Mounting Instructions
Öhlins front fork kit FGHO 691
for HONDA CR 125/ 250, CRF 250/ 450 2006
Kit Contents
Before installing this front fork kit, please
check the contents of the kit, listed below.
If any part is missing, please contact your
Öhlins dealer.
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00. Fax +46 8 590 025 80.
www.ohlins.com
FGHO 691 - Issued 2005 12 29
© Öhlins Racing AB. All rights reserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
Front fork 48MXF FGHO691 (1 pair)
Tool for End Cap 01873-01 (1)
Spring 43.6/467/3.9 02428-39 (2)
Spring 43.6/467/4.5 02428-45 (2)
Preload tube 20 mm MX48 02437-20 (2)
Triple clamp, lower 02443-01 (1)
Triple clamp, upper 02443-02 (1)
Handlebar clamp, lower 04315-01 (2)
Screw M8 02456-03 (8)
Screw MC6S 01046-45 (2)
Sticker “ÖHLINS” 00197-01 (2)
Sticker Front Fork 02332-11 (2)
Owner’s manual (1)
ADJUSTMENTS
NOTE!
Read more about compression, rebound
and spring pre-load in your Öhlins Owner’s
manual.
CAUTION!
The front fork springs are delivered separately
and must be installed before the front fork is
mounted to the bike. See section “Installing
springs” in this manual.
The Öhlins front fork is an upside down type
featuring the following adjusters:
Compression damping adjuster
The compression adjuster is located at the bottom
of the fork leg. Adjust by turning the screw. Use a
slot screw driver.
Rebound damping adjuster
The rebound adjuster is located on the top of
the fork leg. Adjust by turning the screw. Use a
slot screw driver.
Compression
damping
adjustment
Rebound damping
adjuster
NOTE!
When delivered the Öhlins front fork is dialed
to recommended settings for the specifi c
brand and make of the vehicle. If you have
changed the settings, reset according to the
following:
The adjusters have a normal right hand thread.
Turn the damping adjusters clockwise to fully
closed (pos. zero [0]). Turn counter clockwise
to open and count the clicks until you reach the
recommended number of clicks. See Setup data
on the last page of this manual.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged.
Please read before installing
Öhlins Racing AB cannot be held responsible
for any damage to the front fork kit, vehicle or
injury to persons, if the instructions for fi tting
and maintenance are not followed exactly.
Similarly, the warranty will become null and
void if the instructions are not adhered to.
In this manual
Safety precautions
Mounting instructions
Before riding
Set-up data
Adjustments
SAFETY PRECAUTIONS
1 6
Read this manual carefully!
Pay special attention to statements proceded by the following notations:
The Safety alert symbol means: Attention!
Your safety is involved!
Failure to follow these warning instructions
may result in severe or fatal injury to anyone working with, inspecting or using this
front fork kit, or to bystanders.
Caution indicates that special precautions
must be taken to avoid damage to the
front fork kit.
Indicates information that is of importance
regarding mounting procedures.
!
WARNING
CAUTION!
NOTE!
WARNING!
1. Installing a front fork, that is not
approved by the vehicle manufacturer,
may affect the vehicle’s stability. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage that may
occur after fi tting the front fork. Contact
an Öhlins dealer or other qualifi ed person
for advice.
2. The vehicle service manual must
be referred to when installing this front
fork kit.
3. Please study and make certain you fully
understand the mounting instructions and
the owner’s manual before handling this
front fork kit. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer or other qualifi ed person.
!
!
NOTE!
During storage and transportation, especially 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.
NOTE!
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, there may be minor differences
between your front fork and this manual.
Please consult your Öhlins dealer if you
have any questions regarding the contents
of this manual.
1
Including:
Safety
Tuning th e
suspension
D
esign
features
Function
Basic
adjustments
Fine tuning
Inspection,
m
aintenance
Owner’s Manual
Öhlins shock absorbers, M
X
/ENDU
R
O/O
F
F
R
OAD
Your vehicle OEM
BEFORE RIDING
SET-UP DATA
IMPORTANT NOTICE!
Before riding your bike, check sag and ride
height according to your Öhlins Owner’s
manual.
To get the most out of your suspension component it is of great importance to make proper
settings and to use the correct spring for your
weight - full riding equipment on!
We recommend you to read your Öhlins
Owner’s manual carefully to understand the
different effects of the different settings.
Recommended settings
Rebound adjustment 15 clicks
Compression adjustment 12 clicks
Spring pre-load 0 mm
Front fork position 4 mm
General facts
Front fork length 940 mm
Stroke 300 mm
?
?
? kg
? lbs
Recommendations
CR 125
Spring rate 3.9 N/mm
Oil level 110 mm
CR 250
Spring rate 4.2 N/mm
Oil level 110 mm
CRF 250
Spring rate 4.2 N/mm
Oil level 110 mm
CRF 450
Spring rate 4.4 N/mm
Oil level 105 mm
Measure fork position
Measure oil level
Measure from the
top of the fork leg
to the top surface of
the triple clamp.
Measure from the
top of the outer leg,
with the top nut
off, fork fully compressed and no
spring installed.
NOTE!
All spring rates above cannot be achieved
with the provided springs. Please contact
your Öhlins dealer for advice.
NOTE!
When delivered, the oil level is 105 mm. For
some models you need to drain some oil to
achieve the recommended level.
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