ADJ UST MENT S
Spring preload adjuster
1
Adjust by turning the nut on the top of the fork
leg. Turn clockwise to increase and counter
clockwise to decrease the spring preload.
Mounting instructions
1
Öhlins Front fork kit FGK132
for Suzuki GSX-R600/750
Increase
Decrease
Rebound damping adjuster
2
This kit should only be installed by an
Öhlins dealer. The installation procedure
requires certain Öhlins tools.
Adjust by turning the screw with an allen key.
Compression damping adjuster
3
Adjust by turning the screw with an allen key.
Reset according to the following:
2
Öhlins Racing AB can not be held responsible
for any damage to the front fork kit, 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.
3
The adjusters have a normal right hand thread.
Turn the damping adjuster clockwise to fully close
(pos. zero [0]). To open, turn the damping adjuster
counter clockwise - count the clicks or turns from
fully closed until you reach the recommended
setting. See Set-up data in this manual.
Caution!
Kit Contents
Do not use force, delicate sealing surfaces can
be damaged.
Front fork kit
Öhlins stickers 47x125
Öhlins stickers 28x74
Base Plug M12x1.25
D I A GRAM: O i l level - f orce
500
Oil level [mm]
450
140
425
150
400
160
375
170
350
180
Force [N]
325
300
190
275
200
250
210
225
220
200
230
175
240
150
125
100
75
50
25
0
0
10
20
30
40
50
60
Stroke [mm]
70
80
90
100
110
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00. Fax +46 8 590 025 80.
www.ohlins.com
120
Recommended tools
Mounting instruction FGK 132_2 Issued 20080918 Öhlins Racing AB
475
FGK132 (1)
00192-01 (2)
01196-02 (2)
03324-01 (2)
Tool 01765-03
Tool 00797-01
Tool 01797-07
Tool 00787-03
GSXR750 from
2008 Only
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
SAFET Y PR ECA UT IO NS
WARNING!
Read this manual carefully!
1. Installing a front fork kit, that is not
approved by the vehicle manufacturer,
may affect the vehicle’s stability. Öhlins
Racing AB can not be held responsible for any
personal injury or damage that may occur after
installing the front fork kit.
Pay special attention to statements
proceded by the following notations:
The Safety alert symbol means: Attention!
Your safety is involved!
2. The vehicle service manual must be
referred to when installing this front fork kit.
WARNING
Failure to follow these warning instructions
may result in severe or fatal injury to
anyone working with, inspecting or using
this front fork kit, or to bystanders.
3. Please study and make certain you fully
understand the mounting instructions before
handling this front fork kit. If you have any
questions regarding proper installation
procedures, contact an Öhlins dealer.
CAUTION!
Caution indicates that special precautions
must be taken to avoid damage to the
front fork kit.
NOTE!
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, there may be minor differences
between your front fork kit and this manual.
Please consult your Öhlins dealer if you have
any questions regarding the contents of this
manual.
NOTE!
Indicates information that is of importance
regarding mounting procedures.
C HE C K S A G AND R I DE HEI G H T
Before riding your bike, check sag and ride height according to the procedure below. To get the
most out of your suspension component it is of great importance to make the proper settings.
See Set-up data below and Adjustments on the next page.
F1
R1
F2
R3
R2
Bike on a stand
F3
Bike on the ground
Bike with rider
Front suspension
Rear suspension
F1 Bike on a stand with the
suspension fully extended= . ...........
R1Bike on a stand with the
suspension fully extended
F2 Bike on the ground without rider= ............
R2Bike on the ground without rider= ............
F3 Bike on the ground with rider= ............
R3Bike on the ground with rider= ............
Free sag
Ride height
F1 - F2= . ...........
Free sag
Ride height
F1 - F3= . ...........
=. ............
R1 - R2= . ...........
R1 - R3= . ...........
S ET- UP D ATA
1
Recommended settings:
Recommended sag and ride height:
Rebound adjustment
Compression adjustment
Spring preload
Oil level Öhlins oil part No.
The measures should not differ from the
following recommendations:
13 clicks
1 turn
8 mm
190 mm
01309
6
Without rider:
Rear
Front
10 - 20 mm (R1-R2)
20 - 30 mm (F1-F2)
With rider:
Rear
Front
25 - 40 mm (R1-R3)
35 - 50 mm (F1-F3)
M OUNTI NG I NST R UCT I ONS
M OUNT I NG I N ST R U CTIONS
19
Suzuki GSX-R750 from 2008 only
Make sure the shaft is in the bottom of the fork
leg and that the outer fork leg is in the bottom
position. Measure the oil level with a scale.
Recommended setting according to chapter
Set-up data and Diagram: Oil level-force.
•
XXX mm
•
Tool
1765-03
20
Fig.19
Put the preload tube and the spring on top of
the cartridge.
Spring
support
GSX-R750 from 2008 and forward: Before
you begin the installation of the Front Fork
kit FGK 132 you must replace the base plug
due to a different thread in the plug.
GSX-R600 and GSX-R750 models from
2007 and before: Go to page 3.
Replace the Base Plug
Fig.1
1
21
Install the cylinder tube in a vice, use Cylinder
Tube Holder 00787-03.
Spring
Fasten tool 1765-03 on the top of the shaft.
Install the spring support by leading it over the
tool.
2
22
Fig.2
Remove the base valve assembly from the
cylinder tube.
Pull up the shaft with tool 1765-03 and grab
the spring support with a 19 mm wrench.
Note!
Preload
tube
23
Remove the pull-up tool and install the top cap
to the shaft. Tighten with torque 15 Nm.
Use a heat gun to loosen the loctite between the
cylinder tube and the base plug.
3
Fig.20
24
Pull up the outer fork leg. Make sure the fork
leg is in a fully extended position. Use tool
0797-01 to tighten the top cap. Tighten the top
cap with torque 10 Nm.
Spring
support
Fig.21
Shaft
19 mm
wrench
25
Set the spring preload, rebound and
compression adjusters according to
Adjustments and Set-up data in this
manual.
Fig.22
Top cap
26
15 Nm
Install the front fork legs into the fork crowns.
Tighten the upper fork crown with torque 20
Nm, and the lower fork crown with torque 10
Nm.
Move the piston and shims from the standard
base plug to the GSX-R750 base plug.
Piston assembly nut tightening torque 7 Nm.
Loctite 222.
Note!
Fig.3
Make sure you install the piston assembly with
surrounding parts in the correct order.
4
Base Plug
(GSX-R750
from 2008)
03324-01
(M12x1.25)
Install the base valve assembly in the cylinder
tube. Tightening torque 20 Nm. Loctite 2701.
Continue on page 3.
Fig.4
Fig.23
NOTE!
It is very important that the front fork are in the
same position as they were before changing
the fork kit!
10 Nm
Fig.24
5
Base Plug
(Standard)
03324-03
(M10x1.25)
2
M OUNT I NG I N ST R U CTIONS
M OUNTI NG I NST R UCT I ONS
WARNING!
Disassemble the original front fork
1. It is advisable to have an Öhlins dealer install
the front fork kit. The installation procedure
requires certain Öhlins tools.
2. Follow the instructions in the vehicle service
manual when changing the front fork kit.
3. When working on a raised vehicle, make
sure that it is securely supported to prevent it
from falling.
2
9
Tool
1797-07
Remove the original top cap from the shaft
assembly.
Fig.12
10
Remove the original cartridge from the fork leg.
1
11
Spring
support
Turn the fork legs upside down to pour out all
oil.
Removing the original front fork
1
Installing the Öhlins front fork kit
Put the motorcycle on a workstand so that the
front wheel is off the ground.
Spring
12
2
Remove the top cap from the shaft on the
Öhlins front fork kit.
Fig.3
Remove the front fender, brake caliper and the
front wheel.
13
3
Measure the position of the front fork:
Measure the distance from the top of the fork
leg to the top of the upper triple clamp.
20 Nm
Top cap
Preload
tube
Remove the spring support, spring and the
preload tube.
Fig.5
Screw
14
Put the cartridge into the fork leg.
NOTE!
It is very important that the front fork is
reattached at the exact same position.
15
4
Release the spring preload.
Tighten the cartridge to 20 Nm using tool
1797-07 and an allen key. Smear som locktite
243 on the threads.
5
16
Loosen the upper fork crown by loosening the
screws.
Remove tool 1797-07 and pour approximately
0,5 litre Öhlins oil 01309 into the fork leg.
Fig.4
6
Loosen (do not remove) the top cap ½ turn.
Fig.13
Locktite
Fig.14
Fig.15
17
Top cap
Install the top cap directly to the shaft (no
spring or preload tube). Pull up the outer fork
leg and screw it to the top cap. Handtighten
only. Pump out all the air from the fork leg
by pulling the cartridge up and down 10‑15
times.
7
Loosen the lower fork crown by loosening the
screws.
1/2 turn
8
18
Remove the top cap from the outer fork leg.
Remove the fork legs from the fork crowns.
Fig.16
Fig.6
3
4
Fig.17