Owners Manual
Mounting instruction Öhlins front fork kit FG 841
for Ducati 750/900 SS 91-97 and Monster
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:
Lenght 730 mm
Stroke 120 mm
Rebound adjustment 12 clicks
Compression adjustment 10 clicks
Spring pre-load 10 mm
Spring rate 9.5 N/mm
Oil level 85 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 841. Issued 02 04 10
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.
Fork legs (pair) 1 01676-11
Bolt MC6S 4x14 4 01046-10
Bolt MC6S 5x16 4 01046-18
Caliper bracket 1 01677-07
Caliper bracket 1 01677-08
Fender bracket 1 01682-11
Fender bracket 1 01682-12
Fender bracket 2 01686-02
Boss* 1 01688-01
Shaft sleeve M18x1.5/30 1 01680-04
Shaft sleeve 25/30/44 1 01687-01
Spacer 6.5/15/5 (SS only) 4 01138-01
Sticker Öhlins 2 00194-10
Owners manual 1
* Only needed when motocycle is equipped with
boss from factory
Notes
6
WARNING!
1. It´s advisable to have an Öhlins dealer or other
qualified person to fit your front fork.
2. Instructions in the vehicle service manual are
to be followed when changing the front fork.
3. When working on a lifted vehicle it must be
securely supported to prevent it from falling.
Mounting instruction
1
Lift up the motorcycle so that the front wheel is
free. Ensure that the motorcycle is properly se-
cured and cannot fall over.
6th groove
Position of the Öhlins front legs in the upper
triple clamp (on SS models).
2
Release the brake caliper on each side and let
them hang by the brake leads.
3
Remove the front wheel.
4
Remove the front fender.
5
Release the fasteners of the fork legs in the lower
triple clamps, and loosen the screws on the clip-
on handles. Release the upper triple clamps.
6
750/900 SS
Pull the fork legs out downwards and fit Öhlins fork
legs to the triple clamps and clip-on handles. (SS
only)
7
Monster
Pull the fork legs out downwards and fit Öhlins
fork legs to the triple clamps. Put back the screws
in the fork crowns. Do not tighten fully until you
have adjusted the fork legs in correct position.
Distance to
handlebar.
(on Monster)
NOTE !
The Öhlins front fork is 10 mm longer than the
original front fork. It is important that fork legs
are mounted so the top nuts are not in contact
with the handlebar. (Monster only)
8
Tighten the triple clamp screws on the fork legs so
that the fork legs are fixed in position.
NOTE !
Tighten the screws to a torque of 15 Nm. If the
screws in the lower triple clamp are tightened
too hard they can deform the fork tube and im-
pair the spring action.
9
Fit the circlip model fender bracket by first press-
ing it over the lower fork leg. The open side shall
be facing rearwards with the thin wall outwards.
7
9
20 Nm
7 Nm
25 Nm
5 Nm
NOTE!
Make sure that all bolts are tightened in correct
torque and that nothing restrains the front fork
when the suspension is being compressed.
Check with the Workshop manual of the motor-
cycle.
14
Fit the sleeve with the two fastening screws on
the left fork bottom and the bushing to the right
front bottom. Put the wheel and the wheel axle
back in position. Do not tighten until the machine
is standing on the ground.
15
Fit the brake calipers.
WARNING!
It might be necessary to fit slightly longer brake
hoses. To avoid malfunction this should be car-
ried out by a skilled mechanic.
16
Lower the motorcycle to the ground. Use the
brake to lock 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 wheel shaft and shaft clamps so the
fork legs are in fixed position. See the Workshop
manual.
18
Continue with adjustments according to the
Owner’s Manual.
17
14
Former bracket
position
New bracket
position
NOTE!
New fender position will be slightly forward
10
Then open it slightly so it can be slided into posi-
tion.
11
Fit the sticker to the fender bracket.
12
Fit the brake caliper brackets and the fender
brackets. Refit the front fender, use the four plas-
tic spacers to obtain proper clearance to the fork
leg.
NOTE!
As the fender brackets are tilted a bit forwards
compared to the original brackets the fender will
be positioned slightly forwards.
SS only
10
11
12
13
The speedometer drive is positioned between the
wheel and the left front fork bottom. The boss
shall be positioned as shown in illustration, when
the motorcycle is equipped with a such.
NOTE!
It might be necessary to grind the speedo-meter
drive according to the illustration, so the speed-
ometer drive not will interfere with the fork bot-
tom.
13
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1
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2
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