HLINS FKA 116 Front Fork Kit for Yamaha Tenere 700 World Raid Instructions
- June 9, 2024
- HLINS
Table of Contents
HLINS FKA 116 Front Fork Kit for Yamaha Tenere 700 World Raid
MOUNTING INSTRUCTIONS
Note!
Please note that there can be small differences between your product and the images in these instructions.
Note!
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.
Kit Contents
Description| Part No| Pcs
Front fork kit| FKA 116| 1
O-ring 40×2.5| 00576-02| 2
O-ring 23.52×1.78| 00438-02| 2
Bottom screw| 21950-02| 2
Sticker set Öhlins| –| –
Owner’s manual| 07287-01| 1
Warning!
This kit should only be installed by an authorized Öhlins dealer. The installation procedure requires certain tools.
Note!
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 and this document. This product is an important part of the vehicle and the vehicle stability
Warning!
We strongly recommend to let an 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!
When you work with this product, see the vehicle service manual for vehicle specific procedures and important data.
Note!
Before you install this product clean the vehicle.
Warning!
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.
TOOLS, GREASE AND FLUID
Tools needed for the 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 needed for the Öhlins cartridge kit
| Tool | Part no | Applies | Size |
|---|---|---|---|
| Vehicle service manual | |||
| Torque wrench | |||
| Wrench | Shaft extension | 19 mm | |
| Hex key | Compression and rebound bleed adjusters | 3 mm | |
| Socket | Main spring preload adjuster | 14 mm | |
| Ruler | Suspension fluid level | ||
| Öhlins tool | 01765-03 | Shaft extension | |
| Wrench | Top cap | 46 mm | |
| Öhlins tool | 01797-07 | Seal head | |
| Suspension fluid | 01309-xx | ||
| Grease | 00146-01 | 100 g |
Remove the original front fork
Note!
The following procedure applies to both front fork legs.
Put the motorcycle on a work stand so that the front wheel barely touches the ground.
Warning!
- Make sure the vehicle is securely supported so that it will not fall over
- Slide outer tube down until it stops.
- Loosen and remove top cap from shaft according to vehicle service manual.
- Remove main spring and surrounding parts from front fork leg.
- Drain front fork leg of suspension fluid.
- Loosen cartridge according to vehicle service manual.
- Remove cartridge from front fork leg.
- Remove washer from bottom screw, it will be used when installing Öhlins cartridge kit.
Remove original
-
Loosen top cap from outer tube.
-
Slide outer tube down until it stops.
-
Loosen and remove top cap from shaft according to vehicle service manual.
-
Remove main spring and surrounding parts from front fork leg.
-
Drain front fork leg of suspension fluid.
-
Loosen cartridge according to vehicle service manual.
-
Remove cartridge from front fork leg.
-
Remove washer from bottom screw, it will be used when installing Öhlins cartridge kit
Install the Öhlins cartridge kit
Caution! -
Remove top cap (A), spring support (B), guide sleeve and preload tube (C).|
-
Insert cartridge in front fork leg.
-
Install standard washer and o-ring on bottom screw. Apply grease on o-ring.
[00438-02 o-ring] [21950-02 bottom screw]
-
Install bottom screw according to instructions in the vehicle service manual.
-
Pour approximately 0.5 litre Öhlins suspension fluid in front fork leg.
Warning!
Fluid level must be approximately 50 mm above top of seal head.
-
Use a hex key to open compression and rebound adjusters fully. Install top cap directly to shaft extension (no main spring or preloadtube). Pull up outer tube and tighten it to the top cap with your hand. [Hex key 3 mm]
-
Pull outer tube up and down 10-15 times to pump out all air from the cartridge.
-
Remove top cap from front fork leg.
-
Make sure that shaft assembly and outer tube are in their bottom positions. Set suspension fluid level according to chapter “Setup Data”.
-
Install shaft extension tool on top of shaft extension. Install main spring with the marking up (A), guide sleeve and preload tube (B) and spring support (C) over shaft extension tool. [01765-03 shaft extension tool]
-
Pull up shaft assembly and grab spring support with a wrench tool. [Wrench 19 mm]
-
Install o-ring on top cap. Apply grease on o-ring and thread. [00576-02 O-ring] [00146-01 grease]
-
Make sure that compression and rebound adjusters are fully open before installing top cap. Use a hex key to open compression and rebound adjusters. Remove pull-up tool and install top cap to the shaft extension. Tighten to 20 Nm.
[Hex key 3 mm] [Socket 14 mm]
-
Remove wrench from spring support.
-
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.
[Wrench 46 mm] -
Set compression, rebound and main spring preload adjusters according to chapter “Setup Data”. Use a hex key for compression and rebound adjusters. Use a socket for main spring preload adjuster.
[Hex key 3 mm] [Socket 14 mm]
Install the front fork in the vehicle
- Install front fork legs in vehicle at recommended front fork leg position, according to chapter “Setup data”.
- Remaining installation, instructions according to vehicle service manual.
SETUP DATA
| Compression | 14 | clicks |
|---|---|---|
| Rebound | 14 | clicks |
| Suspension fluid level | 140 | mm |
| Suspension fluid volume | 450 | ml |
| Front leg position | Standard position | |
| Suspension fluid | 01309-xx |
MAIN SPRING RECOMMENDATION
Make sure you choose the correct main spring for your rider weight, driving
style and preferences.
Below you find a general recommendation of main spring rate for your weight.
Contact an authorized Öhlins service center for advice
FKA 116 Yamaha Tenere 700 World Raid
| Rider weight [kg] | 50 | 60 | 70 | 80 | 90 | 100 | 110 |
|---|---|---|---|---|---|---|---|
| Spring rate [N/mm] | 5 | 5.5 | 5.5 | 6 | 6 | 6.5 | 6.5 |
| Preload [turns] | 8 | 4 | 7 | 3 | 5 | 2 | 4 |
| Part number (pair) | 08438-50 | 08438-55 | 08438-55 | 08438-60 | 08438-60 | ||
| 08438-65 | 08438-65 |
Main springs are packed in pairs.
CUSTOMER SUPPORT
To find the latest information contact an Öhlins distributor. Please
contact Öhlins if you have any questions regarding the contents in this
document.
Öhlins Racing AB Box 722
S-194 27 Upplands Väsby, Sweden
Phone +46 8 590 025 00
fax +46 8 590 025 80
Documents / Resources
|
HLINS FKA 116 Front Fork Kit for Yamaha Tenere 700 World
Raid
[pdf] Instructions
FKA 116 Front Fork Kit for Yamaha Tenere 700 World Raid, FKA 116, Front Fork
Kit for Yamaha Tenere 700 World Raid, Yamaha Tenere 700 World Raid, Tenere 700
World Raid
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