Ohlins FGK128 Mounting Instruction
- Category
- Motorcycle Accessories
- Type
- Mounting Instruction
Ohlins FGK128 is a front fork kit designed to improve the handling and performance of your Yamaha R1 motorcycle. This kit includes a pair of front fork legs, which are fitted with Öhlins' high-performance cartridges. These cartridges feature adjustable rebound and compression damping, as well as adjustable spring preload. This allows you to fine-tune the suspension of your motorcycle to suit your riding style and the conditions you are riding in.
The Öhlins FGK128 front fork kit is a great way to improve the overall performance of your Yamaha R1.
Ohlins FGK128 is a front fork kit designed to improve the handling and performance of your Yamaha R1 motorcycle. This kit includes a pair of front fork legs, which are fitted with Öhlins' high-performance cartridges. These cartridges feature adjustable rebound and compression damping, as well as adjustable spring preload. This allows you to fine-tune the suspension of your motorcycle to suit your riding style and the conditions you are riding in.
The Öhlins FGK128 front fork kit is a great way to improve the overall performance of your Yamaha R1.
Mounting Instructions
Öhlins Front fork kit FGK 128
for Yamaha R1
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
© 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 FGK128 (1)
Öhlins Sticker 47x125 00192-01 (2)
Öhlins Sticker 28x74 01196-02 (2)
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.
CAUTION!
Do not use force, delicate sealing surfaces
can be damaged.
1
2
Recommended tools
Tool 0797-04
Tool 1797-02/
-04/ -07
1
2
2
This kit should only be installed
by an Öhlins dealer. The instal-
lation procedure requires certain
Öhlins tools.
!
Mounting Instructions FGK128 - Issued 2006 05 29
Tool 4702-04
Tool 0797-01
Tool 0787-03
Tool 4705-01
DIAGRAM: OIL LEVEL - FORCE
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
0 102030405060708090100110120
Stroke [mm]
Force [N]
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
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
Tool 1765-03
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 service manual must be re-
ferred 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 damping 13 clicks
Compression damping 14 clicks
Spring preload 8 mm
Oil level 175 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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© Öhlins Racing AB. All r
i
ghts reserved. Any reprinting or
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 tip-
ping over.
!
6
Loosen, but do not remove, the top cap ½ turn.
Use tool 0797-04.
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 tube 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 17 mm
wrench.
5
Loosen the upper fork crown by loosening the
screws.
1
2
!
Removing the original front fork
3
5
8
27
Put the pre-load tube and the spring on top of
the cartridge.
28
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 (28a).
29
Pull up the top cap holder and grab the spring
support with a 19 mm wrench.
30
Open the rebound adjuster fully. Put the
top cap on the fork. Tighten the top nut.
Torque 15 Nm.
31
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.
32
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.
33
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.
34
Tighten the torque:
Upper fork crown 20 Nm
Lower fork crown 10 Nm
27
4
6
31
32
NOTE!
30
33
29
28
28a
MOUNTING INSTRUCTIONS
3 4
9
Loosen the top cap from the fork leg.
10
Pull down the fork leg.
11
Remove the top cap assembly from the shaft.
Use tool 4705-01.
12
Remove the spring and the pre-load tube. Use
a bent wire to fetch it from the bottom.
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.
15
Put the cartridge unit on a vice, use a clamp-
ing tool 0787-03. Put the clamping tool 50 mm
from the end.
16
Use a heat gun on the seal head. Loosen the
cartridge with tool 4702-04. Remove the whole
unit from the cylinder.
17
Clean the inner and the outer threads of the
damper tube. Make sure you remove all access
Loctite.
Disassembling the original front fork
18
Remove the top cap from the Öhlins front fork
kit.
19
Remove the spring spacer, spring and the pre-
load tube.
Installing the Öhlins front fork kit
20
Put the cartridge assembly into the damper
tube.
21
Tighten the seal head to the damper tube. Use
tool 1797-02/ -04/ -07. Torque: 45 Nm.
22
16
19
175 mm
23
24
26
Put the cartridge assembly into the fork leg.
Tighten the cartridge. Use tool 1797-02/ -04/
-07. Torque 30 Nm. Put some red grease on
the threads.
23
Pour approximately 0.5 litre Öhlins Oil article
no. 01311-01 into the fork leg.
24
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.
25
Remove the top cap from the fork leg.
26
Make sure the outer tube is in the bottom posi-
tion. Measure the oil level.
15
50 mm
NOTE!
CAUTION!
18
20
11
17
Tool 4702-04
Clean
thoroughly!
16
Clean!
Use Loctite 2701
22
Torque
30 Nm
Tool 4705-01
Tool 00787-03
NOTE!
Red grease
-
1
-
2
-
3
-
4
Ohlins FGK128 Mounting Instruction
- Category
- Motorcycle Accessories
- Type
- Mounting Instruction
Ohlins FGK128 is a front fork kit designed to improve the handling and performance of your Yamaha R1 motorcycle. This kit includes a pair of front fork legs, which are fitted with Öhlins' high-performance cartridges. These cartridges feature adjustable rebound and compression damping, as well as adjustable spring preload. This allows you to fine-tune the suspension of your motorcycle to suit your riding style and the conditions you are riding in.
The Öhlins FGK128 front fork kit is a great way to improve the overall performance of your Yamaha R1.
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