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
FG329 Issued 2006 02 10
Mounting Instructions
Öhlins front fork kit FG 329
for Honda CBR 1000 Fireblade
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Kit Contents
Before installing the front fork, please check
the contents of the kit. If anything is missing,
please contact your Öhlins dealer.
Before Installing
Öhlins Racing AB can not be held responsible
for any damage to front fork or vehicle, or
injury to persons, if the instructions for fi tting
and main tenance are not followed exactly.
Similarly, the warranty will become null and
void if the instructions are not adhered to.
R1
R2
R3
F1
F2
F3
Bike on a stand. Bike on the ground. Bike with rider on.
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 = ............
Setup Data
Front fork length 717 mm
Front fork stroke 120 mm
Spring preload 13 mm
Rebound damping adjuster 12 clicks
Compression damping adjuster 10 clicks
Checking Sag and Ride Height
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 = ............
Part No. (Pcs.)
Front Fork legs 04790-07 (2)
Caliper bracket LH 01677-47 (1)
Caliper bracket RH 01677-46 (1)
Fender bracket left front 01682-36 (1)
Fender bracket right front 01682-37 (1)
Fender bracket rear 01682-35 (2)
Spacer 04785-08 (4)
Spacer 01691-05 (1)
O-ring 04722-03 (1)
Bolt MC6S 5x12 01046-34 (4)
Bolt MF6S M5x12 00382-08 (2)
Bolt 01691-02 (1)
Shaft sleeve 01687-03 (1)
Shaft spacer 01691-03 (1)
Sticker Öhlins 00194-10 (2)
Owners Manual (1)
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 that may occur after fi tting
the front fork. Contact an Öhlins dealer or
other qualifi ed person for advice.
2. Please study and make certain that you fully
understand all 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 qualifi ed 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:
Attention! 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 front fork, or to bystanders.
CAUTION!
Caution indicates that special pre-
cautions must be taken to avoid damage
to the front fork.
NOTE!
Indicates information that is of importance
regarding to mounting procedure.
!
!
!
1
6
Öhlins products are subject to continuous im-
provement and development. All information
in this manual is based on the latest product
information available at the time of approval
for publishing. Consequently, there may be mi-
nor differences between your suspension and
the suspension in this manual. Please consult
your Öhlins dealer if you have any questions
regarding the contents of this manual.
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out in-
side the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
front fork.
The Öhlins front fork FG329 is an upside down
type front fork featuring the following adjust-
ers:
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 pre-load adjuster
Adjustments are made by turning the nut at the
top of the fork leg. Clockwise for harder adjust-
ment, counter clockwise to release the pre-load.
Use a 17 mm wrench.
NOTE!
When delivered the Öhlins front fork is dialed to
recommended settings for the specifi c brand
and make of the motorcycle. 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 recommended number of clicks. See Setup
data in this manual.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
Adjustments
Rebound damping
adjuster
Spring pre-load
adjuster
Compression damping
adjuster
5 2
1
Put the motorcycle on a workstand so that the
front wheel is off the ground. Make sure the
vehicle is securely positioned so that it will not
fall over.
2
Release the brake caliper on each side and let
them hang by the brake hoses.
3
Remove the front wheel. Loosen the shaft and
pull it out.
4
Remove the front fender.
5
Release the attachments of the front fork legs in
the lower and the upper triple clamps.
6
Pull the fork legs out downwards and remove
them from the motorcycle.
NOTE!
Do not tighten the bolts and screws while per-
forming operations 7 – 10!
Mounting Instructions
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.
!
15
Lower the motorcycle. Apply the front wheel
brake and push the front suspension down, two
or three times.
NOTE!
Another way is to rotate the wheel as fast as
possible and bring it to a fast stop by braking.
This will bring the legs in correct position.
16
Tighten the wheel shaft and shaft clamps so the
fork legs are in fi xed position. Tighten the fender
and caliper brackets. See the Workshop Manual
for tightening torques.
17
Install the o-ring 04722-03 to spacer 01691-05.
Press the spacer assembly into the left fork
leg until it comes to a stop against the wheel
shaft.
NOTE!
Apply some red grease (00146-02) on the o-ring
before installing it.
NOTE!
Make sure that all bolts are tightened to the
correct torque and that nothing restrains the
front fork when the suspension is being com-
pressed or extended. Consult your vehicle
servie manual.
18
Continue your work with Owners manual, sec-
tion Adjustments.
01677-46
00382-08
04790-07
04785-08
01682-35
01677-47
01687-03
01682-36
01691-02
01046-34
01682-37
01691-03
01691-05
04722-03
16
5 Nm
10 Nm
25 Nm
17
Spacer
O-ring
Standard spacer for
the 2006 model
3 4
7
Install the shaft sleeve (01687-03) to the right
fork bottom of the Öhlins front fork.
8
Install the brake caliper brackets with the bolts
provided in this kit.
CAUTION!
It is of greatest importance that you apply some
Loctite 222 or similar to all caliper bracket bolts
before installing and tightening them.
9
Install the fender brackets with the bolts pro-
vided in this kit.
10
Install the Öhlins front fork legs to the triple
clamps. Do not tighten until the legs are in
correct position, see Note!
NOTE!
The fork legs are to be installed so that the dis-
tance from the top surface of the triple clamp
to the top nut is 7 mm.
11
First, tighten the upper triple clamp, then the
lower one to the correct torque. Consult your
vehicle service manual.
CAUTION!
Do not overtighten. The legs can be deformed
and cause malfunction.
12
Install the front fender. Use the spacers provided
for the rear fender brackets.
13
Reinstall the wheel and the front wheel shaft.
Use the wheel shaft spacer (01691-03) and
the shaft bolt (01691-02) provided. Do not
tighten yet!
14
Install the brake calipers on both sides. Use the
spacers (04785-08) supplied.
NOTE!
For the 2006 model; use standard spacers.
Shaft sleeve
(01687-03)
Caliper bracket
(01677-47)
Caliper bracket
(01677-46)
Top nut
7 mm
9
Fender bracket
(01682-36)
Fender bracket
(01682-37)
Fender bracket
(01682-35)
Bolt
(01046-34)
Bolt
(00382-08)
Spacer
(04785-08)
Standard spacer
(2006 models)
-
1
-
2
-
3
-
4
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