Ohlins FGR 156 User manual

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

2
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

3
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

4
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

5
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

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

7
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 [phone]
fax [phone]
© Öhlins Racing AB. All rights
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]
0
50
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