Pressurized Front Fork Kit for Kawasaki ZX-6R
FGR 156
Mounting Instructions
Warning!⚠
Only approved Öhlins personnel are permitted
to install this kit. The procedure requires
specic tools. Before you install this product,
read the Öhlins Owner’s manual. This product
is an important part of the vehicle and the
vehicle stability.
Note!1
Before you install this product, check the kit
contents. If anything is missing, please contact
an Öhlins dealer.
Kit Contents
Description Part No Pcs
Front Fork Kit FGR156 1
Sticker Tech. Inside wh 00191-32 2
Sticker Tech. Inside bl 00191-33 2
Spring 10,5N/mm 04744-05 2
Spring 10 N/mm 04744-10 2
Spring 9,5 N/mm 04744-95 2
Owner’s manual 07286-01 1
Plug 21652-02 2
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
Please note that there can be small differences
between your product and the images in
these instructions.
Note!1
After this procedure the compression adjuster
will no longer be usable.
Oil, grease and threadlocker
Function grease CaH92 00159-01
Öhlins front fork uid 01309-xx
Threadlocker, high, Loctite 2701 01791-05
Recommended tools
Fork tube tool Ø41 00786-08
Cyl. tube holder Ø36
or Soft jaws 28/36
00787-07
00727-09
Top cap tool 00797-08
Pull-up tool 01765-03
Seal head tool 01797-07
Seal head tool 01797-09
2
MOUNTING INSTRUCTIONS
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 specic
procedures and important data.
Note!1
Before you install this product clean the vehicle.
1 Remove the original front fork
1.1
Put the motorcycle on a work stand so that the
front wheel barely touches the ground.
1.2
Remove the front fender, the brake calipers
and the front wheel.
1.3
Release the spring preload.
1.4
Note the fork leg position.
1.5
Loosen the screws to loosen the upper triple
clamp.
1.6
See the vehicle service manual for correct tool
to loosen the top cap ½ turn, do not remove it.
1.7
Loosen the screws to loosen the lower triple
clamp.
1.8
Remove the fork legs.
1/2 turn
1.3
1.5
1.6
1.8
1.2
1.1
1.4
3
MOUNTING INSTRUCTIONS
2 Disassemble the original front fork
2.1
Loosen the top cap from the outer tube. Pull
down the outer tube.
2.2
See the vehicle service manual for correct tools
to do these steps:
- remove the top cap
- loosen the seal head from the steel tube
- remove the original cartridge
2.3
Remove the upper spring collar and the spring.
2.4
Drain the fork leg from oil and remove the
lower spring collar. Note that the spring collar
can have a different size or shape than the one
in the image.
2.5
Push the outer tube as far up as possible.
Install the fork tube tool (00786-0X) on the
steel tube, close to the outer tube.
Caution!✋
It is important to remove the lock screw in
step 2.6 to prevent damage to the steel tube.
2.6
Apply heat with a heat gun to break down the
threadlocker between the steel tube lock screw
and the fork bottom. See the vehicle service
manual for correct tool to remove the steel tube
lock screw.
2.7
Apply heat with a heat gun to break down the
threadlocker between the steel tube and the
fork bottom. Use the fork tube tool to loosen
and remove the steel tube from the fork
bottom.
Note!1
Do not remove the fork tube tool from the steel
tube yet. You will need it to install the steel tube.
2.8
Remove the O-ring and the steel washer from
the fork bottom. Note that you will not need the
steel washer for the Öhlins kit.
Clean the threads in the fork bottom and on
the inner tube, make sure that there is no
threadlocker left.
2.9
See the vehicle service manual for correct
tool to loosen the spring preload adjuster on
the fork bottom. Remove the spring preload
adjuster parts.
2.2 2.3
2.4
2.5
2.9
2.6
Loading...