ADJ uSt Ment S

Spring preload adjuster

Adjust by turning the nut on the top of the fork leg. Turn clockwise to increase and counter clockwise to decrease the spring preload.

1 Decrease Increase

Mounting instruction
hlins front fork kit fGK137 for Yamaha R6
This kit should only be installed by an hlins dealer. The installation procedure requires certain hlins tools. 3 hlins Racing AB cannot be held responsible for any damage to the front fork kit, vehicle or injury to persons, if the instructions for installing and maintenance are not followed exactly. Similarly, the warranty will become null and void if the instructions are not adhered to.

Rebound damping adjuster

2 Adjust by turning the screw with an allen key.

Compression damping adjuster

3 Adjust by turning the screw with an allen key. 2

Reset according to the following:

The adjusters have a normal right hand thread. Turn the damping adjuster clockwise to fully close (pos. zero [0]). To open, turn the damping adjuster counter clockwise - count the clicks from fully closed until you reach the recommended setting. See Set-up data in this manual.

In this manual
Safety precautions Mounting instructions Check sag and ride height Set-up data Adjustments Diagram: Oil level - Force

CAutIOn!
Do not use force, delicate sealing surfaces can be damaged.

D I A GRAM: O I l level - f ORCe

800 750 700 650 600 550 500

Mounting instruction FGK137_1 Issued 20080429 hlins Racing AB AA/TIHA/DN

Oil level (mm):

120 130 140 150 160 170 180 190 200 210 220

Kit Contents
Front fork kit hlins stickers 47x125 hlins stickers 28x74 FGK137 (1) 00192-01 (2) 01196-02 (2)

Recommended tools
Tool 1765-03 Tool 0797-01

Force [N]

450 400 350 300 250 200 150 100 50 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Tool 1797-07

Tool 4702-04

Stroke [mm]

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

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

SAfet Y PR eCA ut IO nS
Read this manual carefully!
Pay special attention to statements proceded by the following notations:

C He C K S A G AnD R I De HeI G H t
Before riding your bike, check sag and ride height according to the procedure below. To get the most out of your suspension component it is of great importance to make the proper settings. See Set-up data below and Adjustments on the next page.

WARnInG!
1. Installing a front fork kit, that is not approved by the vehicle manufacturer, may affect the vehicles stability. hlins Racing AB cannot be held responsible for any personal injury or damage that may occur after fitting the front fork kit. 2. The vehicles service manual must be referred to when installing this front fork kit. 3. Please study and make certain you fully understand the mounting instructions before handling this front fork kit. If you have any questions regarding proper installation procedures, contact an hlins dealer.

The Safety alert symbol means: Attention! Your safety is involved!

F1 R1 R2

F2 R3

F3

WARnInG
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.

Bike on a stand

Bike on the ground

Bike with rider

CAutIOn!
Caution indicates that special precautions must be taken to avoid damage to the front fork kit.

front suspension
f1 Bike on a stand with the suspension fully extended = ............

Rear suspension
R1 Bike on a stand with the suspension fully extended = .............

nOte!
Indicates information that is of importance regarding mounting procedures.

f2 Bike on the ground without rider = ............ f3 Bike on the ground with rider Free sag Ride height = ............

R2 Bike on the ground without rider = ............ R3 Bike on the ground with rider Free sag Ride height = ............

f1 - f2 = ............ f1 - f3 = ............

R1 - R2 = ............ R1 - R3 = ............

nOte!
hlins 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 kit and this manual. Please consult your hlins dealer if you have any questions regarding the contents of this manual.

S e t- uP D AtA
Recommended settings:
Rebound adjustment Compression adjustment Spring preload Oil level hlins oil part No. 13 clicks 10 clicks 8 mm 160 mm 01309

Recommended sag and ride height:

The measures should not differ from the following recommendations: Without rider: Rear Front With rider: Rear Front 10 - 20 mm (R1-R2) 20 - 30 mm (F1-F2) 25 - 40 mm (R1-R3) 35 - 50 mm (F1-F3)

M Ount I nG I n St R u CtIOnS
25
Make sure the cartridge is in the bottom of the fork leg and that the outer fork leg is in the bottom position. Measure the oil level with a scale. Recommended setting according to chapter Set-up data and Diagram: Oil levelforce.
XXX mm

M Ou n tI nG I nSt R uCt I OnS

WARnInG!
1. It is advisable to have an hlins dealer install the front fork kit. The installation procedure requires certain hlins tools. 2. Follow the instructions in the vehicle service manual when changing the front fork kit. Tool 1765-03 3. When working on a raised vehicle, make sure that it is securely supported to prevent it from falling. Spring support

26
Put the preload tube and the spring on top of the cartridge.

fig.25

Removing the original front fork 1

Put the motorcycle on a workstand so that the front wheel is off the ground.

27
Fasten tool 1765-03 on the top of the piston rod. Install the spring support by leading it over the tool.

Spring

2
Preload tube

28
Pull up the piston rod and grab the spring support with a 19 mm wrench.

Remove the front fender, brake caliper and the front wheel.

fig.3

3
Measure the position of the front fork: Measure the distance from the top of the fork leg to the top of the upper triple clamp. fig.27 It is very important that the front fork is reattached at the exact same position.

29
Open the rebound adjuster fully. Remove the pull-up tool and install the top cap to the piston rod. Tighten with torque 15 Nm. fig.26

nOte!

Screw

30
Pull up the outer fork. Make sure the fork leg is in a fully extended position. Use tool 0797-01 to tighten the top cap. Tighten the top cap with torque 10 Nm.

Spring support

fig.5

19 mm wrench

4
Release the spring preload.

fig.28

Loosen the upper fork crown by loosening the screws.

31
Set the spring preload, rebound and compression adjusters according to Adjustments and Set-up data in this manual.

Top cap 15 Nm

6
Loosen (do not remove) the top cap turn. fig.4

32
Install the front fork legs into the fork crowns. Tighten the upper fork crown with torque 20 Nm, and the lower fork crown with torque 10 Nm. It is very important that the front forks are in the same position as they were before changing the fork kit!

7
fig.29
10 Nm

Loosen the lower fork crown by loosening the screws.

8
Remove the front fork legs from the fork crowns.
1/2 turn

nOte!

fig.30 5 2

fig.5

M Ount I nG I n St R u CtIOnS
Disassemble the original front fork 9
Remove the original top cap from the fork leg.

M Ou n tI nG I nSt R uCt I OnS

Installing the hlins front fork kit 18
Remove the hlins top cap.
Spring Top cap Spring support

10
Pull down the outer fork leg.

11
Remove the original spring and preload tube.

Original base valve

19
Remove the spring support, spring and the preload tube.

fig.18

Preload tube

12
Loosen the original cartridge with tool 04702-04. Take out the whole cartridge from the fork leg. fig.14
Circlip

20
Put the cartridge carefully into the fork leg. Use locktite 270. fig.19

13
Turn the fork legs upside down to pour out all oil.
Original housing Original housing

21
Tighten the cartridge with tool 1797-07 to torque 20 Nm.
Loctite 270 Original base valve hlins base valve

20 Nm

Replace the base valve 14

Remove the original base valve from the front fork bottom, use an adjustable spanner.

Tool 1797-07

22
Remove tool 1797-07 and pour approximately 0,5 litre hlins oil into the fork leg.

15
Remove the circlip and the housing from the original base valve. fig.15 fig.16

23
Install the top cap directly to the cartridge (no spring or preload tube). Pull up the outer front fork leg and screw it to the top cap. Handtighten only. Pump out all the air from the fork leg by pulling the fork up and down 10-15 times. fig.20
Top cap

16
Install the original housing on the enclosed hlins base valve.
Circlip

17
Reinstall the original circlip and reinstall the complete base valve. Tighten with torque 20 Nm. After this installation you can not make any adjustments by turning the top nut on the base valve!

24
Remove the top cap from the outer fork leg. fig.21

nOte!

20 Nm

fig.17 fig.22 3 4 fig.23