Ohlins FGRT 219 Bedienungsanleitung

Front Fork for Yamaha YZF-R1

FGRT 219

Mounting Instructions

Note!1

Please note that there can be small differences

between your product and the images in

these instructions.

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

Before you install this product, check the kit

contents. If anything is missing, please contact

an Öhlins dealer.

Warning!⚠

Before you install this product, read the Öhlins

Owner’s manual. This product is an important

part of the vehicle and the vehicle stability.

Kit Contents

Description Part No Pcs

Front fork FGRT219 1

Screw MC6S M5x10 01046-38 8

Fender bracket front 21665-09 2

Fender bracket rear 21665-17 2

Sticker Öhlins 01196-02 1

Owner’s Manual 07282-07 1

Put the motorcycle on a work stand so that the

front wheel barely touches the ground.

Remove the front fender, brake calipers, speed

sensor and the front wheel. Refer to the vehicle

service manual for correct procedure.

MOUNTING INSTRUCTIONS

Warning!⚠

We strongly recommend to let an authorized

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 specic

procedures and important data.

Note!1

Before you install this product clean the vehicle.

Measure the distance from the top of the outer

fork leg to the top of the upper triple clamp.

Note this distance.

Note!1

It is very important that the Öhlins front fork is

installed at the exact same posiition as the OEM

front fork.

Loosen the bolts to loosen the upper and the

lower triple clamps.

Remove the fork legs from the motorcycle.

Apply Loctite 243 or similar to the bolts. Install

the supplied fender brackets to the fork legs,

see gure 6. Tighten the screws to 4 Nm.

Install the fork legs in the triple clamps at the

same position as measured in step 3. Turn the

handle bars fully from side to side to make sure

that nothing restricts the movement, and that

the throttle cable and the wire harness run in

smooth bends.

Note!1

The eccentrically machined surfaces on the

outer tube must be at a 90º angle from the

vehicle direction.

Bracket

21665-17

Bracket

21665-17

Bracket

21665-09

Bracket

21665-09

2x bolt

01046-38

Loctite 243

Torque 4 Nm

2x bolt

01046-38

Loctite 243

Torque 4 Nm

2x bolt

01046-38

Loctite 243

Torque 4 Nm

2x bolt

01046-38

Loctite 243

Torque 4 Nm

MOUNTING INSTRUCTIONS

Tighten:

Upper triple clamp: 20 Nm

Lower triple clamp: 10 Nm

Install the front fender, front wheel and the

brake calipers. Do not tighten yet.

Warning!⚠

Ensure that the speed sensor cable does not

touch the wheel at full lock turns and when the

suspension is fully compressed or extended.

Install the speed sensor bracket:

Place the sensor cable bracket at the rear

screw (position A) that holds the rear fender

bracket. Cable routing according to the gure.

Ensure that the speed sensor cable does not

touch the wheel at full lock turns and when the

suspension is fully compressed or extended.

Put the vehicle on the ground, apply the front

brake and compress the front fork distinctly

3-4 times. This will position the front fork legs

parallell.

Tighten the front axle, brake calipers and the

front fender.

Front axle pinch bolts torque: 19 Nm

Close the compression and rebound adjusters.

Compress the front fork as much as possible

several times to bleed out the air. Ensure that

there is damping on the full stroke.

Set the compression and rebound adjusters,

see setup data on the next page.

Caution!✋

Make sure that you tighten all screws to the

correct torque and that nothing fouls or restricts

movement of the front fork when the suspension

is fully compressed or extended.

Cable behind

the brake hose

Hose down

towards

the speed

sensor.

Speed sensor

bracket on the

outer side of

the brake hose

attachment.

The tab of

the bracket

below the

rear fender

bracket.

Torque and

thread locking

according to

vehicle service

manual.

ADJUSTMENTS

Warning!⚠

Before you ride/drive, always make sure that the

setup is according to the recommended setup

data. Read about adjustments and setting up

in the Öhlins Owner’s Manual before you make

any adjustments. Contact an Öhlins dealer if

you have any questions about set up.

Spring

preload

adjuster

Compression/

Rebound

adjuster

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00

fax +46 8 590 025 80

reserved. Any reprinting or

unauthorized use without the written

permission of Öhlins Racing AB

is prohibited.

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, minor updates

may occur.

To nd the latest information

contact an Öhlins distributor.

Please contact Öhlins if you have

any questions regarding the

contents in this document.

SETUP DATA

OIL LEVEL - FORCE DIAGRAM

Part no. MI_FGRT219_0

Issued 2015-09-08

Compression 12 clicks

Rebound 12 clicks

Spring preload 6 mm

Oil level 150 mm

Fork leg position Standard position

Öhlins Front fork uid 01309-01

Recommended sag and ride height

No rider (Free sag)

Front 15-30 mm (F1-F2)

With rider (Ride height)

Front 35-50 mm (F1-F3)

Spring

Part No. Rate (N/mm)

04744-95 (optional) 9.5

04744-90 (optional) 9.0

04744-10 (standard) 10.0

04744-05 (optional) 10.5

04744-11 (optional) 11.0

100

150

200

250

300

350

400

450

500

0102030405060708090100 110120 130

Force [N]

Stroke [mm]

Oil level [mm]

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

Air spring for one leg.

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