Today, I swapped the stock forks on my 05 R1 for Ohlins R/T forks. I took some extra time to document the process and make a quick How-To:
1.Place the rear of the bike on a stand.
2.Jack the front wheel of the bike approximately 6" off the ground. I used a piece of wood on top of a floor jack to lift it up from just under the exhaust header flange and used 2 jack stands to support it.
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3.Remove the brake line guides and caliper mounting bolts.
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4.Remove calipers and hang from grip/clip-on using cable ties or string, etc.
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5.Loosen & remove axle bolt and axle clamping screws (2 on each fork).
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6.Remove axle and drop wheel away from bike. Set aside.
7.Remove (4) fender mounting screws and pull fender out from between forks. Set aside.
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8.Locate left fork lower triple clamp clamping screws.
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9.Loosen with small angle-head bit ratchet (w/allen bit).
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Screws can also be reached from underneath:
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10.Locate and loosen upper triple clamp clamping screw and clip-on clamping screw.
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11.Carefully pull fork out through the bottom of the triple clamps.
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12.Repeat for right side fork, except loosen throttle cable guide clamp before removing fork.
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Here's the clamp after it's been removed from the fork tube:
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13.These 2 cables are the throttle cables and are held in place by the clamp. There is a tab on the clamp that rests against the aluminum tab shown to position the throttle cables correctly. Be sure and re-install the clamp correctly when re-installing the right side fork.
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14.To re-install the forks I use a long screwdriver to wedge open the lower triple clamp. It makes inserting the fork tube a LOT easier.
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15.Once the fork tube is through the upper triple clamp, be sure and install the top of the tube to the height you desire.
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16.Tighten the triple clamp clamping screws and clip-on clamping screw. Repeat for remaining fork.
17.Re-install fender and wheel, leaving axle bolt and clamping screws finger tight.
18.De-jack front of bike.
19.Compress front suspension several times and allow it to rebound.
20.Tighten axle clamping screws and axle bolt.
21.Re-install brake calipers and brake line guides.
22.Put your tools away before your kids run off with them.
1.Place the rear of the bike on a stand.
2.Jack the front wheel of the bike approximately 6" off the ground. I used a piece of wood on top of a floor jack to lift it up from just under the exhaust header flange and used 2 jack stands to support it.
3.Remove the brake line guides and caliper mounting bolts.
4.Remove calipers and hang from grip/clip-on using cable ties or string, etc.
5.Loosen & remove axle bolt and axle clamping screws (2 on each fork).
6.Remove axle and drop wheel away from bike. Set aside.
7.Remove (4) fender mounting screws and pull fender out from between forks. Set aside.
8.Locate left fork lower triple clamp clamping screws.
9.Loosen with small angle-head bit ratchet (w/allen bit).
Screws can also be reached from underneath:
10.Locate and loosen upper triple clamp clamping screw and clip-on clamping screw.
11.Carefully pull fork out through the bottom of the triple clamps.
12.Repeat for right side fork, except loosen throttle cable guide clamp before removing fork.
Here's the clamp after it's been removed from the fork tube:
13.These 2 cables are the throttle cables and are held in place by the clamp. There is a tab on the clamp that rests against the aluminum tab shown to position the throttle cables correctly. Be sure and re-install the clamp correctly when re-installing the right side fork.
14.To re-install the forks I use a long screwdriver to wedge open the lower triple clamp. It makes inserting the fork tube a LOT easier.
15.Once the fork tube is through the upper triple clamp, be sure and install the top of the tube to the height you desire.
16.Tighten the triple clamp clamping screws and clip-on clamping screw. Repeat for remaining fork.
17.Re-install fender and wheel, leaving axle bolt and clamping screws finger tight.
18.De-jack front of bike.
19.Compress front suspension several times and allow it to rebound.
20.Tighten axle clamping screws and axle bolt.
21.Re-install brake calipers and brake line guides.
22.Put your tools away before your kids run off with them.
