1

Including:

Setting upyour bike

Fine-tuning

Servicethe fork

Generalhandlingset-up

Technicalinfo

Spare parts& tools

Traction, handling,comfort and safety

Owners ManualÖhlins motocross front fork

FG 103, FG 104, FG 105, FG 106, FG 107

2

Safety signalsImportant information concerning safetyis distinguished in this manual by thefollowing notations

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injuryto anyone working with, inspecting orusing the suspension, or to bystanders.

CAUTION!Caution indicates that special pre-cautions must be taken to avoid dam-age to the suspension.

NOTE!This indicates information that is of im-portance with regard to procedures

© Öhlins Racing AB.All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofÖhlins Racing AB is prohibited.

Printed in Sweden.

Öhlins motocrossfront forks

FG 103 KTMFG 104 YamahaFG 105 KawasakiFG 106 SuzukiFG 107 Honda

ContentsSafety signals 2Introduction 3Design 3Before you start 3Marking 3Recommended settings 3Mounting instructions 4Setting up the bike 4Checking front sag 4Checking rear sag 4Checking front ride height 5Checking rear ride height 5Fine-tuning the bike 5Making adjustments 6Oil level adjustment 6Maintenance 6General handling set-up 7Preload adjustment 8Changing springs 9Dismantling the front fork 10Assembly of the front fork 11Service tools 13Technical specifications 13Spare parts 14

3

IntroductionÖhlins Racing congratulates you onyour choice of front fork for your moto-cross bike.

All Öhlins products are designed withjust one purpose; to win races. To de-sign a winner you need a concept start-ing with a unique know-how. You addengineering skill, precision and the bestmaterial available. The result is quality,endurance and winning performance.

Your new Öhlins front fork is devel-oped from experience gained duringyears of successful cooperation with theWorld Championship winning worksmotocross teams.

Spring rates and damping forces aredeveloped just for your bike. The de-sign and the settings are consequentlythe results of extensive testing and nogueswork!

Öhlins shock absorbers and frontforks have dominated the motorcyclescene for several years and have cap-tured more World Championship titlesthan any other brand, over 80 titles!

A well equipped network of authorisedÖhlins service centres around the world,with specially trained mechanics, canhelp you with personally tuned settings,service, repairs and spare parts.

DesignÖhlins new up-side-down (USD) frontfork is designed to combine the advan-tages of comfortable, safe conventionalforks and rigid, light USD forks. The re-sult is a unique combination of beingrigid, precise in corners and during hardbraking yet comfortable, forgiving when“over-landing“ and in big bumps.

Your new Öhlins USD front fork hasaluminium outer legs and 46 mm steelinner legs, with a polished titanium ni-tride surface for lowest possible friction.

The legs also feature a completelynew bushing design with two fixed andone sliding bushing.

The new USD fork features the Öhlinschampionship winning cartridge damp-ing system.

The fork is fully adjustable withexternal adjuster for compression- andrebound damping.

The compression adjuster is locatedat the bottom of the fork leg, fig 1, therebound adjuster at the top, fig 2.

Spring preload is adjusted with wash-ers, fig 3, and optional springs are avail-able to suit different tracks and riders.In the legs there are also “air-springs“(the air trapped above the oil) that worktogether with the “real“ spring. You ad-just the air-spring by raising or loweringthe oil level in the legs.

By using different combinations ofsprings and air-springs you can alter thecharacteristic of the fork. For example,a soft spring in combination with a smallair-spring (high oil level) makes the forkprogressive, see “Fine-tuning the bike“.

Before you start

WARNING!Installing a front fork, that is not ap-proved by the vehicle manufacturer,may affect the stability of your vehi-cle. Öhlins Racing AB cannot be heldresponsible for any personal injury ordamage whatsoever that may occurafter fitting the front fork. Contact anÖhlins dealer or other qualified personfor advice.

Öhlins Racing AB can not be held re-sponsible for any damage whatsoeverto front fork or vehicle, or injury to per-sons, if the instructions for fitting andmaintenance are not followed exactly.Similarly, the warranty will become nulland void if the instructions are not ad-hered to.

WARNING!Please study and make certain thatyou fully understand all the mountinginstructions and the owner´s manualsbefore handling this front fork kit. If youhave any questions regarding properinstallation procedures, contact anÖhlins dealer or other qualified person.

WARNING!The vehicle service manual must bereferred to when installing the Öhlinsfront fork.

NOTE!Öhlins products are subject to con-tinual improvement and development.Consequently, although these instruc-tions include the most up-to-date in-formation available at the time of print-ing, there may be minor differencesbetween your suspension and thismanual. Please consult your Öhlinsdealer if you have any questions withregard to the contents of the manual.

MarkingAll Öhlins front forks are marked. Youwill find the part number on the insideof the fork bottom.

Your Öhlins front fork has the follow-ing marking:

FG 103: KTMFG 104: YamahaFG 105: KawasakiFG 106: SuzukiFG 107: Honda

Recommended settingsThe front fork in your kit is adjusted tothe Öhlins recommended setting foryour bike, see “Making adjustments“.We advise you to use this as your startsetting.

4

Mounting instructions

WARNING1. It is advisable to have an Öhlinsdealer or a qualified mechanic to fityour front fork kit.2. To install the kit you need yourmotorcycle’s work shop manual.3. When working on your motorcycle,support it securely so it does not fall over.

The Öhlins front fork is designed to fityour bike’s standard triple clamps andto use the standard brake componentsand wheel.

APut your bike on a stand and remove thefront wheel, the front brake componentsand the fork legs from the bike accordingto the work shop manual.

CAUTION!1. The outer legs, both left and right,should be adjusted evenly in the forkcrown.2. The Öhlins fork legs feature grooveson top of the outer fork legs to makeadjustment of the fork height easier. Thedistance between the grooves is 4 mm.

BFit the Öhlins front fork legs. Forrecommended front fork mountingheight see mounting instruction.

CFit the brake components and the frontwheel according to the work shopmanual.

DTighten all screws. For maximumtorque, please see your bike’s workshop manual.

Setting up the bikeWe would like to give you some basicguidelines how to set up your bike withyour new Öhlins front fork.

However, remember that the front forkis just one part of your motorcycle andto get the fork to work properly thewhole motorcycle has to be set upaccording to standards.

Please follow the instructions below,see also your bike’s work shop manual.Your new front fork is dialled-in to theÖhlins recommended settings for yourbike. The same goes for the rear shockabsorber if you are using an Öhlins unit.All settings are based on a bike and arider of normal weight.

Depending on your own and yourbike’s actual weight minor differences,between the Öhlins recommendedsettings and the settings you achieve,

may occur. Therefore, it is always wiseto start the setting up by checking!

The sag effects not just only thesuspension but also the rake of the frontfork and therefore the overall behaviourof the bike.

Checking front static sag

APut your bike on a stand.Arrange the stand so that the front wheelis off the ground and the front fork fullyextended.

BMeasure the distance between theupper fork crown and the front wheelaxle, fig 4 distance A. Make a note ofthe measurement.

CRemove the stand. With the wheels onthe ground measure the distance again,fig 4 distance B.

The difference of the two measure-ments is the static sag.

DThe static sag should be 30 ± 10 mm.

EIf the static sag is less than 20 mm, youneed to reduce spring preload.If the static sag is more than 40 mm,you need to increase spring preload.

FSpring preload is adjusted with spacers,see “Preload adjustment“ on page 8.Maximum allowed spring preload is13 mm.

If you need to preload the springsmore than 13 mm, we recommend youto change to a “stiffer“ spring.

Checking rear static sag

APut your bike on a stand. Arrange thestand so that the rear wheel is off theground and the rear suspension fullyextended.

BMeasure the distance between the rearwheel axle and a point near the rear endof the seat, for example a seat bolt, fig4 distance A.Make a note of the measurement.

CRemove the stand. With the wheels onthe ground measure the distance again,fig 4 distance B.

The difference of the two measure-ments is the static sag.

1.The compression adjuster islocated at the bottom of the forkleg.

Compression adjuster

3.Spring preload is adjusted withwashers and optional springs areavailable.

Preload adjustment

2.The rebound adjuster at the top ofthe fork leg.

Rebound adjuster

5

Setting up the bike4.Checking sag and rideheight.

Front sag:A - B = 30 ± 10 mm.

Front ride height:A - C = 50 ± 10 mm.

Rear sag:A - B = 30 ±10 mm.

Rear ride height:A - C = 100 ± 10 mm.

NOTE!Refer to mounting instruction for morespecific set-up data.

DThe static sag should be 30 ±10 mm.

EIf the static sag is less than 20 mm, youneed to reduce spring preload.

If the static sag is more than 40 mm,you need to increase spring preload.

FAdjust the spring preload according toyour rear shock mounting instruction.

Checking front ride height

APut your bike on a stand.Arrange the stand so that the front wheelis off the ground and the front fork fullyextended.

Measure the distance between theupper fork crown and the front wheelaxle, fig 4 distance A. Make a note ofthe measurement.

BRace dressed sit on the bike, straightabove the foot pegs, with the feet barelytouching the ground.

Have somebody to measure betweenthe same point as before, fig 4 distance C.

CThe difference of the two measurementsshould be 50 ± 10 mm.

CAUTION!Do not try to alter ride height byaltering the spring preload.New springs are needed.

DIf you need to change the springs, see“Changing springs“ on page 9.

EStiffer springs are needed if thedifference is more than 60 mm.Softer springs if the difference is lessthan 40 mm.

Consult your Öhlins dealer for theright rate.

Checking rear ride height

APut your bike on a stand. Arrange thestand so that the rear wheel is off theground and the rear suspension fullyextended.

Measure the distance between therear wheel axle and a point near the rearend of the seat, for example a seat bolt,fig 4 distance A.

Make a note of the measurement.

BRace dressed sit on the bike, straightabove the foot pegs, with the feet barelytouching the ground. Have somebodyto measure between the same point asbefore, fig 4 distance C.

CThe difference of the two measurementsshould be 100 ± 10 mm.

CAUTION!Do not try to alter ride height byaltering the spring preload.A new spring is needed.

DA stiffer spring is needed if the differenceis more than 110 mm.

A softer spring if the difference is lessthan 90 mm.

Consult your Öhlins dealer for a springof the right rate.

Should you still experience excessivebottoming or that the bike feels muchto stiff and suspension travel is not fullyused, harder/softer than normal springsmay be needed for the track you aretesting on.

Consult your Öhlins dealer for advice!

Fine-tuning the bikeLearning how to use the adjusters will taketime but you quickly appreciate themonce you know the tricks. Even thespecialists sometimes need a specialist!With the adjusters you optimize thesuspension for your riding style and thetrack you are competing on.

The same basic guide lines goes forboth the front fork and the rear shockabsorber.

Too much compression damping willgive you a harsh ride as your bike“jumps“ along the track.

With too much rebound dampingyour bike will have difficulties with sev-eral bumps in a row. The suspensionwill not extend fast enough betweenbumps, your bike will ride lower andlower and eventually the suspension willbottom!

External adjustersOn the Öhlins front fork the adjustersare bleed valves, totally separated fromeach other.

The compression bleed valve controlsthe flow in the cartridge tube during thecompression stroke, the rebound bleedvalve the flow during the reboundstroke.

CAUTION!Using too much force when closing theadjusters will destroy importantsealing surfaces.

A: F

ully

ext

ende

d.

B: O

n th

e gr

ound

.

C: R

ider

on.

A: F

ully

ext

ende

d.

B: O

n th

e gr

ound

.

C: R

ider

on.

6

Both the adjusters have a normal right-hand thread.

Click position zero (0) is when theadjusters are turned clockwise to fullyclosed.

The adjustment range, from fullyclosed until maximum open valve (anti-clockwise), is 20 clicks.

In order not to click in the wrongdirection; always first close the adjuster,then dial-in the new setting.

Making adjustmentsTo make improvements using theadjusters, it is important to understandthe function of the front fork and theshock absorber and through testinglearn how they effect the handling ofyour bike.

Make sure that you have the correctsprings and the correct spring preloadbefore making any adjustments. Andalways start with the Öhlins recommendedsettings:

NOTE!See mounting instruction for recom-mended settings.

NOTE!Higher click numbers give less damp-ing force.

When making adjustments; keep notes,make adjustments one at a time... andin small steps.

The adjusters should normally not beadjusted in steps of more than 2 clicksat a time and not outside the usable clickrange.

When you think you have made animprovement, go back to what youstarted with and double check to besure. Pay attention to changes in

conditions like tires, temperatures etc.In general, compression dampingchanges should be used to influence thebike’s stability and response, whilerebound damping changes should beused to influence comfort and traction.

When you need more damping force,you should mainly try to increasecompression damping and use as littlerebound damping as possible.

This usually means that you gaincomfort and performance in handling.

Oil level adjustmentAs the air trapped between the oil andthe top nut acts as an air-spring, achange in oil level will effect the dampingforces. Not in the early stage of forktravel, but a great deal in the later stage.

A general description of how the oillevel/air-spring effects the dampingforces are shown in fig 5.

The air-spring gives the Öhlins USDfork a progressive spring rate, prevent-ing it from bottoming out hard.

By using different combinations ofsprings and oil levels/air-springs youcan alter the characteristic of the forkand tailor it to suit different tracks andconditions.

CAUTION!The oil level must be the same in bothfront fork legs.Riding a bike with different oil levelswill cause instability.

When the oil level is raised:The air-spring in the later half of travelis strong, and thus the front fork hard.

When the oil level is lowered:The air-spring in the later half of travelis soft, and thus the front fork soft.

CAUTION!Adjust the oil level with the fork leg fullycompressed and no preload washer norspring installed.

NOTE!See mounting instruction for recom-mended oil level.

The oil level is measured from the topof the outer leg, with the top nut off, seefig 6.

A change in oil level should be madein small steps. We recommend a changeof 5 mm at a time and not outside therange of 90-130 mm.

MaintenanceTelescopic front forks depend on asmooth, friction free action.

Make sure your forks are regularlyserviced.

Do not use strong solvents, such asbrake cleaner, to clean the front forks.This will dry out the seals and the steeltubes and cause friction or leakage.

After every race:Clean externally and spray with anall-purpose oil after washing withdetergent.

Check externally for damage.Put a little Öhlins green grease

(148-01) on the steel tubes and work itin by pushing the fork up and down.

Every 20 hours:Dismantle the fork and check all partsfor wear and damage, replace ifnecessary, see page 10.

Oil level6.Oil level ismeasured fromthe top of theouter leg, withthe top nut off,the fork fullycompressedand no preloadwasher norspring installed.

Air spring5.A change in oillevel will effectthe dampingforces, not inthe early stageof fork travelbut a greatdeal in the laterstage.

500

450

400

350

300

250

200

150

100

5 0

0

Force kgf

Stroke mm

0 2 0 4 0 6 0 8 0 100 120

Oil level 100 mm Oil level 110 mm Oil level 120 mm Oil level 130 mm

Fo

rce

Stroke

Oil

leve

l

7

General handling set-up

AFront end falls into the curves (over-steering) especially in sand.Steep front fork angle. Front end too lowin comparison to rear end.� Increase the front fork

compression damping.� Change to harder springs.� Lower fork leg approximately

5 mm in the triple clamp.

BFront end ”ploughs”, understeers.Shallow front fork angle. Front end toohigh in comparison to rear end.� Decrease the front fork

compression damping.� Raise the fork legs approximately

5 mm in the triple clamp.� Change to softer fork springs.

CFront end unstable at high speed,unstable when accelerating out ofcurves.Front fork angle too steep. Front endtoo low in comparison to rear end.� Lower the fork legs approximately

5 mm in triple clamp.� Change the front fork springs to

harder ones.

DFront end unstable during decelera-tion.Front fork angle too steep duringbraking. Front end too low or rear endtoo high.� Increase the oil level in the

front fork.� Change to harder fork springs.� Increase the front fork

compression damping.

Front suspension.

AFront fork travel is not used to its fullcapacity. Harsh feeling, front wheelgrip is not satisfactory in bumpy turns.Suspension too hard.� Decrease the front fork

compression damping.� Change to softer springs.

BSuspension bottoming, too soft duringentire travel.Spring too weak or compressiondamping too soft.� Increase oil level 5 mm.� Increase compression damping.� Change to stiffer springs.

CSuspension bottoming, but can handlesmaller bumps.Damping force not progressive enough.� Increase the oil level.

DCan handle smaller bumps but is toohard during the last part of the travel.Damping force is too progressive.� Decrease the oil level.

EFront end feels low, initially feels soft,but is not bottoming.The initial spring rate is too soft or springpreload is too low.� Increase the spring preload.

EFeels harsh over small bumps, butusing full wheel travel.Too much spring preload or too muchcompression damping.� Increase the oil level or change

to softer springs.� Decrease the compression

damping.� Decrease the spring preload.� Clean the oil seals and scrapers.

Use Öhlins grease 148-01 forregreasing.

FCan handle the first in a series ofbumps but feels hard after a few morebumps. Frontal grip insufficient inrough and bumpy turns.Too much rebound damping.� Decrease the rebound damping.

GFront end rebound too fast after abump. Front wheel grip insufficient inbumpy curves.Not enough rebound damping, or toomuch spring preload� Increase the rebound damping.� Decrease the spring preload.

Rear suspension.

ARear suspension stroke is not usedto its capacity. Suspension feelsharsh. Traction not satisfactory inbumpy curves.Suspension hard in general or too muchcompression damping, too much springpre-load.� Decrease the compression

damping.� Decrease the spring preload.� Change to softer spring.

BSuspension is bottoming, feels softduring the entire wheel travel.Spring too soft, compression dampingtoo low.� Increase the compression

damping.� Change to harder spring.

CSuspension is bottoming, feels harshand sags down too much with therider in the saddle.Spring too soft or compression damp-ing too low.� Increase the spring preload,

check ride height. 95 +- 5 mm.� Change to harder spring if the

load is more than 100 mm.� Increase compression damping.

DRear wheel jumps over small bumpsduring deceleration or when goingdownhill. Traction not satisfactory inwashboard curves.Too much spring preload, as the springis probably too soft, will cause the springto extend too fast.� Change to a harder spring inorder to achieve a balanced

position using less spring pre-load.

� Check the static sag andride height.

ERear end kicks up over bumps withsharp edges, but can handle bumpswith round edges.Compression damping too hard.� Decrease the compression

damping.

FRear end becomes too low in seriesof bumps. Traction not satisfactory inwashboard type curves or whendecelerating on washboard ground.Rebound damping too slow.� Decrease the rebound damping.

GRear end very unstable. Shock doesnot respond to adjustments.Shock damping is gone, caused of lowgas pressure, bad oil is used, or com-ponents are broken in the shock ab-sorber. Service is needed.� Gas filling required.� Change shock oil.� Repair or change the shock

absorber.

8

Preload adjustment

1Put the bike on a stand and loosen thescrews in the fork top crown that holdthe fork legs.

NOTEOn most MX-bikes you have to take ofthe handle bar before you can unscrewthe top cap.

Unscrew the top cap, use a24 mm wrench.

2Put a box under the front wheel so thatthe springs are visible.

Remove the top cap from the damperrod extender.Use a 16 and 24 mm wrench.

Remove the spring support.

3Install a new preload spacer to achievethe right static sag.

Fit the spring support, top cap and thehandle bar.

Tighten all screws.

For tightening torques,please see your bike'swork shop manual.

1

2

3 6

4

5

9

Changing springs

4Loosen the screws that hold the forklegs in the upper fork crown.

With the fork leg still tightened in thelower fork crown unscrew the top cap,use a 24 mm wrench.

Loosen the screws that hold the forklegs in the lower fork crown.

Remove the fork legs from themotorcycle.

5Fasten the fork leg with soft jaws in avice and loosen the lock nut on the topof the fork cap.

6Remove the top cap from the damperrod extender, use a 16 and 24 mmwrench.

Remove the spring support, the preloadwasher and the spring.

For free spring length see technicalinformation on page 13.

7NOTE

Closing the compression- and therebound valves will keep the damperrod extended making it easier to installthe new spring.

Pull out the damper rod as far as possible.

Close the compression and the reboundvalve (clockwise).

8Install the spring and the preloadwasher.

9Install the spring support fork top capand the lock nut.

Tighten the top cap and the lock nutagainst each other, use a 16 and 24 mmwrench.

Adjust the compression- and the reboundvalves according to specification card.

Fit the fork legs on the motorcycle.

For tightening torques, please see yourbike's work shop manual.

7

8

9

10

Dismantling

10Perform steps 4-6 "Changing springs"on page 8-9.

Loosen the bush head, on top of thecartridge tube, with tool 1797-01.

Lift up the damper rod assembly anddrain the oil.

Pull up the scraper with a screwdriver,release and remove the circlip.

11CAUTION!

The fork legs have two fixed and onesliding bushing. Be very careful whendisassembling the fork legs.

Fasten the fork leg horizontally with softjaws in a vice.

Use a hot air gun to warm up the outerleg where the bushings are located.

The first bushing is located at thebottom end of the outer leg, the secondapproximately 150 mm further up theleg.

Between them is a sleeve to maintainthe distance.

12Use the special tool 1702-02 to removethe bushings.

Install the tool in the top of the inner steelleg.

Screw the top cap onto the tool andinstall the cap in the outer leg.

Rotate the tool to press out the bushings.

If tool 1702-02 not is avaliable push theinner steel leg to the bottom and thenpull it back quickly, so that the fork istopping out hard.

Repeat this procedure until the seal andthe bushings can be pulled out from theouter leg.

1702

-02

��

1797-01

15o mm

10

11

12

13

14

15

11

13Remove the seals and bushings andcheck them for wear and damage.Replace if necessary.

CAUTION!When removing the oil seal andbushings use a small plastic bag tocover the bushing attachment grooveand edges of the inner tube, to avoiddamage to the seals.

14Fasten the damper rod assembly withsoft jaws in a vice.

Remove all parts from the damper rod.

NOTEIf the right order is lost, use thespecification card as a guide.

Put them in the right order on the bench.

Inspect all parts for wear and damage,replace if necessary.

Clean all parts thoroughly.

Assemble the damper rod.

15Remove the compression valveassembly from the fork bottom, use a17 mm socket.

Fasten the valve assembly with soft jawsin a vice.

Remove all parts from the valve body.

Put them in the right order on the bench.

Inspect all parts for wear and damage,replace if necessary.

Clean all parts thoroughly.

Assemble thecompression valve.

Assembling

16Apply a thin layer of Öhlins green grease(148-01) on the scraper ring and on thesealing surface of the fork seal.

CAUTION!When installing the oil seal andbushings use a small plastic bag tocover the bushing attachment grooveand edges of the inner tube, to avoiddamage to the seals.

18Apply some Öhlins green grease on theseals.

Again, use tool 1799-02 turn it aroundto install the seal in the outer leg.

Install the circlip and the scraper.

CAUTION!Make sure the circlip is fitted correctlyinto the groove in the outer leg.

1799-02

1799-02

16

17

18

17Mount the scraper, circlip, fork seal,support ring and the bushings separatedby the sleeve on the inner steel leg.

Fasten the outer leg with soft jaws in avice.

Install the inner leg and mount the upperbushing with tool 1799-02, and thesleeve.

Mount the lower bushings.

12

Notes19Fasten the fork leg, at the fork bottom,with soft jaws in a vice.

Install the compression valve assemblyin the fork bottom.

Tightening torque 65 Nm.

Apply some front fork oil on the outersurface of the inner leg, and push theouter leg up and down a few times.

Measure the correct amount of oilaccording to the specification card.

First, fill up the cartridge tube, thenraise up the outer leg about 250 mmand add the remaining oil.

21Install the fork top cap and the lock nut.

Tighten the top cap and the lock nutagainst each other, use a 16 and 24mm wrench.

Fit the fork legs on the motorcycle.

For tightening torques, please see yourbike's work shop manual.

Adjust the compression- and the reboundvalves according to the specification card.

20Install the damper rod assembly intothe cartridge tube.Use Loctite 542 on the cartridge top lid.

Tighten with tool 1797-01.Tightening torque 65 Nm.

Pump the damper rod up and down afew times to check that there is no airleft.

Pull out the damper rod as far aspossible and close the compression-and the rebound valves.

Install the spring and the preloadspacer.

19

20

21

13

1

2

3

4

5

ØA

ØB

L

70

300

200

Technical specifications

Fork lengths and diametersFront fork Motorcycle Length (L) ØA ØBFG 103 KTM* 932 mm 53.9 mm 58.4 mmFG 104 Yamaha 938 mm 53,9 mm 58,4 mmFG 105 Kawasaki 945 mm 54,9 mm 58,4 mmFG 106 Suzuki 940 mm 55,9 mm 59,6 mmFG 107 Honda 940 mm 52,9 mm 58,4 mm

* KTM delivered with bottom triple clamp, for uppertriple clamp use std. or Öhlins 02376-01

Rebound and compression adjustmentRefer to mounting instruction for set-up data.Maximum open rebound and compression valve: 20 clicks.

Free Spring Length:All forks: 467 mm (service limit 460 mm).

Spring preload:Maximum allowed adjustmentrange 3-13 mm (with washers).

Spring rate:KTM:

2328-39 3.9 N/mm2328-45 4.5 N/mm supplied

Yamaha, Kawasaki, Suzuki, Honda:2328-41 4.1 N/mm.2328-43 4.3 N/mm supplied

Optional spring rate:2328-39: 3.9 N/mm.2328-41 4.1 N/mm.2328-43 4.3 N/mm2328-45: 4.5 N/mm.2328-47: 4.7 N/mm

Oil level:See mounting instruction for recommended oil level.Adjustment range 90-130 mm.

CAUTION!Use only Öhlins high performance front fork fluid No. 5(1305-01).

Loctite glue:542 for fork bottom thread and cartridge top lid.

Tighten torque:Triple clamp bolt: See your bike's work shop manual.Compression valve: 65 Nm (Base valve).Cylinder tube lid (cartridgetube): 65 NmCompression valve, 8 mm nut 8 Nm.Rebound valve, 8 mm nut 8 Nm.

Grease:Öhlins Front Fork grease 148-01(Green grease).

Service Intervals:Every 20 hours.

Service toolsPos. Part No. Description

1 1799-02 Bushing/seal mounting tool2 0786-03 Inner tube tool3 1797-01 Tool-cylinder tube lid4 0787-03 Cylinder tube tool (cartridge)5 1702-02 Bushing remover tool

14

Spare partsPos. Part No. Pcs. Description Type/remarks

1 02306-02 2 Top cap2 00438-17 2 O-ring3 02337-01 2 Spring support4 02319-01 Preload washer see spec. card5 02328-39 2 Spring front fork 3,9 N/mm

02328-41 2 4,1 N/mm02328-43 2 4,3 N/mm02328-45 2 4,5 N/mm02328-47 2 4,7 N/mm

6 02324-01 2 Fork leg outer, Yamaha02324-02 2 Fork leg outer, Honda02324-03 2 Fork leg outer, Kawasaki02324-04 2 Fork leg outer, Suzuki02324-01 2 Fork leg outer, KTM

7 02332-04 2 Cover Sticker Öhlins8 00329-02 2 Circlip9 02373-01 4 Bushing lower10 02325-03 2 Sleeve11 01552-01 2 Washer12 02336-01 2 Seal13 02015-01 2 Circlip14 02014-01 2 Scraper15 02339-01 2 Cylinder tube cartridge16 02022-01 2 Bushing upper17 02315-01 2 Fork leg inner18 00438-30 2 O-ring19 02309-80 1 Cover fork leg pair20 02314-01 6 Bolt21 02310-01 1 Fork bottom left, Yamaha

02311-03 1 Fork bottom left, Kawasaki02312-01 1 Fork bottom left, Honda02323-03 1 Fork bottom left, Suzuki02374-01 1 Fork bottom left, KTM

22 02310-02 1 Fork bottom right, Yamaha02311-04 1 Fork bottom right, Kawasaki02312-02 1 Fork bottom right, Honda02323-04 1 Fork bottom right, Suzuki02374-02 1 Fork bottom right, KTM

23 02314-02 4 Bolt fork bottom- 00195-01 2 Sticker Öhlins white / transparent

1

2

3

4

5

6

7

8

9

10

9

11

121314

15

16

17

18

19

20

2223 21

23

15

Spare partsPos. Part No. Pcs. DescriptionType/remarks

1 02338-01 2 Lock nut2 01050-01 2 Screw3 00338-59 2 O-ring4 02306-02 2 Top cap5 01473-02 2 Circlip6 00338-53 2 O-ring7 02321-02 1 Adjustment screw8 01248-01 2 Spring9 00884-04 4 Ball

10 02366-12 2 Adjustment rod11 00338-76 2 O-ring12 02301-03 2 Needle housing13 02302-03 2 Guiding sleeve14 02303-01 2 Sleeve15 02304-01 2 Hydraulic stop16 00131-05 2 Circlip17 01499-02 2 Circlip18 02305-03 2 Cylinder tube cap19 02059-01 2 Bushing holder20 00338-19 2 O-ring21 00110-01 2 Bushing22 02340-01 2 Washer23 02307-01 2 Shaft24 02063-02 2 Spring

25 00438-31 2 O-ring26 02356-03 2 Rebound needle27 02322-01 2 Spring28 02320-03 2 Piston holder29 00530-18 8 Shim washer see spec. card,

notes30 01149-01 6 Wave washer see spec. card,

notes31 - Shims see spec. card,

notes32 02335-01 2 Rebound piston33 01447-02 2 Piston ring34 - - Shim see spec. card,

rebound35 - 2 Clamp washer see spec. card,

rebound36 00153-01 2 Washer37 00430-05 2 Lock nut

38 01473-02 2 Circlip39 00338-53 2 O-ring40 01242-05 2 Adjustment needle41 01248-01 2 Spring42 00884-04 4 Ball43 02054-02 2 End piece44 00438-02 2 O-ring45 00641-03 2 Clamp washer see spec. card

compression46 - - Shims see spec. card

compression47 01660-02 2 Compression piston48 00438-03 2 O-ring49 00530-22 2 Shims50 01149-01 2 Wave washer51 02056-01 2 One way valve seal52 00153-01 2 Washer53 00430-05 2 Nut

1

4

56

7

23

8

910

11

12

13

14

151617

18

19202122

23

24

25

26

27

28

293031

323334

353637

38394041

43

42

444546

47484950515253

16

0729

5-07

, Tek

nisk

Illu

stra

tion,

OM

mot

ocr o

ss fr

ont f

ork,

01

05, 5

00 e

x.

More infowww.ohlins.com

The ultimate suspension site.Find out everything about your suspension.

Down-load mounting instructions, manuals and brochures.And a lot more.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80

Your Öhlins dealer: