Ohlins FGR 156 Manuel utilisateur

Pressurized Front Fork Kit for Kawasaki ZX-6R

FGR 156

Mounting Instructions

Warning!⚠

Only approved Öhlins personnel are permitted

to install this kit. The procedure requires

specic tools. Before you install this product,

read the Öhlins Owner’s manual. This product

is an important part of the vehicle and the

vehicle stability.

Note!1

Before you install this product, check the kit

contents. If anything is missing, please contact

an Öhlins dealer.

Kit Contents

Description Part No Pcs

Front Fork Kit FGR156 1

Sticker Tech. Inside wh 00191-32 2

Sticker Tech. Inside bl 00191-33 2

Spring 10,5N/mm 04744-05 2

Spring 10 N/mm 04744-10 2

Spring 9,5 N/mm 04744-95 2

Owner’s manual 07286-01 1

Plug 21652-02 2

Note!1

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.

Note!1

Please note that there can be small differences

between your product and the images in

these instructions.

Note!1

After this procedure the compression adjuster

will no longer be usable.

Oil, grease and threadlocker

Function grease CaH92 00159-01

Öhlins front fork uid 01309-xx

Threadlocker, high, Loctite 2701 01791-05

Recommended tools

Fork tube tool Ø41 00786-08

Cyl. tube holder Ø36

or Soft jaws 28/36

00787-07

00727-09

Top cap tool 00797-08

Pull-up tool 01765-03

Seal head tool 01797-07

Seal head tool 01797-09

MOUNTING INSTRUCTIONS

Warning!⚠

We strongly recommend to let an Öhlins dealer

install this product.

Warning!⚠

If you work with a lifted vehicle, make sure that it

is safely supported to prevent it from tipping over.

Note!1

When you work with this product, see the

vehicle service manual for vehicle specic

procedures and important data.

Note!1

Before you install this product clean the vehicle.

1 Remove the original front fork

1.1

Put the motorcycle on a work stand 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

Note the fork leg position.

1.5

Loosen the screws to loosen the upper triple

clamp.

1.6

See the vehicle service manual for correct tool

to loosen the top cap ½ turn, do not remove it.

1.7

Loosen the screws to loosen the lower triple

clamp.

1.8

Remove the fork legs.

1/2 turn

1.3

1.5

1.6

1.8

1.2

1.1

1.4

MOUNTING INSTRUCTIONS

2 Disassemble the original front fork

2.1

Loosen the top cap from the outer tube. Pull

down the outer tube.

2.2

See the vehicle service manual for correct tools

to do these steps:

- remove the top cap

- loosen the seal head from the steel tube

- remove the original cartridge

2.3

Remove the upper spring collar and the spring.

2.4

Drain the fork leg from oil and remove the

lower spring collar. Note that the spring collar

can have a different size or shape than the one

in the image.

2.5

Push the outer tube as far up as possible.

Install the fork tube tool (00786-0X) on the

steel tube, close to the outer tube.

Caution!✋

It is important to remove the lock screw in

step 2.6 to prevent damage to the steel tube.

2.6

Apply heat with a heat gun to break down the

threadlocker between the steel tube lock screw

and the fork bottom. See the vehicle service

manual for correct tool to remove the steel tube

lock screw.

2.7

Apply heat with a heat gun to break down the

threadlocker between the steel tube and the

fork bottom. Use the fork tube tool to loosen

and remove the steel tube from the fork

bottom.

Note!1

Do not remove the fork tube tool from the steel

tube yet. You will need it to install the steel tube.

2.8

Remove the O-ring and the steel washer from

the fork bottom. Note that you will not need the

steel washer for the Öhlins kit.

Clean the threads in the fork bottom and on

the inner tube, make sure that there is no

threadlocker left.

2.9

See the vehicle service manual for correct

tool to loosen the spring preload adjuster on

the fork bottom. Remove the spring preload

adjuster parts.

2.2 2.3

2.4

2.5

2.9

2.6

3 Install the Öhlins front fork cartridge kit

Caution!✋

We strongly recommend that you work with

one leg at a time, make sure not to mix the

parts.

Caution!✋

The kit consists of one compression cartridge

and one rebound cartridge. Note the marks.

Make sure you install the cartridge in the

correct fork leg;

REB (Rebound) in the right fork leg.

COMP (Compression) in the left fork leg.

3.1

Remove the top cap.

3.2

Remove the spring support and the preload

tube.

3.3

Use the seal head tool (01797-07) and the

cylinder tube holder (00787-07) or the soft

jaws (00727-09) to 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.

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.

3.1

3.2

3.3

seal head

cylinder

tube

extension

3.4

Remove the steel adaptor from the cylinder

tube adaptor.

3.5

Apply function grease (00159-01) on the

original O-ring and insert it in the fork bottom.

3.6

Insert the steel adaptor in the fork bottom.

Caution!✋

Make sure to install the adaptor correctly. See

gure.

Note!1

Do not install the original steel washer removed

in chapter 2.

3.7

Apply function grease (00159-01) on the O-ring

and install the plug provided in the kit. Tighten

to 12 Nm.

3.8

Apply threadlocker (01791-05) on the steel

tube. Tighten to 130 Nm.

3.9

Apply threadlocker (01791-05) on the steel

tube lock screw. Tighten to 3 Nm.

3.10

Carefully insert the cartridge in the fork

leg. Apply [moly-grease or equivalent] on

the adaptor thread. Use the seal head tool

(01797-09) to install the cartridge into the front

fork and tighten to 30 Nm.

Note!1

Make sure that the seal head tool clamps

around the seal head and the cylinder tube

extension.

3.4

3.7

3.10

3.9

3.5 3.6

3.11

Use the seal head tool (01797-07) to tighten

the seal head to the cylinder tube extension.

Tighten to 20 Nm

3.12

Pour 0,5 litre Öhlins Front Fork fuid (01309-xx)

in the fork leg. See setup data and the oil level-

force diagram in this folder.

3.13

Put the preload tube and the spring on top of

the cartridge.

3.14

Fasten the pull-up tool (01765-03) at the top of

the shaft extensioner. Install the spring support

by leading it over the tool.

3.15

Pull up the shaft assembly and use a 19 mm

wrench to grab the spring support.

3.16

Open the compression and the rebound

adjuster fully. Remove the pull-up tool and

install the top cap to the shaft extensioner.

Tighten to 15 Nm

3.17

Pull up the outer tube. Make sure the fork leg is

in a fully extended position.

Use the top cap tool (00797-08) and tighten the

top cap to the outer tube to 10 Nm.

3.18

Set the spring preload, rebound and

compression adjusters according to the setup

data in this manual.

3.11 3.12

3.13

3.14

Spring

Preload

tube

3.15

3.16 3.17

3.19

Install the front fork legs into the triple clamps

at the fork leg position recommended in the

setup data. Tighten according to the vehicle

service manual.

Note!1

Measure the fork leg extension from the upper

triple clamp to the top of the outer tube.

3.19

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00

fax +46 8 590 025 80

reserved. Any reprinting or

unauthorized use without the written

permission of Öhlins Racing AB

is prohibited.

Öhlins 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.

To nd the latest information

contact an Öhlins distributor.

Please contact Öhlins if you have

any questions regarding the

contents in this document.

SETUP DATA

Warning!⚠

Before you ride/drive, always make sure that the

setup is according to the recommended setup

data. Read about adjustments and setting up

in the Öhlins Owner’s Manual before you make

any adjustments. Contact an Öhlins dealer if

you have any questions about setting up.

Part no. MI_FGR156_2

Issued 2014-02-18

Compression 10 clicks

Rebound 8 clicks

Spring rate 9.5 N/mm

Spring preload 6 mm

Oil level 200 mm

Fork leg position Standard

Oil level - Air spring force Diagram

Air spring for one front fork leg

Oil level [mm]

100

150

200

250

300

350

400

450

500

0102030405060708090 100 110 120 130

Stroke [mm]

Force [N]

120

130

140

150

160

170

180

190

200

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