Owners Manual
Mounting instruction Öhlins front fork kit
FG 899 for Yamaha R1
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
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
FG 899, issued 02 05 16
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00, fax +46 8 590 025 80.
E-mail: [email protected]
www.ohlins.com
Bike on a stand. Bike on the ground. Bike with rider on.
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.
Setup data
Length 730 mm
Stroke 120 mm
Rebound adj 12 clicks
Compressionadj 10 clicks
Preload 10 mm
Spring rate 9,5 N/mm
Oil level 85 mm
F1
R1
F2
R2
F3
R3
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 oc-
cur 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 re-
garding proper installation procedures, con-
tact an Öhlins dealer or other qualified per-
son.
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, 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 contents
Before installing the front fork, please check the
contents of the kit. If anything is missing, contact
your Öhlins dealer.
Description Pcs. Part No.
Fork legs (pair) 1 01676-11
Caliper bracket LH 1 01677-21
Caliper bracket RH 1 01677-22
Fender bracket, ring 2 01682-19
Fender bracket 2 01682-01
Fender bracket 2 01678-04
Shaft sleeve, M14 1 01680-08
Shaft sleeve, flanged 1 01679-03
Sleeve 1 01679-01
Bolt M4x14 4 01046-10
Bolt M5x12 4 01046-34
Screw M4x9 4 00382-13
Sticker Öhlins 2 00194-10
Owners Manual
Notes
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 chang-
ing 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. Ensure that the motorcycle is
properly secured and cannot fall over.
2
Remove the front fender by loosening the
six screws.
3
Release the brake caliper on each side and
let them hang by the brake leads.
4
Remove the wheel axle, by loosening the
clamping screw on the left side and then
screw out the wheel axle. Lift out the front
wheel.
5
Release the fasteners of the fork legs in the
triple clamps and loosen the screws on the
clip-on handles.
6
Pull the fork legs out downwards and fit
Öhlins fork legs to the triple clamps. Tighten
the screws in the fork crowns and the clip-
on handles.
3
2
4
6
NOTE !
The fork legs are to be mounted so that the
top nut is visible above the top edge of the
triple clamp. This corresponds to a height
of about 2 mm.
NOTE !
Tighten the screws to a maximum torque of
15 Nm. If screws in the lower triple clamp
are tightened too hard they can deform the
fork tube and impair the spring action.
NOTE!
Make sure that all bolts are tightened in cor-
rect torque and that nothing restrains the
front fork when the suspension is being
compressed. Check with the Workshop
manual of the motorcycle..
5 Nm
7 Nm
25 Nm
5 Nm
20 Nm
16
Fit the brake calipers.
17
Lower the motorcycle so that the front sus-
pension 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.
18
Then tighten the clamping screws on the
right fork leg so that the fork legs are fixed
in position.
19
Continue your work according to the Own-
ers manual, section Adjustments.
7
Fit the brake caliper brackets and the rear
and rear fender bracket on the right and left
sides.
7
9
8
10
8
Fit the circlip model flexible fender bracket
by first pressing it over lower fork leg.
9
Then open it slightly so it can be slided to
the fork bottom.
10
Fit the sticker to the fender bracket.
11
Bolt the circlip fender bracket to the caliper
bracket.
13
CAUTION!
It is of vital importance that the slots in the
sleeves are directed downwards. Use a slot-
ted screwdriver to guide the sleeves into
correct position.
12
Fit the front fender bracket and the front fender.
11
14
Insert the slotted sleeve (1679-01) in the right
fork leg from the outside of the leg. Fit the
sleeve with a flange (1679-08) to the left fork
leg from the inside of the leg. The flange
shold be facing the wheel.
15
Reassemble the wheel and the wheel axle
and thread the axle onto the threaded
sleeve. Tighten to 30 Nm. Then tighten the
screws holding the threaded sleeve. Tighten
the two clamping screws of the left fork leg
to fix the axle.
12
13
Fit the threaded sleeve (1680-08) to the left
fork leg with the screws provided. Do not
tighten yet, the sleeve must be able to move
slightly.
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1
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2
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3
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4
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