Öhlins FGK460 Conversion Kit Mounting Instructions PDF

1 of 4
1 of 4

Summary of Content for Öhlins FGK460 Conversion Kit Mounting Instructions PDF

Mounting Instructions hlins Super Motard Conversion Kit FGK 460

for hlins front forks MXF and EXF 48

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

hlins Conversion Kit MXF/EXF hlins Super Motard conversion kit is designed to convert an hlins front fork MXF and front fork EXF into Super Motard forks. It shortens the total length by 31 mm and makes the high speed com- pression damping harder.

The kit consists of main springs, internal spacers and base valve springs.

Main spring, 4,9 N/mm shorter than MXF and EXF springs.

Spacer replaces the internal washer to shorten the front fork.

Base valve spring replaces original spring to make the high speed compression damping harder.

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 = 305 mm

Ride height F1 - F3 = 50-70 mm

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 = 305 mm

Ride height R1 - R3 = 80-90 mm

NOTE! If ride height is higher than recommended, softer spring/springs must be used. If ride height is lower than recommended, harder spring/springs must be used. Contact your hlins dealer for advice.

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.

F G

K 4

60 . I

ss ue

d 04

0 4

29

Setup data Here you can note your personal settings.

Lenght _____ mm

Stroke _____ mm

Rebound adjuster _____ clicks

Compression adjuster

High speed _____ clicks

Low speed _____ clicks

Spring pre-load _____ mm

Front fork oil level _____ mm

Front fork position _____ mm

Bike on a stand. Bike on the ground. Bike with rider on.

F1

R1

F2

R2

F3

R3

Fork position is measured from the top of the fork leg, to the top surface of the triple clamp.

x mm

Oil level

Oil level is measured from the top of the outer leg, with the top nut off, the fork fully compressed and no spring installed.

Tools 0727-02: Soft jaws 1761-02: Top cap releasing tool 1797-03: Cartridge tool 1860-01: Top cap releasing tool 1863-01: Base valve tool 1873-01: Top cap releasing tool

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 suspen- sion and this manual. Please consult your hlins dealer if you have any questions with regard to the contents of the manual.

NOTE! During storage and transportation, espe- cially at high ambient temperature, the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material. This is not unusual and is in no way detrimental to the front fork kit.

Kit contents Before installing the suspension components, please check the contents of the kit, listed on the front page of this instruction. If anything is missing, contact your hlins dealer.

Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension components 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! 1. Installing suspension components, 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 components. Contact an hlins dealer or other qualified person for advice.

2. Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this suspension components kit. If you have any questions regarding proper installation procedures, contact an hlins dealer or other qualified person.

3. The vehicle service manual must be referred to when installing the hlins suspension components

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 precautions must be taken to avoid damage to the suspension.

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

Tools needed

1873-01

1860-01

1761-02

1863-01

1797-03

0727-02

Description Part No. Pcs. Spring, front fork (4.7 N/mm) 02490-47 2 Spring, front fork (5.1 N/mm) 02490-51 2 Spring, base valve (60 N/mm) 04107-06 2 Spring, base valve (40 N/mm) 04107-04 2 Washer 02528-05 2

A lte

rn at

iv e

to o

ls

EXF only: Refit the adjustment wheel together with the balls and springs.

Balls and springs

Adjust the compression and the rebound valves according to specification card.

Fork bottom

Flat screwdriver

Fork top Compression adjuster

Adjustment wheel

Fit the fork legs on the motorcycle. Tightening torques: Upper triple clamp: 20 Nm Lower tripple clamp: 10 Nm

MXF and EXF

Recommended settings Recommended shims stacks:

Compression Rebound Midvalve 0186-14 (7x) 0184-21 (5x) 0530-22 0520-23 0184-20 1149-01 (5x) 4105-02 0184-19 0530-18 (4x) 0530-18 (2x) 0184-18

0184-17 0184-16 0184-14

Compression adjustment: Low speed: 14 clicks High speed: 1 turn (MXF only)

Rebound adjustment: 12 clicks

High speed compression adjuster (MXF only)

12 mm socket

Fork bottom

Base valve housing

Tool (1863-01)

Poppet valve seat

Poppet valve

Spring (04107-xx)

Base valve 17 mm/23 mm

Shims

Front fork leg

Change of high speed compression spring

1 Put the bike on a stand and loosen the screws in the fork top crown that hold the fork legs.

2 Turn the fork leg upside down and fasten the fork bottom in a vise with soft jaws.

3 Remove the compression valve assembly from the fork bottom using a 23 mm socket (MXF) and a 17 mm socket (EXF). Fasten the valve assembly with soft jaws

in a vice.

NOTE! This operation must be carried out with help of a pneumatic impact driver

4 Fasten the valve in a vise with soft jaws.

5 Use tool (1863-01) or a pair of pointed pliers to loosen the poppet valve seat and remove it together with the poppet valve and the spring.

6 Install the new spring, refit the poppet valve and the poppet valve seat. Tighten to a torque of 5 Nm.

7 Refit the valve unit to the fork bottom as described above. Tighten to a torque of 65 Nm.

65 N/mm

MXF 23 mm Hexagon Key Grip

EXF 17 mm Hexagon Key Grip

Assembly

1 Install the damper rod assembly into the cylin- der tube. Use Loctite 542 on the cylinder tube cap. Tighten with tool 1797-01to a torque 65 Nm.

2 Pump the damper rod up and down a few times to check that there is no air trapped.

3 Measure the correct amount of oil according to the specification card.

4 Pull out the damper rod as far as possible and close the compression and the rebound valves.

5 Install the spring and the spring support, (EXF) and the pre-load tube. (MXF)

NOTE! A spring ratio of 4.9 N/mm is obtained if a 4.7 N/ mm spring is used in one leg and a 5.1 N/mm spring is used in the other.

6 Install the fork top cap and the lock nut. Tighten the top cap and the lock nut against each other, use a 17 and 24 mm wrench. Tighten to 30 Nm.

7 Refit the top cap and thighten. The top cap should not be thightened hard, only turned in position by hand.

65 Nm

Damper rod assy

Cylinder tube

Cylinder tube cap

17 mm wrench

24 mm wrench

17 mm wrench

24 mm wrench

MXF

EXF

Tool 1761-02

MXF

Tool (1860-01)

Tool (1761-02)

Mounting Instructions - Spacers and Springs

Tool 1761-02

Top cap

Fork leg

17 mm wrench

24 mm wrench

Top cap

Pre-load tube

Spring

Top cap

17 mm wrench

Damper rod assy

Damper rod extender

Tool 1860-01

EXF Remove the adjustment wheel and the springs and balls of the adjuster. Unscrew the top cap, use tool (1860-01 or 1761-02). Remove the top cap from the damper rod extender. Use a 17mm wrench, and tool (1860-01 or 1761-02).

Adjustment wheel

Balls and springs

Original spring support

Remove the original spring support and the original spring.

1 Put the bike on a stand and loosen the screws in the fork top crown that hold the fork legs.

NOTE! On most MX and Enduro-bikes you have to take the handle bar off before you can unscrew the top cap.

2 Unscrew the top cap, using top cap tool 1761-02.

MXF Remove the top cap from the damper rod ex- tender, use a 17 and 24 mm wrench. Remove the spring support , the pre-load tube and the spring.

Compress the spring to get the 24 mm correct in position.

Compress the spring to get the 24 mm correct in position. Original

spring

Tool (1873-01)

Alternative tools

MXF and EXF

3 Loosen the cylinder tube cap, on top of the cylin- der tube, with tool 1797-01. Lift up the damper rod assembly and drain the oil.

NOTE! If the fork leg is fixed in upright position during the whole operation it is not necessery to drain the fork leg.

Tool (1797-01)

Cylinder tube

Damper rod assy

Cylinder tube cap

Hydraulic stop close to soft jaws

MXF front fork

EXF front fork

How to fasten the damper rod assembly

Guide sleeve close to the jaws

CAUTION ! Fasten the damper rod assembly in a vice. Be careful not to tighten too hard. The piston rod is very delicate.

Washer Washer (02340-02)

Piston holder

4 Fasten the damper rod assembly in a vice with soft jaws.

5 Remove the piston holder and the spring, so the original washer can be removed.

6 Clean all parts thoroughly and inspect all parts for wear and damage, replace if necessary. Assemble the damper rod assy by fitting the washer provided, the spring an

Manualsnet FAQs

If you want to find out how the FGK460 Öhlins works, you can view and download the Öhlins FGK460 Conversion Kit Mounting Instructions on the Manualsnet website.

Yes, we have the Mounting Instructions for Öhlins FGK460 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 FGK460. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Öhlins FGK460 Conversion 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 FGK460 Conversion 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 FGK460 Conversion 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 FGK460 Conversion Kit Mounting Instructions, simply download the document to your computer. Once downloaded, open the PDF file and print the Öhlins FGK460 Conversion 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.