FGK 236 - Ohlins
Contents
1. Note Kit Contents Description Part No Pcs Front fork kit FGK236 1 Ohlins sticker 60x23 wh 00191 32 2 Ohlins sticker 60x23 blue 00191 33 2 Owner s manual 07284 01 1 A Warning This kit should only be installed by an authorized Ohlins dealer The installation procedure requires certain tools Note Please note that there can be small differences between your product and the images in these instructions Before you install this product check the kit contents If anything is missing please contact an Ohlins dealer Note A Warning Please note that during storage and transport especially at high ambient temperature some of the oil and grease used for assembly may leak and stain the packaging This will not cause damage to the product wipe off the excessive oil or grease with a cloth Before you install this product read the Ohlins Owner s manual and this document This product is an important part of the vehicle and the vehicle stability Front Fork Kit for BMW R1200R FGK 236 Mounting Instructions ADVANCED SUSPENSION TECHNOLOGY Tools needed for the original front fork VIOUN N ON TOOLS GREASE AND FLUID Grease and fluid Refer to the vehicle service manual for tools needed for removing installing the front fork F nctiongrease 00159 02 from the vehicle hlins front for2. fully extended position Use tool 00797 08 to tighten the top cap to the outer tube Tighten to 10 Nm 3 14 Set the spring preload rebound and compression adjusters see setup data in this manual Use a 3 mm Allen key for the compression and rebound bleed adjusters Use a tool 14 mm socket for the preload adjuster 3 15 Install the front fork legs into the triple clamps at the position recommended in setup data Fork leg position See the vehicle service manual for correct procedure and tightening torque Note Measure the fork leg position from the upper triple clamp to the top of the outer tube SETUP DATA Compression 12 clicks Rebound 12 clicks Spring preload 9 mm Oil level 130 mm Fork leg position hlins front fork fluid Standard position 01309 01 SPRING RECOMMENDATION Part No Spring rate N mm 08423 90 9 0 Ohlins products are subject to continuous improvement and development therefore although these instructions include the most up to date information available at the time of printing minor updates may occur Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited To find the latest information contact an Ohlins distributor Please contact Ohlins if you have any questions regarding the contents in this docu
3. anual for correct torque 3 5 Pour 0 5 litre Ohlins Front Fork fluid into the fork leg 3 6 Use a 3 mm Allen key to open the compression and the rebound bleed adjusters fully Install the top cap directly to the shaft extension No spring or preload tube Pull up the outer tube and tighten it to the top cap Only tighten with your hand 3 7 Pull the outer tube up and down 10 15 times to pump out all air from the cartridge 3 8 Remove the top cap from the fork leg 3 9 Make sure that the shaft assembly is in the bottom of the fork leg and that the outer tube is in its bottom position Measure the oil level with a ruler See setup data and oil level force diagram in this folder 3 10 Attach tool 01765 03 on the top of the shaft extension Install preload tube A spring B upper spring support C See the Owner s Manual for available springs 3 11 Pull up the shaft assembly and grab the spring support with a 19 mm wrench 3 12 Make sure that the compression rebound adjusters are fully open before installing the top cap Use a 3 mm Allen key to open the compression and rebound bleed adjusters Use a tool 14 mm socket for the preload adjuster Remove the pull up tool and install the top cap to the shaft extension Tighten to 15 Nm 3 13 Pull up the outer tube Make sure the fork leg is in a
4. k fluid 01309 01 Refer to the vehicle service manual for tools needed for removing the cartridge from the front fork Tools needed for the hlins cartridge Allen key 8 mm bottom screw 19 mm wrench shaft extension 3 mm Allen key compression and rebound bleed adjusters 14 mm socket preload adjuster Ruler oil level Ohlins tool 01765 03 shaft extension Ohlins tool 00797 08 top cap VIOUN LIN 1 Remove the original front fork A Warning We strongly recommend to let an Ohlins dealer install this product A Warning If you work with a lifted vehicle make sure that it is safely supported to prevent it from tipping over Note When you work with this product see the vehicle service manual for vehicle specific procedures and important data Note Before you install this product clean the vehicle 1 1 Put the motorcycle on a work stand so that the front wheel barely touches the ground 1 2 Remove the front fender brake calipers and the front wheel 1 3 Release the spring preload 1 4 Loosen the screws to loosen the upper triple clamp 1 5 Loosen do not remove the top cap turn 1 6 Loosen the screws to loosen the lower triple clamp 1 7 Remove the front fork legs from the triple clamps VIOUN LIN 2 Disassemble the original front fork 2 1 Loosen the top cap from the ou
5. ment Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 Part no MI_FGK236_0 Issued 2015 05 20 ADVANCED SUSPENSION TECHNOLOGY www ohlins com
6. ter tube 2 2 Pull down the outer tube 2 3 Loosen and remove the top cap from the shaft see the vehicle service manual for correct tool 2 4 Remove the spring and surrounding parts from the fork leg Note that the 2 plastic tubes shall not be removed see position A in the figure A Warning It is important that the two plastic tubes inside the outer tube are not removed since this may cause the front fork to work improperly and therefore risk of danger when using the product 2 5 Drain the fork leg from oil 2 6 Loosen the cartridge see the vehicle service manual for correct tool 2 7 Remove the cartridge from the fork leg coco VIOUN N 3 Install the Ohlins front fork kit Ww Caution Do not mix the parts Work with only one fork leg at a time Ww Caution The front fork kit consists of one compression cartridge and one rebound cartridge Important e Install the cartridge marked Comp Compression in the left side fork leg Install the cartridge marked Reb Rebound in the right side fork leg 3 1 Remove the top cap 3 2 Remove the spring support and the preload tube 3 3 Insert the cartridge in the fork leg Make sure that the adapter connects properly to the fork bottom 3 4 Apply threadlocker on the screw see the vehicle service manual Use an Allen key 8 mm to tighten the screw see the vehicle service m
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