Before installing this product, check the

contents of the kit. If anything is missing, please

contact an Öhlins dealer.
Kit Contents
Part No. Pcs.
Front fork kit FGK238 1
Öhlins Sticker (60x23) white 00191-32 2
Öhlins Sticker (60x23) blue 00191-33 2
Owners manual 07284-01 1

Warning!
This kit should only be installed by an authorized
Öhlins dealer. The installation procedure requires
certain tools.
Please note that during storage and
transportation, especially at high ambient
temperature, some of the oil and grease used for
assembling may leak and stain the packaging.
This is in no way detrimental to the product,
wipe off the excessive oil/grease with a cloth.

Warning!
Before installing this product, please read this
document. The front fork is an important part of
your vehicle and will affect the stability.

Note!
Please note that after this installation the
compression adjuster at the fork bottom will no
longer have a function.

Front Fork Kit for Yamaha YZF-R6

FGK 238
Mounting Instructions
Safety Precautions
Note!
The front fork is a very important part of the
Safety Symbols
vehicle and will therefore affect the stability. In this manual, mounting instructions and
other technical documents, important
Read and make sure that you understand the information concerning safety is
information in this manual before you use this distinguished by the following symbols:
product. If you have any questions regarding
installation or maintenance please contact your
nearest Öhlins dealer. The Safety Alert Symbol means: Warning!
Your safety is involved.
Öhlins Racing AB can not be held
responsible for any damage to the front fork, Warning!
vehicle, other property or injury to persons, if the The Warning Symbol means: Failure to
instructions for installing and maintenance are follow warning instructions can result in
not followed exactly. severe or fatal injury to anyone working with,
inspecting or using the front fork, or
Warning!
to bystanders.
This product was developed and designed
exclusively for a specific vehicle model and Caution!
should only be installed on the intended vehicle The Caution Symbol means: Special
model in its original condition as delivered from precautions must be taken to avoid damage
the vehicle manufacturer. to the front fork.
After installing this product, take a test ride
Note!
at low speed to make sure that your vehicle has
The Note Symbol indicates information that
maintained its stability.
is important regarding procedures.
Note!
When working on this product, always consult
your Vehicle Service Manual.

This Manual should be considered as a part

© Öhlins Racing AB. All rights reserved. Any
of the product and should therefore accompany
reprinting or unauthorized use without the written
the product throughout its life cycle. permission of Öhlins Racing AB is prohibited.
Printed in Sweden.

Tools
Tool 00797-08 Tool 01765-03 Tool 01797-07

1
 1 - Remove Original Front Fork
Warning!
It is advisable to have an Öhlins dealer install the
front fork.

When installing, consult your Vehicle Service

Manual. 2
1.1
Put the motorcycle on a workstand so that
the front wheel barely touches the ground.

Warning!
Make sure the vehicle is securely supported so
that it will not tip. 1
1.2 3
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 4
clamp.

1.6
Loosen (do not remove) the top cap ½ turn.
1.7
Loosen the lower triple clamp by loosening
the screws. 5
1.8
Remove the front fork legs from the triple
clamps.
6

1/2 turn

2
2 - Disassemble Original Front Fork
2.1
Loosen the top cap from the outer tube.
2.2
Pull down the outer tube.
2.3
Remove the top cap by loosening it from the
shaft. Use appropriate tool according to your
vehicle service manual.
2.4
Remove the spring and surrounding parts
from the fork leg, Drain the fork leg from oil.

2.5
Loosen the cartridge. Use appropriate tool
according to your vehicle service manual.
2.6
Remove the cartridge from the fork leg.

3
 3 - Install Öhlins Front Fork Kit
Caution!
Work with only one fork leg at a time. Do not mix
the parts. 1 2

Caution! Spring
The front fork kit is divided into one compression support
cartridge and one rebound cartridge. Important:
• Install the cartridge marked “Reb” (Rebound) in the
right side fork leg.
Preload
tube
• Install the cartridge marked “Comp” (Compression) in
the left side fork leg.

3.1
Remove the top cap.
3
3.2
Remove the spring support and the preload
tube.
3.3
Remove the cylinder tube from the cartridge.

Caution!
Be careful not to damage the piston ring.
3.4
Put the cylinder tube carefully into the fork
leg. Tighten the cylinder tube’s adaptor to the
bottom screw using an extended 17 mm allen
key at the adaptor and an appropriate tool
at the bottom screw. See the vehicle service 6
manual for recommended thread locking fluid
and tightening torque.

Caution! 4
Be careful not to damage the inside of the
cylinder tube when tightening with the extended 17 mm
allen key. allen key

3.5 Loctite
Pour 0,5 litre Öhlins Front Fork fuid into the
fork leg.
3.6
Put the cartridge carefully in the fork leg.
Tighten it to the cylinder tube. Use tool
01797-07, and at the same time, hold the
bottom screw in place using an appropriate
tool. Apply red grease on the seal head’s
thread. Torque 20 Nm.

Caution!
Make sure that the piston ring is in its correct
position and be careful not to damage it.

4
3 - Install Öhlins Front Fork Kit
3.7
Open the compression and the rebound
8 10
adjuster fully. Install the top cap directly to the
shaft extension (No spring or preload tube).
Pull up the outer tube and tighten it to the top XXX mm
cap. Handtighten only.
3.8
Pump out all air from the cartridge by pulling
the outer tube up and down 10-15 times.
11
3.9
Remove the top cap from the fork leg. Spring
11 Spring
3.10
support
Make sure the shaft assembly is in the bottom
of the fork leg and that the outer tube is in its
bottom position. Measure the oil level with
a ruler. See set-up data and oil level-force
diagram in this folder. Preload
tube
3.11
Fasten tool 01765-03 on the top of the shaft
extensioner, install preload tube,spring and 12
upper spring support by leading them over
the tool. See the Owner’s Manual for available Spring
support
springs.
3.12
Pull up the shaft assembly and grab the
spring support with a 19 mm wrench.
3.13
Make sure that the comp/rebound adjusters 13
are fully open before installing the top cap.
Remove the pull-up tool and install the top
cap to the shaft extensioner. Torque 15 Nm.
3.14
Pull up the outer tube. Make sure the fork
leg is in a fully extended position. Use tool
00797‑08 to tighten the top cap to the outer
tube. Torque 10 Nm.
14

5
 Install Öhlins Front Fork Kit
3.15
Set the spring preload, rebound and
compression adjusters according to
adjustments and set-up data in this manual.
3.16
Install the front fork legs into the triple clamps
at the position recommended in set-up data
(Fork leg position).
Tightening torque: According to your vehicle
service manual.

Note! Fork leg

position
Measure the fork leg position from the upper
triple clamp to the top of the outer tube.

6
 Set-up Data
Recommended set-up:
Compression 12 clicks
Rebound 12 clicks
Spring rate 9.5 N/mm
Spring preload 12 mm
Oil level 170 mm
Fork leg position Standard position
Öhlins Front Fork Fluid part no 01309-01

Diagram - Oil Level - Air Spring Force

Force vs Stroke
550

500
Oil level
[mm]
450
140
400 150
160
350 170
180
300 190
Force [N]

200
250 210
220
200 230
240
150 250
260
100
270

50

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Stroke [mm]

Öhlins products are subject to To find the latest information contact

continuous improvement and your Öhlins distributor. Please
development, therefore, although consult your Öhlins dealer if you
these instructions include the most have any questions regarding the
up-to-date information available at contents in this document.
the time of printing, minor updates
may occur. Part no. FGK238_0
Issued 2016-03-03

© Öhlins Racing AB. All rights Öhlins Racing AB

reserved. Any reprinting or Box 722
unauthorized use without the written S-194 27 Upplands Väsby, Sweden
permission of Öhlins Racing AB Phone +46 8 590 025 00
is prohibited. fax +46 8 590 025 80
www.ohlins.com