Before installing this product, check the

contents of the kit. If anything is missing, please

contact your hlinsdealer.
Kit Contents

Compression Piston Assembly

Rebound Piston Assembly
hlins Sticker (60x23) white 00191-32
hlins Sticker (60x23) blue
00191-33

Pcs
2
2
2
2

Warning!
This kit should only be installed by an authorized
hlins Centre. The installation procedure
requires special hlins tools.

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, minor updates
may occur.

To find the latest information, please

contact your hlins distributor.
Please consult your hlins dealer if
you have any questions regarding
the contents in this document.

hlins Racing AB. All rights

reserved.
Any reprinting or unauthorized use
without the written permission of
hlins RacingAB is prohibited.

hlins Racing AB
Box 722
S-194 27 Upplands Vsby, Sweden
Phone +46 8 590 025 00
fax +46 8 590 025 80

Front Fork Piston Kit for Yamaha R6

FPK 107

Mounting Instructions

Part no. FPK 107_1

Issued 2009-03-24

www.ohlins.com

Safety Precautions

Set-up Data
Safety Symbols
In this manual, mounting instructions and
other technical documents, important
information concerning safety is
distinguished by the following symbols:

Read and make sure that you understand

the information in this manual before you use
this product. If you have any questions
regarding installation or maintenance please
contact your nearest hlins dealer.

The Safety Alert Symbol means: Warning!

Your safety is involved.

hlins Racing AB can not be held

responsible for any damage to the front fork,
vehicle, other property or injury to persons, if
the instructions for installing and maintenance
are not followed exactly.

Warning!
The Warning Symbol means: Failure to
follow warning instructions can result in
severe or fatal injury to anyone working with,
inspecting or using the front fork, or
to bystanders.

Warning!
This product was developed and designed
exclusively for a specific vehicle model and
should only be installed on the intended vehicle
model in its original condition as delivered from
the vehicle manufacturer.

Caution!
The Caution Symbol means: Special
precautions must be taken to avoid damage
to the front fork.

After installing this product, take a test ride

at low speed to make sure that your vehicle
has maintained its stability.

Note!
The Note Symbol indicates information that
is important regarding procedures.

Recommended set-up
Compression
6 clicks
Rebound
14 clicks
Spring Preload
1 ring
Oil Level
110 mm

Base Valve Piston - Compression

Note!
The front fork is a very important part of the
vehicle and will therefore affect the stability of
the vehicle.

Optional Springs
Part No.
08760-85
08760-90
08760-95
08760-10
Standard Rate

01449-01
Clamp
Shims
01425-12
01425-14
01425-16
01425-18

01451-02
Piston
00438-42
O-ring

Rate
8.5 N/mm
9.0 N/mm
9.5 N/mm
10.0 N/mm
8.9 N/mm

01657-02
Nut
00578-04
Washer
02046-01
Check valve
seat
01453-02
Check valve
wave washer

00186-18
Check valve shim

Note!

This Manual should be considered as a part

of the product and should therefore
accompany the product throughout its life
cycle.

hlins Racing AB. All rights reserved. Any

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

Main Piston - Rebound

When working on this product, always consult

your Vehicle Service Manual.

02046-01
Check valve
seat

01657-02
Nut

01453-02 (3x)
Check valve
wave washer
00186-18
Check valve 01447-01
Piston ring
shim
01448-06
Piston

10

00578-04
Washer
Shims
01420-18
01420-16
01420-14
01420-12

01449-01
Clamp
washer

How to Install

Recommended Tools

6.8
Use tool 01766-02, push down the preload
tube. Pull up the shaft, use an OEM Pull up
Tool. Insert a Stopper plate tool. Assemble
the top cap to the shaft by tightening it to the
lock nut. Tightening torque: 15 Nm.

Recommended hlins Tools

Clamping tool 10/12
00727-02
Clamping tool 24
00787-01
Preload tube pusher tool
01766-02
Seal Head Tool
04702-04

6.8

Lubricants
hlins Front Fork Fluid
hlins Red Grease

Note!
Make sure that the distance between the shaft
lock nut and the top of the shaft does not
change when assembling the top cap.

01309-01
00146-01

Adhesives
Loctite 243
Loctite 270
Loctite 542
Loctite 2701

6.9
Assemble the top cap to the outer fork leg.
Tightening torque: 10 Nm. Put some grease
on the thread and the o-ring. Make sure
that the Front Fork is fully extended when
tightening the top cap.

Recommended OEM Tools

Pull-up tool
Stopper Plate Tool

6.9

7 Install the Front Fork

Recommended Tools
Heat gun
Allen key
Open Wrench
Vice

7.1
Install the front fork legs into the fork crowns.
Tightening torque upper fork crown: 20 Nm
Tightening torque lower fork crown: 10 Nm

Note!
Make sure that the distance between the top
of the fork leg and the upper fork crown is the
same as measured in chapter 1.3.
7.2
Reinstall the front fender, brake calipers and
the front wheel. Do not tighten yet.
7.3
Put the motorcycle on the ground, apply
the front brake and compress the front fork
3-4 times. This will put thte legs in an exact
parallell position.

7.1

7.4
Tighten the front wheel, brake calipers and
the front fender. Consult your Vehicle Service
Manual for correct tightening torques.

Note!
Make sure that nothing restricts the fork
movement when fully compressed.
9

How to install

How to install

1. Remove the Front Fork

6 Install the Cartridge Assembly into the Fork Leg

Warning!
It is advisable to have an hlins dealer install the
Fork Piston Kit.

1.2

When installing, consult your Vehicle Service

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

6.1
Install the cartridge assembly into the fork leg
and tighten it to the form bottom using Seal
head tool 04702-04.
Tightening torque: 20 Nm. Loctite 270.

6.1

6.2

Note!
Check the condition of the copper washer.
Replace if worn or deformed.

1.1

6.2
Pour approximately 0,5 litre hlins Front Fork
fluid into the fork leg.

Warning!
Make sure the vehicle is securely supported so
that it will not tip.

1.3

1.2
Remove the front fender, brake calipers and
the front wheel.

6.3
Install the top cap directly to the shaft, no
spring or preload tube. Pull up the outer fork
leg and screw it to the top cap. Handtighten
only. Pump out all air from the damping
system by pulling the outer fork leg up and
down 10-15 times.

1.3
Measure the distance from the top of the
outer fork leg to the top of the upper fork
crown.

Note the distance. The upper fork crown should

be reinstalled at the same position.
1.4
Release the spring preload and count the
number of turns.

1.5

Note!

6.5

6.4
Remove the top cap.

1.4

Note!

6.3

Note the number of turns.

6.5
Make sure that the shaft is in the bottom of
the cartridge and the outer fork leg is in its
bottom position. Measure the distance from
the top of the outer fork leg to the oil surface.
Recommended oil level according to Set-up
Data in this folder.

6.6

6.6
Set the distance between the shaft lock nut
and the top of the shaft.

1.5
Loosen the upper fork crown by loosening the
screws.

6.7

Note!

1.6
Loosen, but do not remove, the top cap half
a turn.

1.7

Use the same distance between the lock nut

and the top of the shaft as in chapter 2.3
6.7
Drop the spring and preload tube on top of
the cartridge.

1.7
Loosen the lower fork crown by loosening the
screws.

Note!

1.8
Remove the fork legs from the fork crowns.

Parts in the same order as in chapter 2.5

3

How to install

How to install

5 Disable the Hydraulic Stop

5.1

2 Remove cartridge from fork leg

5.2

2.1

2.1
Loosen the top cap from the outer fork leg
and slide the outer fork leg all the way down.

Note!
For best performance on race track, we
recommend you to disable the Hydraulic Stop.

2.2

2.2
Use tool 01766-02 and push the preload tube
down to expose the lock nut. Insert a Stopper
Plate Tool below the lock nut.

Please note that this procedure disables the

Hydraulic Stop permanently.
5.1
Remove the seal head and top-out spring by
sliding them off the shaft.

2.3
Loosen the top cap from the shaft.
2.4
Measure the distance between the lock nut
and the top of the shaft.

Note!
Note the order and the direction of the parts.
5.2
Drill two 4 mm holes a few millimetres
above the bottom surface inside the seal
head.

2.3

Note!

2.4

Note the distance between the lock nut and the

top of the shaft.

Caution!

5.5

Make sure that the holes are above the bottom

surface, otherwise the bushing will be damaged
when drilling.

2.5
Remove the preload tube and the spring.

Note!
5.3

5.3
Assemble the seal head and the top-out
spring by sliding them on to the shaft.

Note the order between the parts and the

direction of the spring.

2.7

2.6
Turn the fork leg upside down and pour out
the oil.

Note!
Assemble the parts in the same order and
direction as before, see step 5.1.
5.4
Put the shaft in a vice, use tool 00727-02 (see
figure). Assemble the piston holder assembly
to the shaft by tightening the piston holder to
the shaft and then the lock nut.
Tightening torque: 15 Nm. Loctite 542.

ca 30-50mm

2.5

2.7
Use Seal Head Tool 04702-04. Remove the
cartridge assembly by loosening the cartridge
from the fork bottom.

5.4
ca 20mm

5.5
Put the cylinder tube in a vice, use tool
00787-01 (see figure). Assemble the shaft
assembly by tightening the seal head to the
cylinder tube.
Tightening torque: 40 Nm. Loctite 2701.

How to install

How to Install
4 Replace Main Piston (Rebound)

3 Replace Base Valve Piston (Compression)

3.1

3.1
Remove the base valve assembly from the
fork bottom by loosening the base valve
housing.

4.1

4.1
Put the cylinder tube into a vice, use
tool00787-01.
4.2
Remove the shaft assembly by loosening the
seal head from the cylinder tube. Use Seal
head tool 04702-04.

3.2
Remove the standard piston and all its parts
from the base valve by loosening the base
valve nut.

4.2

Note!

3.3
Remove the o-ring from the hlins piston kit
delivery holder.

Use a heat gun to loosen the Loctite between

the seal head and the cylinder tube.

3.2

4.3
Put the shaft in a vice, use tool 0072702.
Remove the standard piston holder assembly
from the shaft by loosening the lock nut and
the piston holder from the shaft.

3.4
Slide all components on the delivery holder
directly on the base valve. Tighten the
base valve nut. Tightening torque 5Nm.
Loctite243.

4.4
Remove the standard piston and shims from
the piston holder by loosening the piston
holder nut.

Note!
The o-ring and delivery holder are only delivery
parts and shall not be assembled.

3.3

3.5
Reinstall the base valve assembly in the fork
bottom. Tighten the base valve housing.
Tightening torque 20Nm.

ca 30-50mm

4.3

4.5
Remove the o-ring from the hlins piston kit
delivery holder.

3.4

4.6
Slide all components on the delivery holder
directly on the piston holder and tighten the
piston holder nut.
Tightening torque: 5 Nm. Loctite 243.

Note!
After this installation, turning the top nut of the
base valve will not have any affect.

Note!
3.5

4.5

The o-ring and the delivery holder are only

delivery parts and shall not be assembled.

Note!

4.6

Do not install the piston holder assembly to the

shaft yet, see step 5.4.