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oteg!
1
After this procedure the compression adjuster
will no longer be usable.
⚠
arningg!
Only approved Öhlins personnel are permitted
to install this kit. The procedure requires
specific 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.
oteg!
1
Before you install this product, check the kit
contents. If anything is missing, please contact
an Öhlins dealer.
Pressurized Front Fork Kit for Kawasaki ZX-6R
FGR 156
Mounting Instructions
Kit Contents
Description
Front Fork Kit
Sticker Tech. Inside wh
Sticker Tech. Inside bl
Spring 10,5N/mm
Spring 10 N/mm
Spring 9,5 N/mm
Owner's manual
Plug
Recommended tools
Fork tube tool Ø41
Cyl. tube holder Ø36
or Soft jaws 28/36
Top cap tool
Pull-up tool
Seal head tool
Seal head tool
Oil, grease and threadlocker
Function grease CaH92
Öhlins front fork fluid
Threadlocker, high, Loctite 2701
oteg!
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.
oteg!
1
Please note that there can be small differences
between your product and the images in
these instructions.
Part
o
Pcs
FGR156
1
00191-32
2
00191-33
2
04744-05
2
04744-10
2
04744-95
2
07286-01
1
21652-02
2
00786-08
00787-07
00727-09
00797-08
01765-03
01797-07
01797-09
00159-01
01309-xx
01791-05
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Summary of Contents for Ohlins FGR 156
- Page 1 Before you install this product, check the kit Please note that there can be small differences contents. If anything is missing, please contact between your product and the images in an Öhlins dealer. these instructions. Pressurized Front Fork Kit for Kawasaki ZX-6R FGR 156 Mounting Instructions...
- Page 2 MOU TI G I STRUCTIO S ⚠ arningg! We strongly recommend to let an Öhlins dealer install this product. ⚠ arningg! If you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over. oteg! When you work with this product, see the vehicle service manual for vehicle specific...
- Page 3 MOU TI G I STRUCTIO S 2 Disassemble the original front fork Loosen the top cap from the outer tube. Pull down the outer tube. 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 Remove the upper spring collar and the spring.
- Page 4 3 Install the Öhlins front fork cartridge kit ✋ Cautiong! We strongly recommend that you work with one leg at a time, make sure not to mix the parts. ✋ Cautiong! 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;...
- Page 5 Remove the steel adaptor from the cylinder 3.5 3.6 tube adaptor. Apply function grease (00159-01) on the original O-ring and insert it in the fork bottom. Insert the steel adaptor in the fork bottom. ✋ Cautiong! Make sure to install the adaptor correctly. See figure.
- Page 6 3.11 Use the seal head tool (01797-07) to tighten 3.11 3.12 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.
- Page 7 3.19 Install the front fork legs into the triple clamps 3.19 at the fork leg position recommended in the setup data. Tighten according to the vehicle service manual. oteg! Measure the fork leg extension from the upper triple clamp to the top of the outer tube.
- Page 8 SETUP DATA ⚠ arningg! Compression clicks Before you ride/drive, always make sure that the Rebound clicks setup is according to the recommended setup Spring rate N/mm data. Read about adjustments and setting up Spring preload in the Öhlins Owner’s Manual before you make any adjustments.