Ohlins FGR 156 Mounting Instructions

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Pressurized Front Fork Kit for Kawasaki ZX-6R

FGR 156

Mounting Instructions

arningg!

⚠

Only approved Öhlins personnel are permitted

to install this kit. The procedure requires

specific 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.

oteg!

Before you install this product, check the kit

contents. If anything is missing, please contact

an Öhlins dealer.

Kit Contents

Description

Part o

Pcs

Front Fork Kit

FGR156

Sticker Tech. Inside wh

00191-32

Sticker Tech. Inside bl

00191-33

Spring 10,5N/mm

04744-05

Spring 10 N/mm

04744-10

Spring 9,5 N/mm

04744-95

Owner’s manual

07286-01

Plug

21652-02

oteg!

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.

oteg!

Please note that there can be small differences

between your product and the images in

these instructions.

oteg!

After this procedure the compression adjuster

will no longer be usable.

Oil, grease and threadlocker

Function grease CaH92

00159-01

Öhlins front fork fluid

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

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Summary of FGR 156

Page 1
Pressurized front fork kit for kawasaki zx-6r fgr 156 mounting instructions arningg! ⚠ only approved Öhlins personnel are permitted to install this kit. The procedure requires specific tools. Before you install this product, read the Öhlins owner’s manual. This product is an important part of the ve...
Page 2: Mou Ti G I Structio S
2 mou ti g i structio s arningg! ⚠ we strongly recommend to let an Öhlins dealer install this product. Arningg! ⚠ if you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over. Oteg! 1 when you work with this product, see the vehicle service manual for vehi...
Page 3: Mou Ti G I Structio S
3 mou ti g i structio s 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 ...
Page 4
4 3 install the Öhlins front fork cartridge kit cautiong! ✋ we strongly recommend that you work with one leg at a time, make sure not to mix the parts. Cautiong! ✋ the kit consists of one compression cartridge and one rebound cartridge. Note the marks. Make sure you install the cartridge in the corr...
Page 5
5 3.4 remove the steel adaptor from the cylinder tube adaptor. 3.5 apply function grease (00159-01) on the original o-ring and insert it in the fork bottom. 3.6 insert the steel adaptor in the fork bottom. Cautiong! ✋ make sure to install the adaptor correctly. See figure. Oteg! 1 do not install the...
Page 6
6 3.11 use the seal head tool (01797-07) to tighten the seal head to the cylinder tube extension. Tighten to 20 nm 3.12 pour 0,5 litre Öhlins front fork fuid (01309-xx) in the fork leg. See setup data and the oil level- force diagram in this folder. 3.13 put the preload tube and the spring on top of...
Page 7
7 3.19 install the front fork legs into the triple clamps at the fork leg position recommended in the setup data. Tighten according to the vehicle service manual. Oteg! 1 measure the fork leg extension from the upper triple clamp to the top of the outer tube. 3.19.
Page 8: Setup Data
Öhlins racing ab box 722 s-194 27 upplands väsby, sweden phone +46 8 590 025 00 fax +46 8 590 025 80 © Öhlins racing ab. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins racing ab is prohibited. Öhlins products are subject to continuous improvement and...