Owners Manual
Mounting instruction Öhlins front fork kit
FG 842 for Kawasaki ZX 12R Ninja
© 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 last page.
CAUTION!
Do not use to much force, delicate sealing
surfaces can be damaged.
Spring preload
adjuster
FG 842, Issued 02 08 28
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 13 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 01676-20
Caliper bracket LH 1 01677-23
Caliper bracket RH 1 01677-24
Fender bracket Ring 2 01682-19
Fender bracket 2 01682-20
Fender bracket 2 01678-05
Bracket,
brake hose distributor 1 01688-02
Bolt M10x25 4 04757-01
Bolt M4x14 4 01046-10
Bolt M5x18 4 01046-34
Bolt M6x20 2 05404-03
Screw M4x12 4 00382-04
Allen key 22 mm 1 01862-01
Threaded sleeve 1 01680-10
Sleeve 1 01679-04
Sticker Öhlins 2 00194-10
Owners Manual 1
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 changing
the suspension.
3. When working on a lifted vehicle it must
be securely supported to prevent it from
falling.
6
Mounting instruction
1
Put the bike on a stand so the front wheel
has ground clearance. Make sure it´s stead-
ily positioned and will not fall over.
2
Release the brake caliper on each side and
let them hang by the brake hoses.
3
Remove the front fender.
4
Remove the front wheel, by loosening and
pulling the shaft out.
5
Release the clamping of the front fork legs
in the lower triple clamps and the upper triple
clamps. Pull the fork legs out downwards.
6
Loosen and remove the plastic cover of the
front brake dividing junction. This is carried
out from below. Loosen the brake hose
dividing junction.
7
Loosen the junction bracket and replace it
with the bracket supplied. This is done from
above. Refit the dividing junction and the
plastic cover.
8
Fit the Öhlins front fork legs. Fix them to the
triple clamps. Do not tighten until the legs
are in correct position, see Note!
7
Dividing junction
Bracket
Brake hose to brake lever
Öhlins bracket
View from above
View from below
Brake hose
to wheel
NOTE!
The fork legs are to be mounted so that they
reach against the top of the upper triple
clamp.
9
Tighten first the upper triple clamp then the
lower one to correct torque. See the
motorcycles Workshop manual.
CAUTION!
Do not overtighten. The legs can be deformed
and cause malfunction.
Screw
Plastic cover
8
18
Refit the brake calipers on both sides, with
screws supplied.
19
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.
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.
20
Tighten the wheel shaft and shaft clamps
so the fork legs are in fixed position.
See the Workshop manual.
21
Fit the front fender.
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 motorbike.
22
Continue your work with Owners manual,
read about Adjustments.
5 Nm
7 Nm
25 Nm
5 Nm20 Nm
12
Then open it slightly so it can be pushed to
the fork bottom.
12
10
Fit the brake caliper brackets and the rear
fender brackets with screws supplied.
10
11
13
Bolt the circlip fender bracket to the brake
caliper bracket.
13
11
Fit the circlip model flexible fender bracket
by first pressing it over lower fork leg.
16
17
15
14
Fit the Öhlins sticker to the circlip fender
bracket.
14
15
Fit the front fender brackets with screws
supplied.
16
Fit the threaded sleeve with the two fastening
screws to the left fork bottom and the short
sleeve to the right fork bottom, from outside
of the fork.
17
Refit the wheel and the front wheel shaft.
Do not tighten yet.
Short sleeve
Right fork bottom
-
1
-
2
-
3
-
4
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