Ohlins FGR 156 User Manual

Pressurized Front Fork Kit for Kawasaki ZX-6R
FGR 156
Mounting Instructions
Warning!⚠
Only approved Öhlins personnel are permitted
to install this kit. The procedure requires
specic 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.
Note!1
Before you install this product, check the kit
contents. If anything is missing, please contact
an Öhlins dealer.
Kit Contents
Description Part No Pcs
Front Fork Kit FGR156 1
Sticker Tech. Inside wh 00191-32 2
Sticker Tech. Inside bl 00191-33 2
Spring 10,5N/mm 04744-05 2
Spring 10 N/mm 04744-10 2
Spring 9,5 N/mm 04744-95 2
Owner’s manual 07286-01 1
Plug 21652-02 2
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
Please note that there can be small differences
between your product and the images in
these instructions.
Note!1
After this procedure the compression adjuster
will no longer be usable.
Oil, grease and threadlocker
Function grease CaH92 00159-01
Öhlins front fork uid 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

Ohlins FGR 156 Specifications

General

Type	Front Fork
Model	FGR 156
Fork Tube Diameter	43mm
Application	Motorcycle
Material	Aluminum

Summary

Product Kit Contents and Recommended Tools

Kit Contents Overview

Lists all components included in the front fork kit, such as springs, stickers, and manuals.

Recommended Tools for Installation

Details specialized tools required for the fork installation procedure, including tube and seal tools.

Required Fluids and Chemicals

Specifies the necessary grease, oil, and threadlocker for the fork assembly process.

Remove the Original Front Fork

Initial Motorcycle Preparation

Describes setting up the motorcycle on a stand and removing initial components like the fender and wheel.

Front Fork Disengagement

Covers releasing spring preload and loosening triple clamps to remove fork legs.

Disassemble the Original Front Fork

Outer Tube and Top Cap Removal

Instructions for loosening the top cap and pulling down the outer tube to access internal parts.

Internal Component Extraction

Details steps to remove spring collar, drain oil, and detach the steel tube from the fork bottom.

Install the Öhlins Front Fork Cartridge Kit

Cartridge and Component Preparation

Guides on removing top caps, spring supports, and preparing the seal head for installation.

Adaptor and Plug Installation

Steps for installing the steel adaptor and plug into the fork bottom with specified torque.

Cartridge and Seal Head Tightening

Details on inserting the cartridge and tightening the seal head to the cylinder tube extension.

Fluid Filling and Spring Assembly

Covers pouring fork fluid, assembling the preload tube and spring, and securing the shaft assembly.

Final Assembly and Adjustment

Instructions for installing the top cap, setting spring preload, and tightening the fork legs.

Setup Data and Oil Level Diagram

Key Setup Specifications

Provides critical setup data including compression, rebound, spring rate, oil level, and fork leg position.

Oil Level vs. Air Spring Force

Illustrates the relationship between oil level and air spring force across different stroke lengths.