Owners Manual
Mounting instruction Öhlins front fork kit
FG 848 for Buell XB9R
© 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 page 8.
CAUTION!
Do not use to much force, delicate sealing
surfaces can be damaged.
Spring preload
adjuster
FG 848, issued 03 04 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 adjustment 12 clicks
Compression adjustment 10 clicks
Preload 10 mm
Spring rate 9,5 N/mm
Oil level 85 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 1 pair 01676-17
Screw MF6S M5x18 4 00382-15
Caliper bracket 1 01677-25
Fender bracket 2 01678-09
Fender bracket ring 2 01682-23
Sleeve M24x2 1 01679-07
Sticker Öhlins 2 00194-10
Owners Manual
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.
Mounting instructions
1
Lift up the motorcycle so that the front wheel
is free. Ensure that the motorcycle is
properly secured and cannot fall over.
2
Remove the front fender by loosening the
four screws.
3
Release the radiall brake caliper on the right
fork leg and let it hang by the brake leads.
4
Remove the wheel axle, by loosening the
clamping screw on the left side and then
screw out the wheel axle. Lift out the front
wheel.
NOTE!
The thread of the wheel axle is left handed.
5
Release the fasteners of the fork legs in the
triple clamps and loosen the screws on the
clip-on handles.
6
Pull the fork legs out downwards and fit Öhlins
fork legs to the triple clamps. Tighten the screws
in the fork crowns and the clip-on handles.
6
NOTE !
The fork legs are to be mounted so that the
top of the front fork tube is aligned in height
with the top edge of the triple clamp.
The top of the front fork tube (not top nut)
must be aligned with the surface of the triple
clamp.
NOTE !
Tighten the screws to a maximum torque of
15 Nm. If screws in the lower triple clamp
are tightened too hard they can deform the
fork tube and impair the spring action.
Notes
7
Fit the Öhlins brake caliper bracket to the
right fork leg. The caliper is positioned over
the fork leg bottom attachments and must
be alligned with the shaft tunnel on the inside
of the leg.
10
Fit the sticker to the fender bracket.
8
Fit the circlip model flexible fender bracket
by first pressing it over lower fork leg.
9
Then open it slightly so it can be slided down
all the way to the fork bottom.
7
8
9
10
20 Nm
5 Nm
25 Nm
16
Then tighten the clamping screws on the
right fork leg so that the fork legs are fixed
in position.
11
11
Fit the front fender bracket and the front fender.
12
12
Fit the threaded sleeve (1679-07) to the right
fork leg.
13
Reassemble the wheel and the wheel axle.
Do not tighten yet.
NOTE!
The thread of the wheel axle is left handed.
14
Fit the radiall brake caliper.
15
Lower the motorcycle so that the front
suspension works. Brake the front wheel
and push the front suspension down two or
three times. This will put the fork legs in a
parallel position.
17
Continue your work according to the Owners
Manual, section Adjustments.
16
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 motorcycle..
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