3
4
2 - Disassemble Original Front Fork
3 - Install Öhlins Front Fork Kit
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 Öhlins 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 Öhlins 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
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.
Spring
support
Spring
Preload
tube
Top cap
Top cap
Spring
support
Top cap
Spring
Preload
tube
Spring
support
XXX mm
Loctite
3 - Install Öhlins Front Fork Kit
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 important that the front fork is in the
same position as before changing the fork kit!
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