FGR 151 - Ohlins
Contents
1. s ae A Warning Note This kit should only be installed by an Please note that during storage and 200 A authorized hlins dealer The installation transportation especially at high ambient 150 procedure requires certain tools temperature some of the oil and grease 100 Before installing this product read this used for assembling may leak and stain the document and the Owner s Manual The packaging This is in no way detrimental to the front fork is an important part of your vehicle product wipe off the excessive oil grease with i 0 10 20 30 40 50 si 70 80 90 100 110 i20 130 ang bull gee a stability a cloth Stroke mm hlins 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 hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited To find the latest information contact an hlins distributor Please contact hlins if you have any questions regarding the contents in this document Part no FGR151_1 Issued 2011 11 03 hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 Pressurized Front Fork Kit for Yamaha R1 FGR 151 Mounting Instructions Je Y 7 3 Iso 9001 ENG f ADVANCED SUSPENSION2. Put the preload tube and the spring on top of the cartridge See set up data in this folder for the available springs 3 8 Fasten tool 01765 03 at the top of the shaft extensioner Install the spring support by leading it over the tool 3 9 Pull up the shaft assembly and grab the spring support with a 19 mm wrench 3 10 Open the compression and the rebound adjuster fully Remove the pull up tool and install the top cap to the shaft extensioner Tightening torque 15 Nm 3 11 Pull up the outer tube Make sure the fork leg is in a fully extended position Use tool 00797 08 to tighten the top cap to the outer tube Tightening torque 10 Nm 3 12 Set the spring preload rebound and compression adjusters according to set up data in this manual Read more about adjustments in the Owner s Manual Spring Preload tube 2 1 Loosen the top cap from the outer tube 2 2 Pull down the outer tube 2 3 Use appropriate tool according to your vehicle service manual Remove the top cap by loosening it from the shaft 2 4 Remove the spring and surrounding parts from the fork leg 2 5 Drain the fork leg from oil 2 6 Use tool 04702 04 Loosen the cartridge 2 7 Remove the cartridge from the fork leg Note If the cylinder tube does not follow with the cartridge kit follow these steps 2 8 Remove the outer tube 2 9 I
3. TECHNOLOGY ADVANCED SUSPENSION TECHNOLOGY www ohlins com A Warning It is advisable to have an Ohlins dealer install the front fork A Warning Make sure the vehicle is securely supported so that it will not tip Note When installing read Vehicle Service Manual 1 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground 1 2 Remove the front fender the brake calipers and the front wheel 1 3 Release the spring preload 1 4 Loosen the upper fork triple clamp by loosening the screws 1 5 Loosen do not remove the top cap turn 1 6 Loosen the lower triple clamp by loosening the screws 1 7 Remove the front fork legs from the triple clamp VEHICLE SERVICE MANUAL 3 13 Install the front fork legs into the triple clamps at the position recommended in set up data Fork leg position Tightening torque according to Vehicle Service Manual Note Measure the fork leg position from the upper triple clamp to the top of the outer tube Fork leg position 3 5 Tighten the seal head to the cylinder tube extension using tool 01797 07 Tightening torque 20 Nm 3 6 Pour Ohlins Front Fork fuid into the fork leg and set the oil level See set up data and oil level force diagram in this folder Note Pour the oil slowly and make sure that there are no bubbles in the fork leg 3 7
4. A Warning Recommended set up Before installing this product check the contents of the kit If anything is missing please contact an Ohlins dealer Kit Contents PartNo Pcs Before riding always make sure that the Compression 14 clicks Front fork kit FGR151 1 basic settings made by hlins are according Rebound 14 clicks hlins Sticker 60x23 white 00191 32 2 to recommended Set up Data Read about Spring rate 10 N mm hlins Sticker 60x23 blue 00191 33 2 adjustments and setting up in the hlins Spring preload 6 mm Shim 00520 32 2 Owner s Manual before you make any Oil level 160 mm Spring 10 5N mm 04744 05 2 adjustments Contact an hlins dealer if you Fork leg position Standard position Spring 10N mm 04744 10 2 have any questions about setting up the shock Ohlins Front Fork Fluid part no 01309 01 Spring 9 5N mm 04744 95 2 absorber Owner s Manual 07286 01 1 Recommended Tools Cylinder tube holder 36 00787 07 or Soft jaws 28 36 00727 09 Po Top cap tool 00797 08 Oil level mm g Pull up tool 01765 03 i Seal head tool 01797 07 550 130 By oe Seal head tool 01797 09 so Air spring for one front fork leg 140 Cartridge tool 04702 04 Fork tube tool 00786 05 450 160 j i 400 170 Note Z350 180 S Please nore that after this installation the g n 190 compression adjuster will no longer be useful
5. l easier Note When mounting make sure that the shim stays in place 3 5 Use tool 01797 09 Install the cartridge into the front fork Smear moly grease or equivalent grease on the adaptor thread Tightening torque 30Nm Note Make sure that tool 01797 09 grips both the seal head and the cylinder tube extension asan SO 0 gt
6. nstall tool 00786 05 43 on the steel tube above the holes Loosen the steel tube from the fork bottom Note Use a heat gun to soften the Loctite between the steel tube and the fork bottom Note Do not remove tool 00786 05 from the steel tube yet You will need it to reinstall the stel tube 2 10 Use appropriate tool 34 and remove the cylinder tube 2 11 Use tool 00786 05 Reinstall the steel tube Loctite 2701 Tightening torque 130Nm Wa Caution Do not mix the parts Work with only one fork leg at a time M Caution The front fork kit is divided into one compression cartridge and one rebound cartridge Make sure to install cartridge marked Reb Rebound in the right side fork leg Comp Compression in the left side fork leg 3 1 Remove the top cap 3 2 Remove the spring support and the preload tube 3 3 Loosen the seal head from the cylinder tube extension just enough to align the grooves on the seal head with the grooves on the cylinder tube extension Use tool 01797 07 and 00787 07 or 00727 09 M Caution Do not loosen the seal head more than is necessary to align the grooves If you loosen the seal head too much the oil may leak 3 4 Use a small dab of grease to attach the shim provided in this kit to the bottom of the adaptor This to avoid the cartridge unit seizing in the fork bottom and making remova
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