Öhlins Front Fork Kit for

Motocross and Enduro

Owner’s Manual - General Mounting Instructions
Safety Precautions
Note!
The front fork is a very important part of the
Safety Symbols
vehicle and will therefore affect the stability. In this manual, mounting instructions and
other technical documents, important
Read and make sure that you understand the information concerning safety is
information in this manual and the mounting distinguished by the following symbols:
instructions before you use this product. If you
have any questions regarding installation or
maintenance please contact your Öhlins dealer. The Safety Alert Symbol means: Warning!
Your safety is involved.
Öhlins Racing AB can not be held
responsible for any damage to the front fork, Warning!
vehicle, other property or injury to persons, if the The Warning Symbol means: Failure to
instructions for installing and maintenance are follow warning instructions can result in
not followed exactly. severe or fatal injury to anyone working with,
inspecting or using the front fork, or
Warning! to bystanders.
This product was developed and designed
exclusively for a specific vehicle model and shall Caution!
only be installed on the intended vehicle model in The Caution Symbol means: Special
its original condition as delivered from the vehicle precautions must be taken to avoid damage
manufacturer. to the front fork.

This product contains pressurized nitrogen Note!

gas (N2 ). Do not open, service or modify this The Note Symbol indicates information that
product without proper education (authorized is important regarding procedures.
Öhlins dealer/distributor) and proper tools.

After installing this product, take a test ride at

low speed to make sure that your vehicle has
maintained its stability.

If the suspension makes an abnormal noise,

or the function is irregular, or if you notice any
leakage from the product, please stop the
vehicle immediately and return the product to an
Öhlins Service Centre.

Note!
When working on this product, always consult
your Vehicle Service Manual.

This Manual shall be considered a part of the

product and shall therefore accompany the
product throughout its life cycle.
© Öhlins Racing AB. All rights reserved. Any
reprinting or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
Printed in Sweden.

1
 Contents

Page
Safety Precautions 1
Contents 2
Recommended Tools 2
How to Install 3
Replace Spring 6
Set-up 7
Measure Spring Preload 8
Adjustments 9
Oil Volume - Force Diagram 9
Spring Guide 10
Inspection and Maintenance 10

Note!
To install the Cartridge Kit on your motorcycle you will also need the Application
Specific Mounting Instructions. Contact an Öhlins dealer for advice.

Recommended Tools
OEM Fork Cap Tool *
Öhlins Fork Cap Tool octagon 50 mm
Socket for OEM Base Plug *
Socket for Öhlins Base Plug *
Socket 12 mm for Öhlins Shaft End
Pliers (for security snapring)
Tool 01890-01 Plug

* See Application Specific Mounting Instructions

2
How to Install
Remove the fork legs from the vehicle

Warning!
It is advisable to have an Öhlins dealer install the
front fork kit.

When installing, consult your Vehicle Service

Manual.
1
Put the motorcycle on a workstand so that 1
the front wheel barely touches the ground.
Upper triple clamp
Warning!
Make sure the vehicle is securely supported so
that it will not tip. Lower triple clamp 4
2
6
Remove the front wheel and the brake caliper.
3
2
Measure the distance from the top of the 2
fork leg to the top of the upper triple clamp Front Brake
according to figure. wheel caliper

Note!
Note this dimension as fork height position.
4
Loosen the upper triple clamp by loosening
the screws.
Top cap
5
Loosen (but do not remove) the top cap
3
1/2 turn. Use the OEM Fork Cap tool from the
motorcycle manufacturer.
6
Loosen the lower triple clamp by loosening
the screws.
7
Remove the front fork legs from the
motorcycle.
5
8
Clean the fork legs thoroughly. Make sure to
clean underneath the fork bottoms.

3
 How to Install
Disassemble the original front fork

9
Follow your vehicle service manual to remove
the original front fork kit and spring from the
fork leg. Turn the fork leg upside down to
pour out the oil.

Install the Öhlins front fork kit

Note!
On some brands/models step 10 shall not be 10
performed. See Application Specific Mounting
Instructions for information.
10 11
Install the hydraulic stop cup from the upper Fork bottom
Base Hydraulic
end of the fork tube. Clean contact surfaces
plug stop cup
between the hydraulic stop cup and fork
bottom with contact cleaner.

Caution!
Make sure that the hydraulic stop cup is well
seated before tightening.
11
Install and tighten the base plug into the fork
bottom.
Tightening torque 45 Nm

Caution!
If the hydraulic stop cup is turning, carefully use
an impact machine.
Spring support washer,
12 if applicable
Install spring support washer (if applicable,
see Application Specific Instruction Sheet). 12 Preload washer
(plastic, optional)
Install optional preload washer(s) (optional
- see Set-up data, Spring preload), the Spring
recommended Öhlins spring (see Spring
guide) and the cartridge kit into the standard Fork leg Cartridge kit
fork leg.

Note!
The preload washers must be below the spring,
at the bottom end of the fork leg.

4
How to Install

13
Tighten the cartridge shaft end into the base Cartridge shaft end/
13 Base valve plug
plug by turning counter clockwise.
Use a 12 mm socket
Tightening torque 18 Nm - Do not overtighten.
14
Install the security snap-ring at the shaft end
groove according to figure.
15 Security snapring
14
Pour Öhlins Front Fork Fluid in the fork leg
according to the recommended settings.
16
Tighten the Öhlins fork top cap gently. Use
the 50 mm octagon Fork Cap Tool.
Tightening torque maximum 10 Nm.
17
Check and set the rebound and compression
valves click positions according to the
recommended settings in Set-up data in the
16
Application Specific Instruction Sheet.
18
Install the front fork legs into the triple
clamps. Use, to begin with, the same height
Top cap tool
position as before. Tightening torque - see
your Vehicle Service Manual.
Reinstall the brake caliper and front wheel.
Make sure that all removed parts are
reinstalled as they were before the installation
of the Öhlins Front Fork Kit.

Note!
It is very important that the triple clamps are
tightened to the correct torque. See your Vehicle
Service Manual.

5
 Replace Spring
Replace Spring (only)

1
Follow steps 1-8 in chapter Remove the fork 2
legs from the vehicle.
2
Unthread top cap from the outer tube.
3
Remove the security snapring in the bottom
of the fork with a pair of pliers. Loosen the 3
bottom end of the cartridge kit by turning
clockwise. Bottom
end
4
Install the tool 01890-01 (oil plug) by pushing
it into the fork bottom. The plug will keep the
oil in the fork while changing the spring.
5
Remove the cartridge kit from the fork leg and
change the spring. Note the plastic preload 4
washer(s) and spring support washer (if any).

Note! Oil plug

The preload washers must be below the spring,
at the bottom end of the fork leg.
6
Install the cartridge kit into the fork leg and
push out the oil plug tool 01890-01. Spring support washer, on
some brands/models.
7 5
Tighten the shaft end (counter clockwise) into Preload washer
the fork bottom. Tightening torque 18 Nm. (plastic, optional)

8 Spring
Install the security snapring.
Fork leg Cartridge kit
Note!
When removing spring and cartridge kit there
will be a loss of front fork fluid. Therefore, we
recommend adding 15 ml Öhlins Front Fork fluid 10
into each fork leg. Install the front fork legs into the triple
clamps. Use, to begin with, the same height
9 position as before. Tightening torque - see
Tighten the Öhlins fork top cap gently. Use your Vehicle Service Manual. Reinstall the
the 50 mm octagon Fork Cap Tool. brake caliper and front wheel - make sure that
Tightening torque maximum 10 Nm. all removed parts are reinstalled as they were
before the installation of the Öhlins Kit.

6
Set-up

Warning! Recommended Measures

Before riding, always ensure that the basic If no other recommendations are given in the
settings made by Öhlins are intact. Take notes, Vehicle Manual follow the measures below:
adjust in small steps and make only one Free sag (R1-R2)
adjustment at a time.
Rear 30 - 45 mm
Ride height (R1-R3), (F1-F3)
Step 1 Rear 100 - 115 mm
Front 40 - 50 mm
Check Sag and Ride Height

Note! Step 2
The following procedure should be performed on
Adjust spring preload
a flat surface.
1. If your measurements differ significantly
from the recommendations from the table
1. Put the motorcycle on a workstand so
above, adjust the spring preload. (See
that both wheels are off the ground and
section Spring Preload in this manual).
the suspension is unloaded.
2. If the ride height still differs from the
2. Mark, for example with a piece of tape, a
recomendations, you may need to change
point immediately above the rear wheel
spring. Contact your Öhlins dealer for
axle.
advise.
3. Measure the distance from the marked
point to a fixed point, for example the Warning!
wheel axle. (See figure below: R1) Incorrect spring rate may produce a fork angle
4. Measure the distance from the bottom of that is too steep or too flat. This in turn will give a
the upper triple clamp to a fixed point, for tendency for over- or understeering, which could
example the front wheel axle. (F1) seriously affect the handling characteristics of
5. Put the motorcycle on the ground so the motorcycle.
that the front and the rear suspensions
are slightly compressed. Repeat the
measuring procedures. (R2 and F2)
6. Sit on the motorcycle in normal riding
position, properly outfitted in your riding
gear. Repeat the measuring procedures.
(R3 and F3)

7
 Measure Spring Preload

Five Steps to measure and adjust spring Fork springs may differ in length. Therefore
preload; we recommend you to check the preload on
1. Measure A. Fork outer tube should be each fork leg and, if necessary, install preload
slid down to stop and cartridge left at washers to get the correct value. A negative
free length (internal gas pressure extends preload of up to minus 2 mm is possible,
cartridge). since the top-out spring still gives a small
2. Measure B. compression on the main spring.
3. Measure C. Preload less than -2 mm will make the fork
4. Calculate preload: Preload = B – A – C spring loose when the front wheel is off the
5. Adjust preload according to the desired ground, which increases wear inside the fork.
value according to set-up data, by
Caution!
adding/removing preload washers below
Preload washers must be placed below the
the spring.
spring, otherwise they will restrict oil flow and the
For recommended Spring Preload, see fork may break.
Application Specific Mounting Instructions.

8
Adjustments
Compression damping adjuster
The compression adjuster is located at the top
of the fork leg. Adjust by turning the screw with Compression damping adjuster
a 3 mm allen key.
Rebound damping adjuster
The rebound adjuster is located at the bottom
of the fork leg. Adjust by turning the screw
with a 3 mm allen key.
To Reset
The adjusters have a normal right hand
thread. Turn the damping adjusters gently
clockwise to fully closed (pos. zero [0]). To
open, turn counter clockwise, and count Rebound damping adjuster
the clicks until you reach the recommended
number. For recommended clicks see Set-up
data. Static sag can only be changed with
softer or harder spring rate.

Caution!
Do not use much force, delicate sealing
surfaces can be damaged.

Note!
The total stroke of the front fork may differ
from the original stroke, so that more or less
of the steel tube will be visible when the fork is
fully compressed.

Diagram: Oil Volume - Force

more oil
less oil
Force

Stroke

9
 Spring Guide

Spring Guide Rider’s weight* Spring rate

kg/pounds N/mm
Motocross/Enduro 250 70/154 4,1-4,4
75/165 4,3-4,5
80/176 4,5-4,8
85/187 4,6-4,9
90/198 4,7-5,0
95/209 4,8-5,1
Motocross/Enduro 450 70/154 4,3-4,6
75/165 4,4-4,7
80/176 4,5-4,8
85/187 4,6-4,9
90/198 4,7-5,0
95/209 4,8-5,1
* Rider’s weight: Rider wearing all riding equipment

Inspection and Maintenance

Preventive maintenance and regular inspection
reduces the risk of functional disturbance.
Breather plug Breather plug
Make sure to aerate the front fork at regular
intervals:
1. Put the motorcycle on a workstand so that
the front wheel barely touches the ground.
2. Loosen the breather plug to release
excessive pressure in the front fork.
Recommended Service Intervals
Every 25 hours. Make your service and
maintenance according to Öhlins Workshop
manual.
Disposal
Discarded Öhlins products should be handed
over to an authorized Öhlins workshop or
distributor for proper disposal.

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 Öhlins Owner’s Manual and General Mounting Instructions | Part No. 07296-90_1 | Issued 2010-06-10 | © Öhlins Racing AB

Your Öhlins retailer:

Öhlins Racing AB
Box 722 Phone: +46 (0)8 590 025 00
SE-194 27, Upplands Väsby Fax: +46 (0)8 590 025 80
Sweden www.ohlins.com