Ohlins 21944-01 Front Fork Kit for Yamaha YZF-R3 Mounting Instruction

Kit Conttnts

Dtscription

Front fork kit

O-ring

Part o

21944-01

00438-85

Pcs

1

2

Öhlins sticker (60x23) wh 00191-32 2

Öhlins sticker (60x23) blue 00191-33 2

Owner’s manual 07289-01 1

1

otte!

Please note that there can be small differences between your product and the images in these instructions.

1

otte!

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.

⚠

arninge!

This kit should only be installed by an authorized

Öhlins dealer. The installation procedure requires certain tools.

1

otte!

Before you install this product, check the kit contents. If anything is missing, please contact an Öhlins dealer.

⚠

arninge!

Before you install this product, read the Öhlins

Owner’s manual and this document. This product is an important part of the vehicle and the vehicle stability.

Front Fork Kit for Yamaha YZF-R3

21944-01

Mounting Instructions

MOU TI G I STRUCTIO S

⚠

arninge!

We strongly recommend to let an Öhlins dealer install this product.

⚠

arninge!

If you work with a lifted vehicle, make sure that it is safely supported to prevent it from tipping over.

⚠

arninge!

Spring compression creates a potential danger because of the violent force that loaded springs are capable of. Beware of this when you work with the front fork.

1

otte!

When you work with this product, see the vehicle service manual for vehicle specific procedures and important data.

1

otte!

Before you install this product clean the vehicle.

TOOLS, GREASE A D FLUID

Tools nttdtd for tht original front fork

• Refer to the vehicle service manual for tools needed for removing/installing the front fork from the vehicle.

• Refer to the vehicle service manual for tools needed for removing the cartridge from the front fork.

Tools nttdtd for tht Öhlins cartridgt kit

Tool Part no Applits

Vehicle service manual

Torque wrench

Heat gun

Wrench

Hex key

Soften thread locker

Shaft extension

Compression and rebound bleed adjusters

Socket

Ruler

Öhlins tool

Top cap tool

Clamp tool

Sleeve

01765-08

00797-08

24670-01

24669-04

Preload adjuster

Oil level

Shaft extension

Top cap

24669-04

Original inner tube

Öhlins tool

Suspension fluid

Grease

Loctite 2400

Loctite 2700

01797-08 Seal head

01309-xx

00146-01

01791-25

01791-27

Sizt

15 mm

3 mm

14 mm

37 mm

100 g

50 ml

50 ml

2

MOU TI G I STRUCTIO S

1 Rtmovt tht original front fork

4

1

otte!

The following procedure applies to both front fork legs.

1.1

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

⚠

arninge!

Make sure the vehicle is securely supported so that it will not fall over.

1.2

Remove front fender, brake calipers, speed sensor (if present) and front wheel.

1.3

Release main spring preload fully (if present).

1.4

Note front fork leg position.

1.5

Loosen upper triple clamp.

1.6

Loosen (do not remove) top cap ½ turn.

1.7

Loosen lower triple clamp.

1.8

Remove front fork legs from triple clamps.

Front fork leg position

3

MOU TI G I STRUCTIO S

2 Ltft hand sidt front fork ltg

8

Rtmovt original

2.1

Loosen top cap from outer tube.

2.2

Slide outer tube down until it stops.

2.3

Loosen and remove top cap from shaft according to vehicle service manual.

2.4

Remove main spring and surrounding parts from front fork leg.

2.5

Drain front fork leg of suspension fluid.

2.6

Loosen cartridge according to vehicle service manual.

2.7

Remove cartridge from front fork leg.

9

10

Install tht Öhlins comprtssion cartridgt kit

✋

Cautione!

The cartridge kit is divided into compression and rebound cartridges.

Install compression cartridge marked “COMP” in left hand side front fork leg.

2.8

Remove top cap (A), spring support (B) and preload tube (C).

2.9

Insert the cartridge in the front fork leg.

2.10

Install bottom screw according to instructions in the vehicle service manual.

A

B

C

4

MOU TI G I STRUCTIO S

2.11

Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg.

[01309-xx suspension fluid]

2.12

Use a hex key to open compression bleed adjuster fully. Install top cap directly to shaft extension (no main spring or preload tube). Pull up outer tube and tighten it to the top cap with your hand.

[Hex key 3 mm]

2.13

Pull outer tube up and down 10-15 times to pump out all air from the cartridge.

2.14

Remove top cap from front fork leg.

13

2.15

Make sure that shaft assembly and outer tube are in their bottom positions.

Set suspension fluid level according to chapter

“Setup Data”.

2.16

Install shaft extension tool on top of shaft extension.

Install preload tube (A), main spring (B) and spring support (C) over shaft extension tool.

[

01765-08 shaft txttnsion tool

]

2.17

Pull up shaft assembly and grab spring support with a wrench tool.

[

rtnch 15 mm

]

16

17

C

B

A

15

5

MOU TI G I STRUCTIO S

2.18

Install o-ring on top cap. Apply grease on o-ring and thread.

[

00438-85 o-ring

]

[

00146-01 grtast

]

2.19

Make sure that compression adjuster is fully open before installing top cap.

Use a hex key to open compression adjuster.

Remove pull-up tool and install top cap to the shaft extension. Tighten to 12 Nm.

[

Htx kty 3 mm

]

[

Socktt 14 mm

]

2.20

Remove wrench from spring support.

[

rtnch 15 mm

]

2.21

Pull up outer tube. Make sure front fork leg is in a fully extended position. Tighten top cap to outer tube. Tighten to 10 Nm.

[

00797-08 top cap tool

]

2.22

Set main spring preload and compression adjusters according to chapter “Setup Data”.

Use a hex key for compression adjuster.

Use a socket for the preload adjuster.

[

Htx kty 3 mm

]

[

Socktt 14 mm

]

19

6

MOU TI G I STRUCTIO S

3 Right hand sidt front fork ltg

1

Rtmovt original

3.1

Loosen top cap from outer tube and shaft.

3.2

Slide outer tube down until it stops.

3.3

Remove seal head from inner tube according to instructions in the vehicle service manual.

3.4

Remove main spring and associated parts according to instructions in the vehicle service manual.

3.5

Drain front fork leg of suspension fluid.

3.6

Remove outer tube from inner tube according to instructions in the vehicle service manual.

3.7

Remove inner tube lock screw .

3

⚠

arninge!

If the lock screw is not removed, the inner tube and front fork bottom will be damaged.

7

4

7

MOU TI G I STRUCTIO S

⚠

arninge!

The inner tube thread must be repaired before removing the inner tube.

8

3.8

Install inner tube tool on inner tube. Do not place the tool at sealing or gliding surface.

[24670-01 Clamp tool]

[24669-04 Sleeve 37]

3.9

Soften thread locker between inner tube and front fork bottom using a heat gun.

[

Htat gun

]

3.10

Remove inner tube from front fork bottom.

3.11

Remove and replace o-ring if worn or damaged. Part no according to the vehicle spare part list.

3.12

Remove washer.

9

10

Install tht Öhlins rtbound cartridgt kit

✋

Cautione!

The cartridge kit is divided into compression and rebound cartridges.

Install rebound cartridge marked “REB” in right hand side front fork leg.

3.13

Remove the adaptor ring from the cartridge.

3.14

Install adaptor ring in front fork bottom.

13

1

otte!

Check the position and rotation of adaptor ring.

3.15

Install o-ring in front fork bottom.

[

00146-01 grtast

]

15

14

11

12

8

MOU TI G I STRUCTIO S

3.16

Install inner tube using inner tube tool.

Apply Loctite 2700. Tighten to 130 Nm.

[24670-01 Clamp tool]

[24669-04 Sleeve 37]

[

01791-27 Loctitt 2700

]

16

1

otte!

To get the correct torque, make sure to place the torque wrench in a 90 degree angle to the

Fork tube tool.

3.17

Remove top cap (A), spring support (B) and preload tube (C).

3.18

Apply Loctite 2400 on adaptor thread.

Install cartridge using seal head tool.

Tighten to 25 Nm.

[

01791-25 Loctitt 2400

]

[

01797-08 stal htad tool

]

17

18

A

B

C

9

MOU TI G I STRUCTIO S

3.19

Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg.

[01309-xx suspension fluid]

3.20

Use a hex key to open rebound bleed adjuster fully. Install top cap directly to shaft extension

(no main spring or preload tube). Pull up outer tube and tighten it to the top cap with your hand.

[Hex key 3 mm]

3.21

Pull outer tube up and down 10-15 times to pump out all air from the cartridge.

3.22

Remove top cap from front fork leg.

21

3.23

Make sure that shaft assembly and outer tube are in their bottom positions.

Set suspension fluid level according to chapter

“Setup Data”.

3.24

Install shaft extension tool on top of shaft extension.

Install preload tube (A), main spring (B) and spring support (C) over shaft extension tool.

[

01765-08 shaft txttnsion tool

]

3.25

Pull up shaft assembly and grab spring support with a wrench.

[

rtnch 15 mm

]

24

25

C

B

A

23

10

MOU TI G I STRUCTIO S

3.26

Install o-ring on top cap. Apply grease on o-ring and thread.

[

00438-85 o-ring

]

[

00146-01 grtast

]

3.27

Make sure that rebound adjuster is fully open before installing top cap.

Use a hex key to open rebound adjuster.

Remove pull-up tool and install top cap to the shaft extension. Tighten to 12 Nm.

[

Htx kty 3 mm

]

[

Socktt 14 mm

]

3.28

Remove wrench from spring support.

[

rtnch 15 mm

]

3.29

Pull up outer tube. Make sure front fork leg is in a fully extended position. Tighten top cap to outer tube. Tighten to 10 Nm.

[

00797-08 top cap tool

]

3.30

Set main spring preload and rebound adjusters according to chapter “Setup Data”.

Use a hex key for compression adjuster.

Use a socket for the preload adjuster.

[

Htx kty 3 mm

]

[

Socktt 14 mm

]

27

4 Install tht front fork in tht vthiclt

1

otte!

The following procedure applies to both front fork legs.

4.1

Install the front fork legs into the triple clamps at the position recommended in setup data

(Front leg position). See the vehicle service manual for correct procedure and tightening torque.

1

otte!

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

1

11

300

250

200

150

100

50

0

0

500

450

400

350

SETUP DATA

Compression

Front leg position

8

Rebound

Suspension fluid level

12

120

Minimum suspension fluid level 300

Suspension fluid 01309-xx clicks clicks mm mm

Standard position

MAI SPRI G RECOMME DATIO

Rider weight [kg] 50 60 70 80 90 100 110

Spring rate [N/mm]

Preload [turns]

6

10

6,5

8

6,5

10

7

8

7

10

7,5

8

7,5

10

Part number (pair) 08428-60 08428-65 08428-65 08428-70 08428-70 08428-75 08428-75

Spring are packed in pairs.

Force vs Stroke

550

10 20 30 40 50 60 70

Stroke [mm]

80 90 100 110 120 130

Level

[mm]

190

200

210

220

230

240

250

260

110

120

130

140

150

160

170

180

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 find the latest information contact an Öhlins distributor.

Please contact Öhlins if you have any questions regarding the contents in this document.

Part no. MI_21944_01

Issued 2019-10-16

© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited.

Öhlins Racing AB

Box 722

S-194 27 Upplands Väsby, Sweden

Phone +46 8 590 025 00 fax +46 8 590 025 80