Mounting Instructions
Contents
1. 1 Put the motorcycle on a workstand so that the front wheel is off the ground 2 Detach but do not remove the brake caliper on each side of the vehicle let them hang by the brake hoses 3 Remove the front wheel by loosening and remov ing the shaft 4 Remove the front cover 5 Remove the attachments of the lower and the upper triple clamps 6 Remove the original front fork legs by pulling them downwards CAUTION When performing steps 7 10 do not tighten the bolts 7 Install the Caliper brackets to the fork legs use the bolts already installed into the fork bottom 8 Install the Fender brackets to the fork bottom Triple clamp Front fork tube Shaft sleeve Fender PA gt bracket 9 Install the Ohlins front fork legs to the triple clamps Do not tighten until the legs are in cor rect position See Note below NOTE The fork legs should be installed so that the top of the front fork tube is aligned with the top of the triple clamp 10 Tighten the upper triple clamp first Then tighten the lower one to the correct torque Consult your Vehicle Service Manual CAUTION Do not overtighten The lags can be deformed and thereby cause malfunction 11 Reinstall the wheel and the front wheel shaft Do not tighten yet 12 Install the shaft sleeves spacers and nut to the fork bottom of the Ohlins front forks See figure 132. Install the brake calipers on both sides Consult your vehicle service manual Caliper bracket 14 Install the front fender 15 Put the motorcycle back on the ground Apply the front wheel brake and at the same time push the front suspension down two to three times This will put the fork legs in a parallel position NOTE Another way to put the fork legs in a parallel posi tion is to rotate the wheel as fast as possible and then bringing it to a fast stop by braking 16 Tighten the wheel shaft and shaft clamps so that the fork legs are in a fixed position Tighten the fender and caliper brackets Consult your Vehicle Service Manual for torques NOTE Make sure that all bolts are tightened to the cor rect torque and that nothing restrains the front fork when the suspension is compressed or extended Consult the Vehicle Service Manual 17 Read more about the front fork in your Ohlins Owner s Manual
3. result in severe or fatal injury to any one working with inspecting or using this front fork or to bystanders CAUTION Caution indicates that special precautions must be taken to avoid damage to the front fork NOTE Indicates information that is of importance regarding mounting procedures 1 Installing a front fork that is not ap proved by the vehicle manufacturer may affect the vehicle s stability Ohlins Rac ing AB cannot be held responsible for any personal injury or damage that may occur after fitting the front fork 2 The vehicle service manual must be referred to when installing this front fork 3 Please study and make certain you fully understand the mounting instructions and the Owner s manual before handling this front fork If you have any questions regard ing proper installation procedures contact an Ohlins dealer During storage and transport 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 MOUNTING INSTRUCTIONS 1 It is advisable to have an hlins dealer install the front fork 2 Follow the instructions in the vehicle service manual when changing the front fork 3 When working on a raised vehicle make sure that it is securely supported to prevent it from tipping over
4. SET UP DATA Length 743 mm Recommended settings Pin A pe Rebound adjustment 12 clicks pring rate mm Compression adjustment 12 clicks Oil Level 170 mm Spring preload 13 mm ADJUSTMENTS Spring preload Turn the nut at the top of the fork leg Turn clockwise to increase the spring preload turn counter clockwise to decrease it Use a 17 mm wrench 2 Compression damping Adjust at the bottom of the fork leg Use a 3 mm allen key Rebound damping Adjust at the top of the fork leg Turn clock wise to increase the spring preload turn counter clockwise to decrease it NOTE When delivered the Ohlins front fork is dialed to recommended settings for the specific brand and make of the vehicle If you have changed the setting reset according to the following The adjusters have a normal right hand thread Turn clockwise to fully closed Turn counter clockwise to open and count the clicks until you reach the recommended number CAUTION Do not use force delicate sealing surfaces can be damaged Handtighten only Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 www ohlins com Mounting Instructions FG352_1 Issued 2006 08 08 Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Mounting Instru
5. ctions Ohlins Front Fork kit FG352 Before installing this product check the contents of the kit listed below If anything is missing please contact your Ohlins dealer Kit Contents Art No Pcs Front fork 04790 10 1 pair Shaft sleeve 01687 03 2 Caliper bracket RH 01677 42 1 Caliper bracket LH 01677 43 1 Screw MC6S 01046 34 4 Fender bracket LH 01682 29 1 Fender bracket RH 01682 30 1 Nut M24x1 01680 25 1 Spacer 01680 26 2 hlins Sticker 00194 10 2 1 hlins Owner s Manual 07282 04 Before installing Ohlins Racing AB cannot be held responsible for any damage to front fork or the vehicle or injury to persons if the instructions for installing and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to 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 there may be minor differences between your product and this manual Please consult your hlins dealer if you have any questions regarding the contents of the manual ADVANCED SUSPENSION TECHNOLOGY SAFETY PRECAUTIONS Read this manual carefully Pay special attention to statements pro ceded by the following notations A The Safety alert symbol means Attention Your safety is involved Failure to follow these warning instructions may
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