FGK 202 - Mecadata
Contents
1. Do not mix the parts m Caution The front fork kit is divided into one compression cartridge and one rebound cartridge Important e Install the cartridge marked Reb Rebound in the right side fork leg e Install the cartridge marked 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 Remove the cylinder tube from the cartridge tt Caution Be careful not to damage the piston ring 3 4 Put the cylinder tube carefully into the fork leg Use an extended 17 mm allen key to tighten the cylinder tube s adaptor to the fork bottom Apply Loctite 243 on the adaptor s thread Torque 40 Nm m Caution Be careful not to damage the inside of the cylinder tube when tightening with the extended allen key 3 5 Pour 0 5 litre hlins Front Fork fuid into the fork leg 3 6 Put the cartridge carefully in the fork leg Tighten to the cylinder tube with tool 01797 07 Apply red grease on the seal head s thread Torque 20 Nm M Caution Make sure that the piston ring is in its correct position and be careful not to damage it mi E a m cy Spring Vs a support FPreload tube2. Recommended set up Compression Rebound Spring rate Spring preload Oil level Fork leg position 10 clicks 12 clicks 9 5 N mm 12mm 160 mm Before installing this product check the contents of the kit If anything is missing please contact an Ohlins dealer Kit Contents 1 ring Ohlins Front Fork Fluid part no 01309 01 800 Part No Pcs Front fork kit FGK202 Ohlins Sticker 60x23 white 00191 32 Ohlins Sticker 60x23 blue 00191 33 Owners manual 07284 01 NNa A Warning caer 2 This kit should only be installed by an authorized 750 Oil level Ohlins dealer The installation procedure requires 700 mm certain tools i 650 120 Please note that during storage and 600 Air spring for one front fork leg 550 130 transportation especially at high ambient bo r 150 temperature some of the oil and grease used for 500 assembling may leak and stain the packaging 450 Ey 2 This is in no way detrimental to the product 400 wipe off the excessive oil grease with a cloth Force N 350 180 300 190 A Warning 250 200 Before installing this product please read this 200 210 document The front fork is an important part of 150 100 50 hlins products are subject to continuous improvement and development t
3. See set up data and oil level force 1 3 diagram in this folder y Preload tube Release the spring preload 3 11 Ta Fasten tool 01765 03 on the top of the shaft i ih kinei Bal extensioner install preload tube spring and COSOM iNO peer MPE Camp By oeSanng the screws upper spring support by leading them over the tool See the Owner s Manual for available 1 5 springs Loosen do not remove the top cap turn 3 12 1 6 Pull up the shaft assembly and grab the Loosen the lower triple clamp by loosening spring support with a 19 mm wrench the screws 3 13 1 7 Make sure that the comp rebound adjusters Remove the front fork legs from the fork triple are fully open before installing the top cap clamps Remove the pull up tool and install the top cap to the shaft extensioner Torque 15 Nm 3 14 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 Torque 10 Nm S Z 1 2 turn 2 1 Loosen the top cap from the outer tube 2 2 Pull down the outer tube 2 3 Remove the top cap by loosening it from the shaft Use appropriate tool according to your vehicle service manual 2 4 Remove the spring and surrounding parts from the fork leg drain the fork leg from oil 2 5 Loosen the cartridge Use tool 04702 04 2 6 Remove the cartridge from the fork leg m Caution Work with only one fork leg at a time
4. herefore 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 22 your vehicle and will affect the stability Note oe Please note that after this installation the 50 60 70 80 90 100 Stroke mm To find the latest information contact your Ohlins distributor Please consult your Ohlins dealer if you have any questions regarding the contents in this document Part no FGK202_3 Issued 2011 01 20 Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 af compression adjuster at the fork bottom will no longer have a function 110 120 130 Front Fork Kit for Yamaha RG Mounting Instructions ADVANCED SUSPENSION TECHNOLOGY www ohlins com ADVANCED SUSPENSION TECHNOLOGY Note The front fork is a very important part of the vehicle and will therefore affect the stability Read and make sure that you understand the information in this manual before you use this product If you have any questions regarding installation or maintenance please contact your nearest Ohlins dealer Ohlins Racing AB can not be held responsible for any damage to the front fork vehicle other proper
5. the written permission of Ohlins Racing AB is prohibited Printed in Sweden Tool 01797 07 Tool 04702 04 3 15 Set the spring preload rebound and compression adjusters according to adjustments and set up data in this manual 3 16 Install the front fork legs into the triple clamps at the position recommended in set up data Fork leg position Tightening torque According to your vehicle service manual Note Fork leg Measure the fork leg position from the upper position triple clamp to the top of the outer tube 3 7 A Warning Openihe comprescion and te tepaurid It is advisable to have an Ohlins dealer install the SERVICE adjuster fully Install the top cap directly to the front fork MANUAL shaft extension No spring or preload tube Pull up the outer tube and tighten it to the top cap Handtighten only When installing consult your Vehicle Service Manual 1 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground 3 8 Pump out all air from the cartridge by pulling the outer tube up and down 10 15 times 3 9 A Warning Remove the top cap from the fork leg Make sure the vehicle is securely supported so 3 10 that it will not tip 1 2 Remove the front fender the brake calipers and the front wheel Make sure 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
6. ty or injury to persons if the instructions for installing and maintenance are not followed exactly A Warning This product was developed and designed exclusively for a specific vehicle model and should only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability Note When working on this product always consult your Vehicle Service Manual This Manual should be considered as a part of the product and should therefore accompany the product throughout its life cycle Tool 00797 08 Tool 01765 03 Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distinguished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the front fork or to bystanders We Caution The Caution Symbol means Special precautions must be taken to avoid damage to the front fork Note The Note Symbol indicates information that is important regarding procedures Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without
Download Pdf Manuals
Related Search