FGK 133 - Racing 100
Contents
1. Before installing this product check the contents of the kit If anything is missing please contact your nearest Ohlins dealer Kit Contents Part No Pcs Front fork kit FGK133 1 Ohlins Sticker 60x23 white 00191 32 2 Ohlins Sticker 60x23 blue 00191 33 2 A Warning This kit should only be installed by an authorized Ohlins dealer The installation procedure requires certain tools Please note that during storage and transportation especially at high ambient temperature some of the oil and grease used for assembling may leak and stain the packaging This is in no way detrimental to the product wipe off the excessive oil grease with a cloth A Warning Before installing this product read the Ohlins Owner s Manual The front fork is an important part of your vehicle and will affect the stability Front Fork Kit for Kawasaki ZX GR FGK 133 Mounting Instructions ADVANCED SUSPENSION TECHNOLOGY Note The front fork is a very important part of the vehicle and will therefore affect the stability Read and make sure that you understand the information in this manual before you use this product If you have any questions regarding installation or maintenance please contact your nearest Ohlins dealer Ohlins Racing AB can not be held responsible for any damage to the front fork vehicle other property or injury to persons if the instructions for installing and maintenance are not followed exactly2. A Warning This product was developed and designed exclusively for a specific vehicle model and should only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability Note When working on this product always consult your Vehicle Service Manual This Manual should be considered as a part of the product and should therefore accompany the product throughout its life cycle Tool 1765 03 Tool 0797 01 2 Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distinguished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the front fork or to bystanders Wa Caution The Caution Symbol means Special precautions must be taken to avoid damage to the front fork Note The Note Symbol indicates information that is important regarding procedures Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Tool 1797 07 A Warning Before riding alwa
3. Recommended set up Rebound adjustment 13 clicks Compression adjustment 1 turn Spring preload 2mm Oil level 150 mm Ohlins Front Fork fluid Part No 01309 01 Force N Recommended sag and ride height The measures should not differ from the following recommendations Without rider Rear 5 15 mm R1 R2 Front 20 30 mm F1 F2 With rider Rear 25 35 mm R1 R3 Front 30 40 mm F1 F3 140mm oil lev 150mm oil lev 160mm oil lev 170mm oil lev 180mm oil lev 190mm oil lev 200mm oil lev 210mm oil lev 220mm oil lev 230mm oil lev 240mm oil lev 0 10 20 30 40 50 60 Stroke mm hlins 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 minor updates may occur hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written S 194 27 Upplands V sby Sweden permission of hlins Racing AB is prohibited To find the latest information contact your hlins distributor Please consult your hlins dealer if you have any questions regarding the contents in this document 70 80 90 100 110 120 Part no FGK133_3 Issued 2009 05 14 Ohlins Racing AB Box 722 Phone 46 8 590 025 00 fax 46 8 590 025 80 ADVANCED SUSPENSION TECHNOLOGY www ohlins com wy Naf
4. ant that the front fork is in the same position as before changing the fork kit Spring G4 support
5. ce of tape a point immediately above the rear wheel axle 3 Measure the distance from the marked point to a fixed point for example the wheel axle R1 4 Measure the distance from the bottom of the outer tube to a fixed point for example the front wheel axle F1 5 Put the motorcycle on the ground so 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 procedure R3 and F3 Recommended Measures Recommended measures for Free Sag and Ride Height see Set up Data Note Always check on the Ohlins web site www ohlins com or with your Ohlins dealer distributor for the latest information Adjust spring preload 1 If your measures differ significantly from the recommendations in the Set up Data adjust the spring preload See Adjustments this manual 2 If the ride height still differs from the recommendations you may need to change to softer harder spring Contact your Ohlins dealer for advise A Warning Incorrect spring rate may result in a front geometry that is either too steep or too flat This can result in a tendency of under or over steering that could seriously affect the handling characteristics of the motorcycle D R3 5 A Warning It is advisable to have an hlins dealer install the front fork When installing cons
6. preload tube Pull up the front fork outer tube and screw it to the top cap Handtighten only Pump out all air from the cartridge by pulling the outer tube up and down 10 15 times 3 7 Remove the top cap from the fork leg cy Spring support Spring Loctite 2 3 8 Make sure the piston 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 ruler Recommended setting according to chapter Set up data and Diagram Oil level force 3 9 Put the preload tube and the spring on top of the cartridge 3 10 Fasten tool 01765 03 on the top of the shaft Install the spring support by leading it over the tool 3 11 Pull up the piston shaft with tool 01765 03 and grab the spring support with a 19 mm wrench 3 12 Open the rebound adjuster fully Remove the pull up tool and install the top cap to the shaft Tighten with torque 15 Nm 3 13 Pull up the outer tube Make sure the fork leg is in a fully extended position Use tool 00797 01 to tighten the top cap Tighten the top cap with torque 10 Nm 3 14 Set the spring preload rebound and compression adjusters according to Adjustments and Set up data in this manual 3 15 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 Note It is very import
7. ult your Vehicle Service Manual 1 Put the motorcycle on a workstand so that the front wheel barely touches the ground A Warning Make sure the vehicle is securely supported so that it will not tip 2 Remove the front fender brake caliper and the front wheel 3 Measure the position of the front fork Measure the distance from the top of the fork leg to the top of the upper fork crown Note It is very important that the front fork is reattached at the exact same position 4 Release the spring preload 5 Loosen the upper fork crown by loosening the screws 6 Loosen do not remove the top cap Y2 turn 7 Loosen the lower fork crown by loosening the screws 8 Remove the fork legs from the fork crowns VEHICLE SERVICE MANUAL amp 1 2 B 2 1 Remove the original top cap from the fork leg 2 2 Remove the original cartridge from the fork leg 2 3 Turn the fork legs upside down to pour out all oil 3 1 Remove the Ohlins top cap from the shaft 3 2 Remove the spring support spring and the preload tube 3 3 Put the cartridge into the fork leg 3 4 Tighten the cartridge with tool 01797 07 to torque 20 Nm Smear some loctite 243 on the threads 3 5 Remove tool 01797 07 and pour approximately 0 5 litre Ohlins Front Fork fluid into the fork leg 3 6 Open the rebound adjuster fully Install the top cap directly to the cartridge no spring or
8. ys make sure that the basic settings made by Ohlins are according to recommended Set up Data Contact an Ohlins dealer if you have any questions about setting up the front fork 1 Spring Preload Adjuster Adjust by turning the nut on the top of the fork leg Turn clockwise to increase and counter clockwise to decrease the spring preload 2 Rebound Damping Adjuster Adjust by turning the screw with an allen key 3 Compression Damping Adjuster Adjust by turning the screw use proper tool To Reset 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 W Caution Do not use force delicate sealing surfaces can be damaged Decrease Increase A Warning Before riding always ensure that the basic settings made by Ohlins are intact Take notes adjust in small steps and make only one adjustment at a time Spring Preload Free Sag Ride Height Spring preload is a crucial part of setting your motorcycle since it affects the height of the motorcycle and the fork angle Note The following procedure should be performed on a flat surface 1 Put the motorcycle on a workstand so that both wheels are off the ground and the suspension is unloaded 2 Mark for example with a pie
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