Öhlins 04791-02 Bracket Kit Mounting Instructions PDF

1 of 4
1 of 4

Summary of Content for Öhlins 04791-02 Bracket Kit Mounting Instructions PDF

hlins Radial Caliper Bracket Kit is designed for Brembo radial calipers. The Kit contains left and right caliper brackets and fork bottom pieces. Spacers for larger diameter brake disks are provided

Kit 4791-01 includes caliper brackets with 100 mm c-c screw holes. Kit 4791-02 includes caliper brackets with 108 mm c-c screw holes.

No wheel spacers or fender brackets are included in this kit.

The brackets have a side offset of 13.3 mm. The brake discs must have an offset corresponding to this measure.

CAUTION! It is of vital importance that brake discs with correct offset are used

Bracket without spacers fits brake discs with a diameter of 290 mm. When spacers are used discs with a diameter of 320 mm can be fitted.

WARNING! When radial brake calipers are mounted to earlier Front Forks 43 the fork bottoms must be changed. New fork bottoms are provided with the kit. Chang- ing fork bottoms demands good mechanical skills and special tools. This kit must be changed by an authorized hlins Service Centre

Mounting Instructions hlins Radial Caliper Bracket Kit

04791-01 and 04791-02

hlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited. Printed in Sweden.

NOTE! Before dismantling the front fork check the settings and make a note on rebound and com- pression clicks and spring pre-load setting.

hlins Racing AB, Box 722, S-194 27 Upplands Vsby, Sweden. Phone +46 8 590 025 00. Fax +46 8 590 025 80.

www.ohlins.com P ar

t N o.

0 47

91 -0

1. Is

su ed

0 3

05 1

2

Checking sag and ride height

Front suspension F1. Bike on a stand with the

suspension fully extended = ............

F2. Bike on the ground without rider = ............

F3. Bike on the ground with rider = ............

Free sag F1 - F2 = ............

Ride height F1 - F3 = ............

Bike on a stand.

F1

R1

Bike on the ground.

F2

R2

Bike with rider on.

F3

R3

Rear suspension R1.Bike on a stand with the

suspension fully extended = ............

R2.Bike on the ground without rider = ........... .

R3.Bike on the ground with rider = ............

Free sag R1 - R2 = ............

Ride height R1 - R3 = ............

Safety signals Important information concerning safety is distinguished in this manual by the following notations:

The Safety alert symbol means: Caution! Your safety is involved.

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 pre- cautions must be taken to avoid dam- age to the suspension.

NOTE! This indicates information that is of importance with regard to procedures.

Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension or 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.

WARNING! Installing a suspension, that is not approved by the vehicle manufacturer, may affect the stability of your vehicle. hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension. Contact an hlins dealer or other qualified person for advice.

hlins products are subject to continual improve- ment 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 front fork and this mounting instruction. Please consult your hlins dealer if you have any questions with re- gard to the contents of the mounting instruction.

Kit contents Before installing the Caliper Bracket Kit, please check the contents of the kit. If anything is missing, contact your hlins dealer.

Description Pcs. Part No. 04791-01 Caliper bracket LH 1 01593-13 Caliper bracket RH 1 01593-14

04791-02 Caliper bracket LH 1 01593-11 Caliper bracket RH 1 01593-12

Caliper spacer 4 01669-03 Caliper sleeve 4 01669-02 Fork bottom assy 2 04742-05 O-ring 2 04722-08 Sticker hlins 2 00194-10

21 Reinstall the pre load tube, the upper spring seat and the nut of the piston rod..

22 Apply red grease (146-01) to the washer and the key and fit them to the top nut assy. (Top nut A/B assy only)

23 Pull the piston rod upwards and screw it into the top nut assy. Use Top nut holder (4705-01) or a 17 mm wrench to keep a firm hold of the cartridge nut, use a 12 mm wrench on top nut assy A/B and a 17 mm wrench on top nut assy C/D and tighten to a torque of 30 Nm.

24 Pull the outer tube up and reinstall the top nut. Use top nut tool (797-04) and tighten it gently by hand.

25 Fit the radial caliper brackets. Torque: M8=25Nm, M6=12 Nm.

26 Adjust compression and rebound by first turning the adjusters clock vise to 0-position. Then turn them counter clock vise to correct number of clicks according to your notes. Set the pre-load.

27 Reinstall the fork legs to the motorcycle.

NOTE! The shaft hole of the fork bottom has a diameter of 32 +0,05 -0 mm. We recommend a sleeve with the following valves: 32 h9 +0 -0,052. Max. radial play between the sleeves and the wheel shaft is 0,1 mm.

21

22

23

24

27

25

Washer Nut

Spring seat

Pre-load tube

Outer tube

Key

Washer

12 mm wrench

17 mm wrench

Top nut assy tool 797-04

Front fork bottom

Spacer

Caliper bracket

30 Nm

M6 screw

M8 screws

28 The sleeve 01669-02 shall be mounted with the chamfer inside the caliper bracket, not inside the brake caliper.

4

Mounting instructions

1 Remove the front fork legs from the motorcycle.

2 Fasten the fork leg in a vice. Use soft jaws.

3. Loosen the spring pre load by turning the upper adjustment nut counter clock vise. Use a 12 mm wrench to Top nut type A/B and a 17 mm wrench to Top Nut type C/D

4 Loosen the top nut assembly. Use Top nut tool (797-04).

1

2

3

Top nut tool 797-04

15 Make sure that the thread of the inner tube is clean and free form oil, grease and loctite. Position the o-ring (04722-08) provided into the bottom piece. When reinstalling the inner tube to the new fork bottom piece, locking fluid Loctite 270 or similar must be used. Tighten to a torque of 110 Nm.

16 Install the outer tube. Fill 500 ml hlins front fork oil (1309-01).

17 Insert the piston rod assy into the cylinder. Apply some red grease (146-01) to the tread and tighten to a torque of 40 Nm. Use a torque wrench

NOTE! Open the compression adjuster fully before pumping procedure. Use a 3 mm allen tool

18 Push the piston rod up and down until the cartridge is completely filled with oil.

19 Reinstall the adjustment rod and put the spring back into the fork leg.

NOTE! The spring is to be positioned with the marking number upwards.

20 Measure the oil level and adjust to correct level (see spec. card for correct data)

17

15

16 16

20

Oil level

See spec. card for correct fluid level

Tool 786-05

New bottom piece

Loctite 270

Outer tube

Inner tube

Spring

hlins front fork oil 1309-01

19

Adjustment rod

110 Nm

5 Let the outer tube drop down. Use Top nut holder (4705-01) or a 17 mm wrench to keep a firm hold of the piston rod nut.

CAUTION! Beware not to damage the O-ring.

NOTE! When a standard 17 mm wrench is used, the upper spring seat must be pressed down, to make access to the nut.

6 Remove the top nut assy from the piston rod. Use a 12 mm wrench. On top nut type A/B the washer and the key should be removed.

7 Unscrew and remove the upper nut from the piston rod to release the upper spring seat and the pre-load tube.

8 Use a steel wire shaped to a hook in one end to grip the spring and pull the spring out.

9 Free the front fork from the vice and pour the front fork fluid out.

NOTE! The adjustment rod must be held in position not to fall out.

10 Put the front fork leg back into the vice and care- fully slide the outer tube upwards to remove it.

NOTE! Use a cloth to avoid excess oil to trickle out from the tube

5

7

8

9

Top nut assy

Spring seat

Pre-load tube

Inner tube

Outer tube

Spring

6

12 mm wrench

17 mm wrench

Outer tube

11 Loosen the piston rod assy and pull it out. Use Cartridge tool (4702-01).

12 Free the fork bottom and inner tube from the vice and pour the remaining oil out.

13 Fasten the fork bottom to the vice again.

14 Remove the inner tube from the fork bottom. Use of clamp tool (786-05) and a heat air gun to release the fork bottom from locking fluid.

12

11

14

Cartridge tool 4702-01

Piston rod assy

Inner tube

Fork bottom

Heat air gun

Clamp tool 786-05

<

Manualsnet FAQs

If you want to find out how the 04791-02 Öhlins works, you can view and download the Öhlins 04791-02 Bracket Kit Mounting Instructions on the Manualsnet website.

Yes, we have the Mounting Instructions for Öhlins 04791-02 as well as other Öhlins manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Mounting Instructions should include all the details that are needed to use a Öhlins 04791-02. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Öhlins 04791-02 Bracket Kit Mounting Instructions is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Öhlins 04791-02 Bracket Kit Mounting Instructions consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Öhlins 04791-02 Bracket Kit Mounting Instructions free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Öhlins 04791-02 Bracket Kit Mounting Instructions, simply download the document to your computer. Once downloaded, open the PDF file and print the Öhlins 04791-02 Bracket Kit Mounting Instructions as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.