Mounting Instructions
Öhlins front fork kit FGK 121 for Kawasaki ZX6 RR
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Öhlins front fork kit 121
Your Öhlins front fork kit 121 is an upside down
type front fork cartridge 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 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 14 mm wrench.
NOTE!
When delivered the Öhlins front fork kit is dialed
to a standard setting. If you have changed the
settings, 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 8.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
Top nut
Retainer
Spring
Pre-load
tube
O-ring
(338-19)
Öhlins
front fork
cartridge
NOTE!
Apply some grease to the cartridge bottom to keep
the o-ring in position when assembling the fork leg.
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. FGK 121. Issued 05 08 10
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 = ............
Bike on a stand.
F1
R1
Bike on the ground.
F2
R2
Bike with rider on.
F3
R3
Setup data
Spring rate (Öhlins spring 4744-90) 9.0 N/mm
Recommended front fork oil Öhlins 01311-01
(When delivered the front fork kit
is adjusted as follows:)
Compression damping 11 clicks
Rebound damping 11 clicks
NOTE!
When delivered the front fork kit is provided with
a spring with a rate of 9.0 N/mm. An alternative
spring (4744-95), offering a rate of 9.5 N/mm, is
also available.
NOTE!
The oil level is measured with
the spring and the pre-load
tube removed from the front
fork. Recommended oil level
for street use is a distance of
130 mm from the top of the
front fork leg down to the sur-
face of the oil inside.
130 mm
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 kit, that is not approved
by the vehicle manufacturer, may affect the sta-
bility 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 the Mounting Instructions before
handling this front fork kit. If you have any ques-
tions regarding proper installation procedures,
contact an Öhlins dealer or other qualified per-
son.
3. The vehicle service manual must be referred
to when installing the Öhlins front fork kit.
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.
Kit contents
Before installing the front fork kit, please check
the contents of the kit, listed below. If anything is
missing, contact your Öhlins dealer.
Description Pcs. Part No.
Front Fork Kit 1 FGK 121
Sticker Öhlins 2 00192-01
O-ring 2 00338-19
Notes
WARNING!
1. It’s advisable to have an Öhlins dealer
to fit your shock absorber.
2. Instructions in the vehicle service manual are
to be followed when changing the shock
absorber.
3. When working on a lifted vehicle it must be
securely supported to prevent it from falling.
8
Mounting instructions
1
Put the motorcycle on a stand so the front wheel
is in a fixed position. Make sure it’s steadily fixed
so it will not fall over.
2
Remove the fender, the brake calipers and the
front wheel. Refer to procedure according to the
Workshop Manual of the motorcycle.
3
Loosen the triple clamps and remove the fork
legs.
4
Disassemble the fork legs according to the Work-
shop Manual of the motorcycle.
5
Clean all parts thoroughly.
NOTE!
Inspect the inner tubes and bushings for surface
damages and make sure that the seals are not
damaged.
6
Assemble the inner and outer tubes. Apply some
fork oil to the sliding surfaces. See the work shop
manual of the motorcycle for procedures.
7
Place the o-ring on the bottom of the Öhlins car-
tridge by applying some grease to the cartridge
bottom. Fit the Öhlins cartridges. Use the origi-
nal cartridge bolts and washers to fix them into
the fork bottoms. Use cartridge tool (1797-02).
See the workshop manual of the motorcycle for
tightening torque.
8
Pour front fork oil (Öhlins oil 01311-01) into the
fork legs so the level is approxemately 60 mm
above the cartridge cap.
9
To bleed the fork legs, push the shaft to the bot-
tom, and close the rebound valve. Pull the shaft
up again. Repeat this procedure until no air is
trapped in the fork legs.
10
Push the inner tube in and out several times to
make sure that no air is trapped between the fork
tubes.
11
Compress the front fork leg fully and push the
piston shaft down. Fill oil to a level of 130 mm
from the top.
12
Pull the shaft up and close the compression valve,
so the shaft remains in upright position.
Notes
13
Fit the pre-load tube with the plastic guide fac-
ing upwards. Fit the spring and the retainer.
13
14
Fasten the pull-up rod (1765-02) to the shaft and
depress the spring until a 19 mm open ended
spanner can be inserted through the retainer on
to the rod nut.
14
Spring
Guide
Pre-load
tube
Upper
forkleg
Retainer
19 mm
spanner
Pull-up
rod
14
Pull-up
rod
15
Fit the top cap assembly to the shaft. Use a 14
mm key. Tighten to a torque of 40 Nm.
CAUTION
To avoid damages of the needle open the rebound
valve adjuster fully before fitting the top cap.
15
16
Fit the top cap into the fork leg. Tighten gently.
NOTE!
Tighten by hand only. The top nut will be fixed in
position, when the upper triple clamp is tightened.
17
Refit the fork legs to the motorcycle and refit
the wheel, the fender and the brake calipers.
See the work shop manual of the motorcycle
for procedures.
18
Adjust the rebound and compression clickers and
spring pre-load according to the specification
card.
NOTE!
Make sure that all bolts are tightened to the correct
torque and that nothing fouls or restricts movement
of the shock absorber when the suspension is
being fully compressed or extended.
40 Nm
19 mm key
14 mm key
19 mm key
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2
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3
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