Ohlins FG896 Mounting Instruction

Brand: Ohlins

Model: FG896

Category: Motorcycles

Type: Mounting Instruction

Owners Manual

Mounting instruction Öhlins front fork kit

FG 896 for Kawasaki ZX 9R

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.

Bike on the ground.

Bike with rider on.

Set-up data:

Length 730 mm

Stroke 120 mm

Rebound adjustment 12 clicks

Compression adjustment 10 clicks

Preload 13 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 896. Issued 02 04 03

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 01676-09

Caliper bracket LH 1 01677-19

Caliper bracket RH 1 01677-20

Fender 1 04782-01

Fender bracket 2 01678-01

Fender bracket 2 01682-01

Fender bracker ring 2 01682-06

Bolt M8x25 4 01046-03

Bolt M6x55 2 01046-39

Bolt M6x40 1 01046-09

Bolt M6x25 1 01046-17

Bolt M6x22 6 01046-05

Bolt M4x14 4 01046-10

Nut M6 2 00437-01

Screw M4x12 4 00382-04

Washer 6,4/12/1,5 2 00153-04

Shaft sleeve 1 01680-09

Fork crown upper 1 01690-07

Spacer 25/32/2 1 01952-03

Handle bar holder LH 1 04786-01

Handle bar holder RH 1 04786-02

Sticker Öhlins 2 00194-10

Owners Manual

20 Nm

25 Nm

5 Nm

7 Nm

Spacer 01952-03

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

Put the bike on a stand so the front wheel has

ground clearance. Make sure it is steadily

positioned and will not fall over.

Remove the upper fairing with windscreen. See

the Owners manual of the motorcycle.

Remove the rear and front seats.

Loosen the bolts (4) of the fuel tank. Turn the fuel

valve to off and remove the knob. Lift the tank

up, release the fuel hose and lift the tank off.

Disconnect the ignition lock from the electronic

box . The connection is positioned to the left

above the intake air filter box. Release the cable

to the ignition lock forwards.

Loosen end remove the spoiler, fitted to the lower

triple clamp, under the air intake. The bolts are

accessible from above.

Loosen the front brake fluid reservoir and the

bracket.

Loosen the brake handle and release the brake

light switch connection. Let the handle hang

down forwards. together wit the brake fluid

reservoir.

Apply the Öhlins sticker to the circlip bracket.

Fit the two forward fender brackets with bolts

supplied.

NOTE!

The front fender bracket shall be positioned with it´s

longer part from the attachment plate downwards.

Fit the new front fender. Use the bolts supplied.

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.

Tighten the wheel shaft and shaft clamps so the

fork legs are in fixed position.

Refit the spoiler to the lower triple clamp. Use

the spacers provided.

Fit the spacer to the wheel shaft.

Refit the wheel and the front wheel shaft. Do not

tighten yet.

Fit the brake calipers on both sides. Use the

standard bolts.

Lower the motorcycle. Brake the front wheel and

push the front suspension down, two or three times.

This will put the fork legs in a parallel position.

Reconnect the ignition lock to the electronic box

and refit the brake fluid reservoir and its bracket.

Refit the fuel tank and the fuel valve device. Fix

the four bolts.

Put the upper fairing back.

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 Workshope manual of the motorbike.

Continue your work according to Owners manual,

read section Adjustments.

Loosen the brake calipers on each side of the

wheel. Remove the whole cluster with calipers,

brake handle and brake fluid reservoir.

Loosen the bolts holding the wheel shaft and

unscrew the shaft with a 22 mm allen key.

Remove front fender.

Loosen the handlebars from the clip-on brackets

and pull them out.

Loosen the fork legs from lower and upper triple

clamps and the clip on handlebars. Pull them out

downwards.

NOTE!

These bolts are secured with Loctite and must

be heated before loosening.

Loosen the center nut holding the upper triangle

clamp. Turn the triple clamp to the right and pull

it off upwards.

Loosen the two adjuster nuts holding the steering

column and pull the lower triple clamp downwards.

Release the ignition lock from the upper triple clamp.

The screws are designed not to be released. Cut a

slot with a chisel and use a screwdriver to loosen

the ignition lock.

Fit the ignition lock to the Öhlins upper triple

clamp. Use spacers and bolts provided.

Fit the Öhlins clip-on handlebar brackets to the

downward side of the upper triple clanp

Fit the steering stops to the Öhlins lower triple

clamp. Fit the lower bearing ring from the original

triple clamp.

Install the Öhlins lower triple clamp with steering

column, refit the adjustment nuts and tighten

them to correct torque.

Fit the Öhlins upper triple clamp and fit the original

center nut. Do not tighten yet.

Reinstall the handlebars. Use Loctite to secure

them into the brackets.

NOTE!

The fork legs are to be mounted so The first

groove is to be aligned with the top of the upper

triple clamp.

Fit the brake caliper brackets with screws

supplied. Fit the small rear fender brackets onto

the caliper brackets.

Fit the circlip model flexible fender bracket by

first pressing it over lower fork leg.

CAUTION!

Be careful not to bend or break the flexible fender

bracket.

Then open it slightly so it can slide to the fork

bottom.

Fit the Öhlins fork legs to the triple clamps.

Tighten the triple clamps and the clip-on

brackets. Tighten the center nut holding the upper

triple clamp. Thightening torque 80 Nm.

Bolt the circlip fender bracket to the brake

caliper bracket.

NOTE!

Tighten first the upper triple clamp than the lower

one to correct torque.

Upper bolts 15 Nm Lower bolts 15 Nm

CAUTION!

Do not overtighten. The legs can be deformed

and cause malfunction.

Fit the sleeve with the two fastening screws to

the left lower leg

Ohlins FG896 Mounting Instruction

Brand: Ohlins

Model: FG896

Category: Motorcycles

Type: Mounting Instruction

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Ohlins FG896 Mounting Instruction

Ohlins FG896 Mounting Instruction

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