spring is used in one leg and a
4.3 N/ mm spring in the other leg.
10
Install the spring support, the desired pre-load
tube and the top nut.
11
Install the fork top cap. Tighten (30 Nm) the top
cap and the lock nut against each other, use tool
1860-01 and 17 mm wrench.
12
Reattach the top cap and tighten. Use top cap
tool 1761-02 or 1860-01.
The top cap should only be hand tightened!
13
Continue your work according to page 2,
step 4.
Spring support
Top cap
17 mm wrench
17 mm wrench
or
Tool (1761-02)
Tool (1860-01)
-
1
-
2
-
3
-
4
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