Ohlins FKR 118 Mounting Instructions Download Page 2

2

MOUNTING INSTRUCTIONS

Tool

Part no

Applies

Size

Vehicle service manual
Torque wrench 10-60 Nm

Torque

Heat gun

Soften thread locker

Hex key

Plug

8 mm

Hex key

Compression and 

rebound adjuster

3 mm

Extended hex key

Cylinder tube assembly 14 mm

Socket

Main preload adjuster

14 mm

Wrench

Spring support

19 mm

Suspension fluid

01309-xx

Grease

00146-01

100 g

Loctite 2400

01791-25 

50 ml

Loctite 2700

01791-27 

50 ml

Shaft extension tool

01765-03

Seal head tool

01797-07

Clip

02810-01

Top cap tool

00797-08

Inner tube tool

00786-05

43 mm

  arninge!

We strongly recommend to let an Öhlins dealer 

install this product.

  arninge!

If you work with a lifted vehicle, make sure that it 

is safely supported to prevent it from tipping over.

  otee!

1

When you work with this product, see the 

vehicle service manual for vehicle specific 

procedures and important data.

  otee!

1

Before you install this product clean the vehicle.

  arninge!

Spring compression creates a potential danger 

because of the violent force that loaded springs 

are capable of. Beware of this when you work 

with the front fork.

Summary of Contents for FKR 118

Page 1: ...roduct wipe off the excessive oil or grease with a cloth 1 Note 1 Before you install this product check the kit contents If anything is missing please contact an Öhlins dealer Warning Before you install this product read the Öhlins Owner s manual This product is an important part of the vehicle and the vehicle stability Kit Contents Description Part No Pcs Cartridge kit FKR 118 1 O ring 40x2 5 005...

Page 2: ...1765 03 Seal head tool 01797 07 Clip 02810 01 Top cap tool 00797 08 Inner tube tool 00786 05 43 mm Warning We strongly recommend to let an Öhlins dealer install this product Warning If you work with a lifted vehicle make sure that it is safely supported to prevent it from tipping over 1 Note 1 When you work with this product see the vehicle service manual for vehicle specific procedures and import...

Page 3: ...ches the ground Warning Make sure the vehicle is securely supported so that it will not fall over 2 Remove front fender brake calipers speed sensor if present and front wheel 3 Release main spring preload fully if present 4 Note front fork leg position 5 Loosen upper triple clamp 6 Loosen do not remove top cap turn 7 Loosen lower triple clamp 8 Remove front fork legs from triple clamps 4 ...

Page 4: ...ng to instructions in the vehicle service manual 8 Remove inner tube lock screw Warning If lock screw is not removed inner tube and fork bottom will be damaged Warning Inner tube thread may need to be repaired before removing inner tube apply appropriate method 9 Install inner tube tool on inner tube Do not place tool at sealing or gliding surface 00786 05 inner tube tool 10 Soften thread locker b...

Page 5: ...leg Install rebound cartridge marked REB in right hand side front fork leg 1 Remove top cap spring support and preload tube 2 Remove cylinder tube assembly from shaft assembly 3 Remove adaptor ring from cylinder tube assembly 4 Clean and degrease inner tube fork bottom and adaptor ring 5 Install adaptor ring in fork bottom Caution Make sure to install the adaptor correctly See figure 5 6 Install o...

Page 6: ...pproximately 0 5 litre Öhlins suspension fluid in front fork leg Warning Fluid level must be approximately 50 mm above top of cylinder tube assembly 13 Install tool on shaft extension 01765 03 shaft extension tool 14 Install tool on seal head 01797 07 seal head tool 1 Note 1 Make sure teeth are securely connected to seal head 15 16 8 7 15 Compress top out spring fully and insert clip 02810 01 clip...

Page 7: ... key to open compression and rebound adjusters Hex key 3 mm 25 Install o ring on top cap Apply grease on o ring and thread 00576 02 o ring 00146 01 grease 26 Install top cap on shaft extension Tighten to 20 Nm Socket 14 mm 27 Remove wrench from spring support 26 28 Pull up outer tube Make sure front fork leg is in a fully extended position Use top cap tool to tighten top cap to outer tube Tighten ...

Page 8: ...0 90 100 110 120 130 Force N Stroke mm 130 140 150 160 170 180 190 200 Level SETUP DATA Recommended setup MAIN SPRING GUIDE Compression adjustment 14 clicks Rebound adjustment 14 clicks Suspension fluid level 180 mm Minimum suspension fluid level 200 mm Suspension fluid part number 01309 xx Front fork leg position Standard Make sure you choose the correct main spring for your rider weight driving ...

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