Owner`s Manual/ Mounting Instructions
Contents
1. Brand Rider s weight Spring Spring rate ADVANCED SUSPENSION TECHNOLOGY kg pounds N mm Yamaha YZF 250 70 154 08763 44 4 4 75 165 08763 44 4 4 80 176 08763 46 4 6 90 198 08763 4646 Owner s Manual Mounting Instructions 95 209 08763 48 4 8 Ohlins front fork kit FGYA 893 FGYA 894 Yamaha YZF 450 70 154 08763 44 4 4 for Yamaha YZF 250 450 2008 75 165 08763 46 4 6 80 176 08763 46 4 6 85 187 08763 48 4 8 90 198 08763 50 5 0 Please read before installing 95 209 08763 52 5 2 Ohlins Racing AB cannot be held responsible for any damage to the front fork kit vehicle or injury to persons if the instructions for fitting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to This kit should only be installed by an authorized Ohlins dealer The installation Rider s weight Rider wearing all riding equipment MAI NTE NAN C E 8 procedure requires certain tools Before installing 2 this front fork kit please check the contents of the Preventive maintenance and regular inspection 2 kit listed below If any part is missing please contact reduces the risk of functional disturbance 5 your Ohlins dealer Breather plug 3 Kit Contents Make sure to ventilate the front fork at regular Front fork kit FGYA 893 894 1 intervals amp Sticker TTX Cartridge 00191 29 2 i Stic2. Top cap tool SET UP DATA Before riding your motorcycle check sag and ride height according to Set up data and Adjustments in this mounting instruction To get the most out of your suspension component it is of great importance to make the correct settings for your weight full riding equipment on F1 F2 F3 R1 R2 R3 Motorcycle on a stand Front suspension F1 Motorcycle on a stand with the suspension fully extended F2 Motorcycle on the ground without rider F3 Motorcycle on the ground with rider Free sag F1 F2 Ride height F1 F3 Recommended settings Rebound damping 12 click Compression damping 12 click Spring preload 5 to 8mm can be changed with washers 15443 02 and 15443 03 Oil volume for 250F 0 370 litre Oil volume for 450F 0 380 litre Use only Ohlins fork oil 0131 1 xx Motorcycle on the ground Motorcycle with rider on Rear suspension R1 Motorcycle on a stand with the suspension fully extended R2 Motorcycle on the ground without rider R3 Motorcycle on the ground with rider Free sag R1 R2 Ride height R1 R3 Recommended sag and ride height If no other recommendations are given in your vehicles manual follow the measures below Without rider Rear 30 10 mm R1 R2 With rider Front 40 10 mm F1 F3 Rear 100 10 mm R1 R3 Spring Prelo
3. ad Measure the spring length The springs may differ in length which will affect the preload The preload can be changed with the preload washers 15443 xx installed before the spring A negative preload of up to 5 mm is possible because the top out spring then still gives a small compression load on the main spring The preload is calculated as A Free spring length B Preload washer thickness C Installed length for spring and preload washer A B C Spring preload The setup for zero 0 preload is calculated below An increase of the spring length and or an increase of the preload washer thickness give a corresponding increase of the preload Free spring length 455 mm Preload washer 15443 xx 15443 03 3 mm Preload 0 mm
4. contents of the manual NOTE During storage and transportation especially at high ambient temperature the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material This is not unusual and is in no way detrimental to the Ohlins product Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden ADJUSTMENTS Adjustments Compression damping adjuster The compression adjuster is located at the top of the fork leg Adjust by turning the slotted screw with a screwdriver Rebound damping adjuster The rebound adjuster is located at the bottom of the fork leg Adjust by turning the slotted screw with a screwdriver Reset the adjusters according to following The adjusters have a normal right hand thread Turn the damping adjusters clockwise to fully closed pos zero 0 To open turn counter clockwise and count 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 too much force delicate sealing surfaces can be damaged Compression damping adjuster Rebound damping adjuster NOTE The total stroke of the front fork may 2 differ from the original stroke so that more or less of th
5. e steel tube will be visible when the fork is fully compressed DIAGRAM Oil volume Force 420cc 400cc 380cc 360cc Force Stroke MOUNTING INSTRUCTIONS 3 Top cap tool Changing springs only This can be done on the motorcycle with Ohlins special tools Make your service and maintenance according to Ohlins work shop manual 1 Put the motorcycle on a work stand 2 Loosen the screws that hold the fork legs in the upper triple clamps 3 Open up the top cap on the fork leg Use a standard fork top cap tool 4 Remove the security snap ring in the bottom of the fork with a pair of pliers 5 Loosen the bottom end of the cartridge kit 6 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 7 Remove the cartridge kit from the fork leg and change the spring Note the preload washer if any 8 Install the cartridge kit into the fork leg and push out the oil plug tool 01890 01 9 Tighten the shaft end into the fork bottom with tightening torque 18 Nm 10 Install the security snap ring NOTE If any oil is needed use Ohlins Front Fork Oil 0131 1 xx only CAUTION The top cap should only be tightened by hand or maximum torque of 10 Nm into the fork leg Oil plug Security snap ring The preload washers must be be
6. is Safety alert symbol means Attention Your safety is involved A WARNING Failure to follow warning instructions could result in severe or fatal injury to anyone working with inspecting or using the suspension or to bystanders CAUTION Caution indicates that special precautions must be taken to avoid damage to the suspension NOTE This indicates information that is of importance with regard to procedures A WARNING 1 Installing a front fork kit that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the front fork kit Contact an Ohlins dealer for advice 2 Please study and make certain that you fully understand the contents in the mounting instruction and the owner s manual before handling this front fork kit If you have any questions regarding installation procedures contact an Ohlins dealer 3 The vehicle service manual must be referred to when installing the Ohlins front fork kit NOTE Ohlins products are subject to continual improvement and development Consequently although these instructions include the most up to date information available at the time of printing there may be minor differences between your suspension and this manual Please consult your Ohlins dealer if you have any questions with regard to the
7. ker Ohlins 00197 01 2 1 Put the motorcycle on a workstand so that Breather plug lt O ring 00338 10 2 the front wheel is off the ground 2 O ring 00438 12 2 2 Loosen the breather plug to release the is Base plug TTX FG 15430 03 2 excess pressure in the front fork Circlip 15440 01 2 Spacer 2 mm 15443 02 2 Recommended Service Intervals Spacer 3 mm 15443 03 2 S Owner s Manual Mounting Instr 07296 50 1 Every 25 hours Make your service and maintenance according to Ohlins Work shop Q manual 8 NOTE 3 Oil and spring kit need to be ordered separately Disposal 3 For correct spring rate see spring guide 2 lt recommendation Discarded Ohlins products should be handed D Use hlins fork oil only 01311 xx over to an authorized Ohlins workshop or gt distributor for proper disposal F lt In this manual 2 Recommended tools Safety precautions 3 Tool STD OEM top cap tool Mounting instruction 7 Tool 20 mm socket bottom plug Set up data Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden a Tool 12 mm socket shaft end adjuster housing Adjustments Diagram Oil volume Force Phone 46 8 590 025 00 Fax 46 8 590 025 80 z Tool Pliers for the security snap ring Spring guide Maintenance www ohlins com ADVANCED SUSPENSION TECHNOLOGY SAFETY PRECAUTIONS Safety signals Important information concerning safety is distinguished in this manual by following notations A Th
8. low the spring at the bottom end of the fork leg __ Preload washer Fork leg MOUNTING INSTRUCTIONS A WARNING 1 It is advisable to have an hlins dealer to install the front fork kit 2 Refer to the instructions in your vehicle service manual when changing the front fork 3 When working on a raised vehicle make sure that it is securely supported to prevent it from tipping Removing the original front fork 1 Put the motorcycle on a workstand so that the front wheel is off the ground 2 Remove the front wheel and the brake caliper 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 according to figure 4 Loosen the upper triple clamp by loosening the screws 5 Loosen but not remove the top cap 1 2 turn Use a standard tool from the motorcycle manufacture 6 Loosen the lower triple clamp by loosening the screws 7 Remove the front fork legs from the motorcycle Disassembling the original front fork 8 Follow your vehicles service manual to remove the original front fork kit from the front fork leg Turn the fork leg upside down to pour out the oil Clean your front fork internally thoroughly 2 Upper triple clamp Lower triple clamp Front leg cover Front wheel Q MOUNTING INSTRUCTIONS Install the Ohlins front fork kit 9 Smear some red grease o
9. r similar on the o rings and install them according to figure 10 Install and tighten the base valve plug into the fork bottom use a 20 mm socket tightening torque 45 Nm 11 Install the preload washer s 15443 xx optional see Set up data Spring preload the recommended Ohlins spring see Spring guide and the cartridge kit into the standard fork leg 12 Tighten the cartridge shaft end into the base valve plug Use a 12 mm socket tightening torque 18 Nm 13 Install the security snap ring at the shaft end groove according to figure 14 Pour Ohlins front fork oil 0137 1 xx into the fork leg according to the recommended settings Oil volume range 0 350 to 0 420 litre 15 Tighten the Ohlins fork top cap gently Use the standard top cap tool from the motorcycle manufacture Handtighten only 16 Check and set the rebound and compression valves click positions according to the recommended settings in Set up data 17 Install the front fork legs into the triple clamps Tightening torque see your vehicle service manual NOTE It is very important that the triple clamps are tightened to the correct torque O ring 00438 12 O ring 00338 10 Base valve D ii oN ey Fork leg NOTE The preload washers must Preload be below the spring at washer the bottom end of the optional fork leg Spring Cartridge shaft end Base valve plug
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