Ohlins FKR 118 User manual

Cartridge kit for Suzuki GSX-R1000

FKR 118

Mounting Instructions

Note!1

Please note that there can be small differences

between your product and the images in

these instructions.

Note!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.

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 00576-02 2

O-ring 17x2 00338-40 2

Plug 21652-02 2

Main spring 9.5 N/mm 04744-95 2

Main spring 10.0 N/mm 04744-10 2

Main spring 10.5 N/mm 04744-05 2

Sticker set Öhlins - -

Owner’s manual 07291-01 1

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 uid 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

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.

Note!1

When you work with this product, see the

vehicle service manual for vehicle specic

procedures and important data.

Note!1

Before you install this product clean the vehicle.

Warning!⚠

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.

MOUNTING INSTRUCTIONS

1 Remove original front fork

Note!1

The following procedure applies to both front

fork legs.

Put the motorcycle on a workstand so that the

front wheel barely touches the ground.

Warning!⚠

Make sure the vehicle is securely supported so

that it will not fall over.

Remove front fender, brake calipers, speed

sensor (if present) and front wheel.

Release main spring preload fully (if present).

Note front fork leg position.

Loosen upper triple clamp.

Loosen (do not remove) top cap ½ turn.

Loosen lower triple clamp.

Remove front fork legs from triple clamps.

MOUNTING INSTRUCTIONS

2 Disassemble original front fork

Note!1

The following procedure applies to both front

fork legs.

Remove top cap from outer tube.

Slide outer tube down until it stops.

Remove top cap from shaft according to

instructions in the vehicle service manual.

Remove seal head from inner tube according

to instructions in the vehicle service manual.

Remove main spring and associated parts

according to instructions in the vehicle service

manual.

Drain front fork leg from suspension uid.

Remove outer tube from inner tube according

to instructions in the vehicle service manual.

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].

Install inner tube tool on inner tube. Do not

place tool at sealing or gliding surface.

[00786-05 inner tube tool]

Soften thread locker between inner tube and

fork bottom with a heat gun.

[Heat gun]

Remove inner tube from fork bottom.

Remove o-ring and washer from fork bottom.

Replace o-ring if worn or damaged.

[Part no according to the vehicle spare part

list]

Remove main spring preload adjuster and

associated parts from fork bottom according to

instructions in the vehicle service manual.

MOUNTING INSTRUCTIONS

3 Install Öhlins cartridge kit

Note!1

The following procedure applies to both front

fork legs.

Caution!✋

The cartridge kit is divided into compression

and rebound cartridges.

Install compression cartridge marked “COMP”

in left hand side front fork leg.

Install rebound cartridge marked “REB” in right

hand side front fork leg.

Remove top cap, spring support and preload

tube.

Remove cylinder tube assembly from shaft

assembly.

Remove adaptor ring from cylinder tube

assembly.

Clean and degrease inner tube, fork bottom

and adaptor ring.

Install adaptor ring in fork bottom.

Caution!✋

Make sure to install the adaptor correctly. See

gure 5.

Install o-ring in fork bottom. Apply grease on

o-ring.

[00146-01 grease]

MOUNTING INSTRUCTIONS

Install inner tube using inner tube tool.

Apply Loctite 2700. Tighten to 130 Nm.

[00786-05 inner tube tool]

[01791-27 Loctite 2700]

Install cylinder tube assembly in front fork leg

with an extended hex key. Apply Loctite 2400

on adaptor thread. Tighten to 60 Nm.

[Extended hex key 14 mm]

[01791-25 Loctite 2400]

Install o-ring on plug. Apply grease on o-ring

and thread.

[00338-40 o-ring]

[21652-02 plug]

[00146-01 grease]

Install plug in fork bottom with a hex key.

Tighten to 12 Nm.

[Hex key 8 mm]

Install outer tube according to instructions in

the vehicle service manual.

Pour approximately 0.5 litre Öhlins suspension

uid in front fork leg.

Warning!⚠

Fluid level must be approximately 50 mm

above top of cylinder tube assembly.

Install tool on shaft extension.

[01765-03 shaft extension tool]

Install tool on seal head.

[01797-07 seal head tool]

Note!1

Make sure teeth are securely connected to seal

head.

15 16

Compress top out spring fully and insert clip

[02810-01 clip].

Warning!⚠

If top out spring is not completely compressed,

adjust shaft extension tool to achieve complete

compression of top out spring.

Insert shaft assembly in front fork leg.

Warning!⚠

Make sure no air is trapped in piston by

carefully pumping shaft assembly up and down

with piston below uid surface.

Install shaft assembly and tighten with your

hand.

Remove clip and shaft extension tool.

MOUNTING INSTRUCTIONS

Tighten seal head to 30 Nm and remove seal

head tool.

Make sure that shaft assembly and outer tube

are in their bottom positions.

Set suspension uid level according to chapter

“Setup Data”.

Install tool on shaft extension.

Install preload tube (A), main spring (B) and

spring support (C) over shaft extension

tool. Select main spring according to chapter

“Main spring guide”.

[01765-03 shaft extension tool]

Pull up shaft assembly and grab spring support

with a wrench.

[Wrench 19 mm]

Remove shaft extension tool.

Make sure that compression and rebound

adjusters are fully open before installing top

cap. Use a hex key to open compression and

rebound adjusters.

[Hex key 3 mm]

Install o-ring on top cap. Apply grease on o-ring

and thread.

[00576-02 o-ring]

[00146-01 grease]

Install top cap on shaft extension. Tighten to

20 Nm.

[Socket 14 mm]

Remove wrench from spring support.

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 to 10 Nm.

[00797-08 top cap tool]

Set compression, rebound and main spring

adjusters according to chapter “Setup Data”.

Use a hex key for compression and rebound

adjusters. Use a socket for main spring preload

adjuster.

[Hex key 3 mm]

[Socket 14 mm]

Install front fork legs in vehicle at

recommended front fork leg position, according

to chapter “Setup data”.

Remaining installation, instructions according

to vehicle service manual.

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00

fax +46 8 590 025 80

reserved. Any reprinting or

unauthorized use without the written

permission of Öhlins Racing AB

is prohibited.

Öhlins 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.

To nd the latest information

contact an Öhlins distributor.

Please contact Öhlins if you have

any questions regarding the

contents in this document.

Part no. MI_FKR118_0

Issued 2017-05-02

100

150

200

250

300

350

400

450

500

550

0102030405060708090100 110120 130

Force [N]

Stroke [mm]

Level

SETUP DATA

Recommended setup

MAIN SPRING GUIDE

Compression adjustment 14 clicks

Rebound adjustment 14 clicks

Suspension uid level 180 mm

Minimum suspension uid level 200 mm

Suspension uid part number 01309-xx

Front fork leg position Standard

Make sure you choose the correct main spring for

your rider weight, driving style and preferences.

Below you nd a general recommendation of main

spring rate for your weight. Contact an authorized

Öhlins service center for advice.

Air spring force diagram

Rider weight [kg] 50 60 70 80 90 100 110

Spring rate [N/mm] 9 9 9,5 10 10,5 10,5 11

Preload [mm] 3 5 5 4 4 6 5

Part number (pair) 08790-90 08790-90 08790-95 08790-10 08790-05 08790-05 08790-11

Part number (single) 04744-90 04744-90 04744-95 04744-10 04744-05 04744-05 04744-11

Note!1

Only 8790-xx main springs are packed in pairs.

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