Öhlins Front Fork Superbike FGR 700 - Zupin
Öhlins Front Fork Superbike FGR 700 - Zupin
Öhlins Front Fork Superbike FGR 700 - Zupin
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OWNER’S MANUAL<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong> <strong>Superbike</strong> <strong>FGR</strong> <strong>700</strong>
Safety signals<br />
Important information concerning safety is<br />
distinguished in this manual by the<br />
following notations:<br />
!<br />
The Safety alert symbol means: Caution!<br />
Your safety is involved.<br />
! WARNING!<br />
Failure to follow warning instructions could<br />
result in severe or fatal injury to anyone<br />
working with, inspecting or using the suspension,<br />
or to bystanders.<br />
CAUTION!<br />
Caution indicates that special precautions<br />
must be taken to avoid damage to the<br />
suspension.<br />
NOTE!<br />
Note indicates information that is of importance<br />
regarding procedures.<br />
Introduction<br />
All of <strong>Öhlins</strong> advanced suspension products<br />
are adapted to the brand and model. This<br />
means that length, travel spring action and<br />
damping charac teristics, are tested individually<br />
just for the motorcycle that you have<br />
decided to fit with <strong>Öhlins</strong> suspension.<br />
Before installing<br />
<strong>Öhlins</strong> Racing AB cannot be held respon<br />
si ble for any damage whatsoever to<br />
sus pen sion or vehicle, or injury to persons,<br />
if the instruc tions for installing and maintenance<br />
are not fol lowed exactly. Similarly,<br />
the warranty will be come null and void if<br />
the instructions are not followed.<br />
© <strong>Öhlins</strong> Racing AB.<br />
All rights reserved.<br />
Any reprinting or unauthorized use<br />
without the written permission of<br />
<strong>Öhlins</strong> Racing AB is prohibited.<br />
Printed in Sweden.<br />
1<br />
! WARNING!<br />
1. Installing a suspension, that is not approved<br />
by the vehicle man u fac tur er, may<br />
affect the stability of your ve hi cle. <strong>Öhlins</strong><br />
Rac ing AB cannot be held responsible<br />
for any per son al in ju ry or dam age whatso<br />
ev er that may oc cur after installing the<br />
sus pen sion.<br />
2. Please study and make certain that you<br />
ful ly un der stand the mount ing in struc tions<br />
and the owner´s man u al before han dling this<br />
suspension kit. If you have any questions<br />
regarding proper in stal la tion pro ce dures,<br />
contact an <strong>Öhlins</strong> deal er.<br />
3. The vehicle service manual must be<br />
re ferred to when installing the <strong>Öhlins</strong> suspension.<br />
NOTE!<br />
<strong>Öhlins</strong> products are subject to continuous<br />
improve ment and de vel op ment. Therefore,<br />
although these in struc tions in clude the<br />
most up-to-date in for ma tion available at<br />
the time of print ing, there may be minor differ<br />
enc es between your sus pen sion and this<br />
manual. Please con sult your <strong>Öhlins</strong> dealer<br />
if you have any ques tions regarding the<br />
con tents of the manual.<br />
NOTE!<br />
During storage and transportation, especially<br />
at high ambient temperature, some of<br />
the oil and grease used for assembling may<br />
run out and stain the packaging. This is in<br />
no way detrimental to the product, wipe off<br />
the excessive oil/grease with a cloth.
The <strong>FGR</strong><strong>700</strong> <strong>Front</strong> <strong>Fork</strong> is the very essence<br />
of front fork technology and is the<br />
evolutionary result from the FG470, FG570<br />
and FG670. The new, improved front fork<br />
comes fully packed with technical solutions<br />
from <strong>Öhlins</strong> MotoGP technicians.<br />
The new <strong>FGR</strong><strong>700</strong> is a giant leap in the<br />
evolution of high tech front fork systems. It<br />
is pressurised as its predecessors but now<br />
it is equipped with the latest TTX-technology.<br />
•<br />
•<br />
•<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong> <strong>FGR</strong> <strong>700</strong><br />
Features:<br />
Consistent behaviour, immediate<br />
response<br />
Wide adjustment range with external<br />
adjusters<br />
Separated compression and rebound<br />
function<br />
NOTE!<br />
Gas pressure should not be changed or<br />
used as an alternative to adjust the damping.<br />
In this manual<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong> <strong>FGR</strong> <strong>700</strong> 2<br />
Adjusters<br />
3<br />
Setting up your forks 4<br />
Work<br />
section<br />
5<br />
Recommended tools 6<br />
Disassemble the <strong>Front</strong> <strong>Fork</strong> 7<br />
Change the Spring 9<br />
Change the Seals 10<br />
Revalve<br />
11<br />
Replace the Tubes 12<br />
Disassemble the Piston Rod 13<br />
Assemble the <strong>Front</strong> <strong>Fork</strong> 14<br />
Oil<br />
level<br />
adjustment<br />
16<br />
Troubleshooting<br />
17<br />
Technical Information 18<br />
Spare Parts List 19<br />
2
Adjusters<br />
This <strong>Öhlins</strong> superbike front fork is<br />
equipped with the following external adjusters:<br />
1<br />
2<br />
3<br />
Spring preload adjuster<br />
Rebound damping adjuster<br />
Compression damping adjuster<br />
Spring preload adjustment<br />
Adjust the spring preload by turning<br />
the nut on top of the fork leg. Use a<br />
14 mm wrench.<br />
The adjustment range is 0-18 mm.<br />
On the adjustment nut one turn will<br />
change 1 mm in spring preload. Recommended<br />
static sag is 25-30 mm.<br />
Rebound adjustment<br />
Adjust the rebound damping by turning<br />
the screw at the fork bottom. Use<br />
tool 00794-01.<br />
The adjustment range from closed<br />
valve (clockwise) until maximum<br />
open valve (counter clockwise) is<br />
20 “clicks”. Recommended adjustment<br />
“click”, from closed position:<br />
See specification card.<br />
Compression adjustment<br />
Adjust the compression damping by<br />
turning the screw at the fork bottom.<br />
Use tool 00794-01.<br />
The adjustment range from closed<br />
valve (clockwise) to maximum<br />
open valve (counter clockwise) is<br />
20 “clicks”. Recommended adjustment<br />
“click”, from closed position:<br />
See specification card.<br />
3<br />
1<br />
Increase spring preload<br />
Reduce spring preload<br />
3<br />
R<br />
C<br />
14 mm wrench<br />
2<br />
Top cap
Setting Up Your <strong>Front</strong> <strong>Fork</strong>s<br />
Basic Guidelines<br />
- how to set up your <strong>Öhlins</strong> front forks<br />
The front forks are just one part of your<br />
motorcycle and to get it to work properly,<br />
the whole motorcycle has to be set up according<br />
to your vehicle service manual.<br />
1<br />
Put the motorcycle on a work stand and<br />
install the <strong>Öhlins</strong> front fork. Consult your<br />
vehicle service manual.<br />
NOTE!<br />
The lower triple clamp must not be tightened<br />
to more than 12-15 Nm. This is also<br />
important for the steering damper bracket,<br />
when located around the upper front leg.<br />
Too high torque may deform the front fork<br />
leg.<br />
2<br />
Set your initial spring preload, use a 14 mm<br />
socket or wrench, until you get a static<br />
sag of 25-30 mm. Each turn gives 1 mm in<br />
preload, maximum preload is 18 mm.<br />
2<br />
3<br />
Increase spring preload<br />
Reduce spring preload<br />
R1<br />
14 mm wrench<br />
F1<br />
4<br />
Guidelines -<br />
Setting the Spring Preload<br />
Bike on a stand Bike with rider on<br />
3<br />
The spring preload is very important since<br />
it affects the height of the motorcycle and<br />
the fork angle. Consequently, handling<br />
characteristics can be changed, even<br />
negatively.<br />
Procedure<br />
We recommend you to have an assistant<br />
for this procedure.<br />
1 Put the motorcycle on a stand.<br />
2 Make sure that the shock absorber is fully ex-<br />
tended.<br />
3 Measure the distance from the lower edge of<br />
the rear mud guard or from a point marked by a<br />
piece of tape, immediately above the rear wheel<br />
axle, to the wheel axle. (R1)<br />
4 Make a similar measurement on the front axle, for<br />
example, from the bottom of the upper fork crown<br />
to the front wheel axle. Make sure that the front<br />
fork is fully extended. (F1)<br />
5 Take the same measurements with the rider<br />
and equipment on the motorcycle. It is important<br />
that the rider has a correct riding posture, so that<br />
the weight is balanced on the front and rear wheel<br />
in the same way as when riding. (R2, F2)<br />
4<br />
The measurements should not differ from<br />
the following:<br />
With rider:<br />
Rear: 15-30 mm (R1-R2)<br />
<strong>Front</strong>: 35-50 mm (F1-F2)<br />
R2<br />
F2
Work Section<br />
Section Plan<br />
Recommended Tools<br />
Page<br />
6<br />
1 Disassemble the <strong>Front</strong> <strong>Fork</strong> 7<br />
2 Change the Spring 9<br />
3 Change the Seals 10<br />
4 Revalve 11<br />
5 Replace the Tubes 12<br />
6 Disassemble the Piston Rod 13<br />
7 Assemble the <strong>Front</strong> <strong>Fork</strong> 14<br />
page 12<br />
page 9<br />
page 10<br />
5<br />
NOTE!<br />
page 13<br />
page 12<br />
page 11<br />
Read through the whole section and make<br />
sure you understand all the steps in the<br />
procedure before you begin<br />
Make sure you have all the proper tools<br />
needed for the section you are about to<br />
work on before you begin<br />
Clean all parts thoroughly after disassembly<br />
Contact an <strong>Öhlins</strong> dealer if you have any<br />
questions regarding the front fork
Tools<br />
1 Vice with soft jaws<br />
2 Wrench 14 mm<br />
17 mm<br />
19 mm<br />
3 Allen key<br />
4 Wire with hook<br />
5 Heat gun<br />
6 Teflon tape<br />
7 Brass wire brush<br />
8 Sleeve pin 00797-01<br />
9 Seal head tool 01797-04<br />
10 Pull-up tool 01765-03<br />
11 Measure pin 00720-02<br />
12 Pin tool 00720-03<br />
13 Soft jaws clamp 00786-05<br />
14 Soft jaws clamp 00786-07<br />
15 Sharp screw driver 00715-01<br />
16 Pull up holder tool 02810-01<br />
17 Gas filling device 01781-01<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong> oil 01311-01<br />
<strong>Öhlins</strong> Red Grease 00146-01<br />
<strong>Öhlins</strong> White Grease 00147-01<br />
Loctite 648<br />
Loctite 222<br />
NOTE!<br />
Check each section for the specifi c tools<br />
needed.<br />
6<br />
1 2<br />
3<br />
6<br />
8 9<br />
10<br />
13 14<br />
16<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong> Oil<br />
rag<br />
4<br />
7<br />
5<br />
11 12<br />
15<br />
17<br />
<strong>Öhlins</strong> Red Grease<br />
<strong>Öhlins</strong> White Grease<br />
waste oil container
1 Disassemble the <strong>Front</strong> <strong>Fork</strong><br />
1.<br />
Remove the fork legs from the motorcycle.<br />
Put the fork legs in upright position for<br />
about 5 minutes to allow the oil to settle.<br />
2.<br />
Fasten the fork leg in a vice. Use soft jaws.<br />
3.<br />
Release the spring preload completely<br />
by turning the adjustment nut counter<br />
clockwise as far as possible. Use a 14 mm<br />
wrench or socket.<br />
NOTE!<br />
Do not use the preload adjuster to tighten<br />
or loosen the top nut assembly.<br />
4.<br />
Loosen the top nut assembly. Use tool<br />
00797-01.<br />
5.<br />
Remove the top nut assembly from the<br />
piston shaft. Use a 14 mm wrench to the<br />
top and a 19 mm wrench to hold the nut on<br />
the lower side of the top nut.<br />
6.<br />
Remove the adjustment driver and the<br />
spring. Use a wire with a hook and carefully<br />
pull out the preload tube.<br />
7.<br />
Use tool 01797-04 and 01765-03 to<br />
unscrew the seal head from the cartridge<br />
tube. Remove the piston rod unit.<br />
8.<br />
Drain all oil from the fork leg.<br />
8<br />
7<br />
2<br />
5<br />
14 mm wrench<br />
19 mm wrench<br />
7<br />
Tool 01765-03<br />
Tool<br />
01797-04<br />
3<br />
14 mm wrench<br />
4<br />
6<br />
Tool 00797-01<br />
Piston rod unit<br />
Adjustment<br />
driver<br />
Spring<br />
Preload tube
Disassemble the Reservoir<br />
9.<br />
Remove the screw and the o-ring from the<br />
reservoir end cap.<br />
NOTE!<br />
Before releasing the gas pressure, count<br />
and note the adjuster settings. Also check<br />
that the gas pressure is correct. Then,<br />
the adjusters should be set in a fully open<br />
position.<br />
! WARNING!<br />
Releasing high pressure gas from the front<br />
fork can be hazardous. Do not perform any<br />
kind of service until gas pressure is completely<br />
released.<br />
10.<br />
Release the nitrogen gas by inserting an<br />
injection needle into the reservoir end cap<br />
through the rubber valve.<br />
11.<br />
Remove the circlip.<br />
12.<br />
Remove the reservoir end cap. Use tool<br />
00720-03.<br />
13.<br />
Remove the gas piston, use tool 00720-02.<br />
14.<br />
Drain the oil from the reservoir by removing<br />
the compression valve. Use a 17 mm<br />
wrench.<br />
8<br />
9<br />
NOTE!<br />
11<br />
12<br />
14<br />
10<br />
Tool<br />
00720-03<br />
! WARNING!<br />
13<br />
Tool<br />
00720-02
2 Change the Spring<br />
1.<br />
Release the spring preload completely<br />
by turning the adjustment nut counter<br />
clockwise as far as possible. Use a 14 mm<br />
wrench or socket.<br />
2.<br />
Loosen the screws that hold the fork legs<br />
in the upper triple clamps.<br />
3.<br />
Loosen the Top nut assembly from the fork<br />
leg. Use tool 00797-01.<br />
4.<br />
Remove the Top nut assembly from the<br />
piston shaft. Use a 14 mm wrench to the<br />
top and a 19 mm wrench to hold the nut on<br />
the lower side of the top nut.<br />
5.<br />
Remove the adjustment driver and the<br />
spring. Use a wire with a hook and carefully<br />
pull out the preload tube.<br />
6.<br />
Check the oil level according to page 16.<br />
NOTE!<br />
Use <strong>Öhlins</strong> <strong>Front</strong> fork oil 01311-01 only.<br />
7.<br />
Install the Preload tube, the new spring<br />
and the adjustment driver.<br />
8.<br />
Reinstall the top nut assembly to the piston<br />
shaft. Tighten the jam nut to 20 Nm.<br />
9.<br />
Reinstall the top nut into the fork leg,<br />
with the front wheel off the ground (use<br />
tool 00797-01). Tighten the upper triple<br />
clamps and adjust the preload according<br />
to the instructions on page 3.<br />
CAUTION!<br />
The top nut should only be tightened by<br />
hand into the fork leg.<br />
9<br />
1 2<br />
3<br />
Tool 00797-01<br />
5<br />
8<br />
20 Nm<br />
14 mm wrench<br />
Adjustment driver<br />
Preload tube<br />
14 mm wrench<br />
19 mm wrench<br />
Spring<br />
4<br />
6<br />
9<br />
CAUTION!<br />
Tool 00797-01<br />
Tool 01765-03<br />
01305-01<br />
Check the oil level
3 Change the Seals<br />
Remove the fork leg from the motorcycle.<br />
Remove the top nut and piston rod<br />
unit according to steps 1-14 in chapter<br />
Disassemble the <strong>Front</strong> <strong>Fork</strong>. Then, continue<br />
below.<br />
15.<br />
Remove the outer tube, clean the seal<br />
and check the condition. If the seal is in<br />
good condition apply some red grease<br />
(00146-01) to it. A damaged seal must be<br />
replaced!<br />
16.<br />
First remove the circlip, then the seal and<br />
finally the washer.<br />
17.<br />
Apply a thin layer of <strong>Öhlins</strong> red grease<br />
(00146-01) to the washer and to the sealing<br />
surfaces of the fork seal. Install the seal<br />
and the washer into the outer tube. Install<br />
the circlip into the groove.<br />
NOTE!<br />
It is important to use the correct grease in<br />
order to achieve optimum fork function.<br />
18.<br />
Apply some front fork oil (01311-01) to the<br />
inner tube surface and carefully reinstall<br />
the outer tube on the fork leg (slide it completely<br />
down).<br />
! WARNING!<br />
Be careful not to damage the fork seal!<br />
19.<br />
Reinstall the front fork leg to the motorcycle<br />
according to chapter Assemble the<br />
<strong>Front</strong> <strong>Fork</strong>, step 1-13.<br />
10<br />
15<br />
17<br />
NOTE!<br />
Circlip<br />
Seal<br />
Washer<br />
18<br />
16<br />
1st, Circlip<br />
2nd, Seal<br />
3rd, Washer<br />
! WARNING!<br />
Tire lever or<br />
equivalent
4 Revalve<br />
Release the gas pressure from the<br />
reservoir according to chapter Disassemble<br />
the <strong>Front</strong> <strong>Fork</strong>, steps 9-14. Then,<br />
continue below.<br />
1.<br />
Put the fork leg, in horizontal position, in a<br />
vice with soft jaws.<br />
NOTE!<br />
Do not mix up the two valves, they must<br />
be installed in their intended valve housing.<br />
We recommend you to remove one valve at<br />
a time to keep them apart.<br />
2.<br />
Remove one valve, use a 17 mm wrench.<br />
3.<br />
Make the necessary changes.<br />
4.<br />
Add some front fork oil into the valve housing.<br />
Reinstall the valve. Make the necessary<br />
service on the other valve according<br />
to the same procedure.<br />
5.<br />
Add gas pressure to the reservoir according<br />
to chapter Assemble the <strong>Front</strong> <strong>Fork</strong>.<br />
11<br />
1<br />
2<br />
NOTE!<br />
Do not mix up the valves, they must be<br />
installed in their intended valve housing.<br />
Also, keep in mind how the parts in the<br />
valves were installed.
5 Replace the Tubes<br />
Remove the fork leg from the motorcycle.<br />
Remove the top nut and piston rod<br />
unit according to steps 1-14 in chapter<br />
Disassemble the <strong>Front</strong> <strong>Fork</strong>. Then, continue<br />
below.<br />
1.<br />
Remove the outer tube<br />
2.<br />
Use a heat gun to warm up the fork bottom.<br />
Use tool 00786-05 to unscrew the<br />
inner tube.<br />
3.<br />
Remove the inner tube. Clean the threads<br />
thoroughly from Loctite.<br />
4.<br />
Install the new inner tube. Use Loctite 648<br />
on the threads. Tighten the torque to<br />
80 Nm.<br />
Removing the Reservoir Tube<br />
5.<br />
Use a heat gun to warm up the tube bottom.<br />
Use tool 00786-07 to remove the<br />
tube.<br />
6.<br />
Remove the tube. Clean the threads thoroughly<br />
from Loctite.<br />
7.<br />
Install the new tube. Use Loctite 222 on<br />
the threads. Tighten the torque to 45 Nm.<br />
8.<br />
Reinstall the outer tube.<br />
9.<br />
Reinstall the front fork according to chapter<br />
Assemble the <strong>Front</strong> <strong>Fork</strong>.<br />
12<br />
1<br />
5<br />
Tool<br />
00786-07<br />
8<br />
2<br />
Tool<br />
00786-05
6 Disassemble the Piston Rod<br />
Remove the fork leg from the motorcycle.<br />
Remove the top nut and piston rod<br />
unit according to steps 1-7 in chapter<br />
Disassemble the <strong>Front</strong> <strong>Fork</strong>. Then, continue<br />
below.<br />
1.<br />
Put the piston rod in a vice with soft jaws.<br />
CAUTION!<br />
Do not tighten the jaws, the piston rod can<br />
be damaged.<br />
2.<br />
Remove the piston, spring and sleeve in<br />
one unit. Use a 16 mm wrench.<br />
3.<br />
Remove the spacer and the o-ring.<br />
4.<br />
Remove the seal head from the shaft.<br />
5.<br />
Check the o-ring and the x-ring. Replace<br />
them if necessary.<br />
6.<br />
Use tool 00715-01 to put the x-ring in right<br />
position. Use plenty of white grease on the<br />
X-ring before installing it.<br />
7.<br />
Wrap some teflon tape around the shaft<br />
thread to protect the seal and O-ring<br />
from damages. Apply some red grease<br />
00146-01 to the tape and the shaft end.<br />
Install the seal head and the O-ring back<br />
on the shaft.<br />
8.<br />
Use a brass wire brush to clean the piston<br />
rod from tape. Install the o-ring, spacer,<br />
sleeve, topout spring and piston. Tighten<br />
the piston to a torque: 8 Nm. Use a 16 mm<br />
wrench.<br />
13<br />
7<br />
6<br />
16 mm Wrench<br />
1<br />
Piston<br />
Topout spring<br />
X-ring<br />
O-ring<br />
Sleeve<br />
Spacer<br />
O-ring<br />
3<br />
2<br />
8<br />
Tool 00715-01
7 Assemble the <strong>Front</strong> <strong>Fork</strong><br />
Assemble the Reservoir<br />
1.<br />
Pour <strong>Öhlins</strong> Oil <strong>Front</strong> <strong>Fork</strong> Oil 01311-01<br />
to the top edge of the reservoir. Carefully<br />
continue to fill until the oil level is the same<br />
in the reservoir and the cylinder tube.<br />
2.<br />
Push the gas piston, with the teflon band<br />
and O-ring installed, to the reservoir bottom<br />
without allowing it to be pushed back<br />
over the circlip groove. Make sure that<br />
there is no air between the piston and the<br />
oil. Use tool 00720-02.<br />
3.<br />
Install the seal head tool and the top-out<br />
spring tool on the piston rod. Pull the<br />
top-out spring tool and, at the same time,<br />
push the seal head tool to contract the<br />
top out spring. Install tool 02810-01 on<br />
tool 01765-03 to keep the contraction.<br />
Assemble the complete piston rod into<br />
the cartridge tube and tighten it by hand<br />
(3-4 turns).<br />
NOTE!<br />
Make sure that the gas piston is in the bottom<br />
of the reservoir.<br />
4.<br />
Tighten the seal head to 20 Nm. Use Seal<br />
head tool 01797-04 and 01765-03.<br />
5.<br />
Check the O-ring on the reservoir end<br />
cap. Replace if necessary. Apply some red<br />
grease on the O-ring and push the reservoir<br />
end cap into the chamber. Use tool<br />
00720-03.<br />
6.<br />
Reinstall the circlip. Make sure that it stops<br />
in the intended groove.<br />
14<br />
1 2<br />
3<br />
4<br />
6<br />
5<br />
Tool<br />
00720-02
7.<br />
Once Assemble again contract the <strong>Front</strong> the top <strong>Fork</strong> out spring using<br />
tool 02810-01, tool 01765-03 and tool<br />
01797-04<br />
NOTE!<br />
Nitrogen (N2) gas. Use pressure gauge<br />
(01781-01)<br />
! WARNING!<br />
Use of infl ammable gas for pressurising<br />
the shock absorber can be hazardous. Use<br />
nitrogen gas (N2) only!<br />
8.<br />
Check the gas pressure stipulated in the<br />
spec. card. Dip the needle of the gas tool<br />
(01781-01) in red grease and insert the<br />
needle through the gas filler valve.<br />
Charge with gas to the correct pressure,<br />
according to the spec. card.<br />
NOTE!<br />
Ensure that there is no leakage of gas or<br />
fl uid.<br />
9.<br />
Screw the gas filler screw with O-ring.<br />
Remove tool 02810-01 and tool 01797-04<br />
to release the top-out spring.<br />
10.<br />
Push tool 01765-03 to a stop and check<br />
the oil level according to page 16.<br />
NOTE!<br />
Use <strong>Öhlins</strong> <strong>Front</strong> fork oil 01311-01 only.<br />
11.<br />
Reinstall the Preload tube. Install the spring<br />
and the adjustment driver.<br />
12.<br />
Reinstall the top nut assembly to the piston<br />
shaft. Tighten the jam nut to 20 Nm.<br />
13.<br />
Reinstall the top nut into the fork leg. Use<br />
tool 00797-01. Adjust the preload, compression<br />
and rebound.<br />
15<br />
7<br />
9<br />
10<br />
12<br />
20 Nm<br />
8<br />
Tool 02810-01<br />
Tool 01797-04<br />
11<br />
13<br />
CAUTION!<br />
The top nut should only<br />
be tightened by hand<br />
into the fork leg.
Oil Level Adjustment<br />
Compared with conventional type of front<br />
forks, the upside down front forks are very<br />
sensitive to variations in oil level. Therefore,<br />
adjust the oil level with special care.<br />
A change in the fork oil level will not affect<br />
the spring force at the beginning of the fork<br />
travel, but will have a great effect at the<br />
end of the travel.<br />
When the oil level is raised:<br />
The air spring in the later half stage of<br />
travel is stronger, and make the front forks<br />
more progressive.<br />
When the oil level is lowered:<br />
The air spring of the travel is reduced, and<br />
thus the front fork less progressive. The<br />
oil level works most efficient at the end of<br />
the fork travel. Air spring characteristics<br />
shown, is a general card description to understand<br />
the difference when the oil level is<br />
changed.<br />
16<br />
NOTE!<br />
Adjust the oil level in mm according to the<br />
fi gure with the fork leg fully compressed.<br />
For the right oil-level, please see the specifi<br />
cation card.<br />
Air spring characteristics<br />
Air inside the front fork works as a spring.<br />
The graph at the bottom of the page shows<br />
the spring force related to stroke when the<br />
oil level is changed between 140 mm and<br />
200 mm. Standard oil level is 180 mm.<br />
Push to a stop,<br />
use tool 1765-03<br />
<strong>Öhlins</strong> front fork fl uid 1311-01<br />
Check the oil level
Troubleshooting<br />
Below are a few examples of how to adjust<br />
for the most common road holding problems<br />
in Road Racing driving.<br />
1.<br />
The front wheel “chatters” entering a<br />
corner, the problem goes away, as soon as<br />
you let the brakes off, or when you get on<br />
the power.<br />
This is caused by the fact that the fork is working<br />
too low in the travel and reaches the progressive, hard<br />
part at the end of the travel.<br />
Put on more preload.<br />
Change to a harder spring.<br />
If a lot of stroke remains after riding, drop the oil<br />
level. See oil level chart.<br />
Make sure the front forks have no friction.<br />
Rear ride height is to high, too much rear spring<br />
preload.<br />
Lower the rear end by taking off preload from rear<br />
shock spring.<br />
2.<br />
The front wheel is jumping during the last<br />
part of braking.<br />
If a lot of stroke remains, the oil level is too high.<br />
Lower the oil level.<br />
If the fork is bottoming, put in harder springs and<br />
keep the oil level.<br />
3.<br />
The front end feels unpredictable and unsafe<br />
in the middle of the corner (between<br />
braking and getting on power).<br />
Not enough rebound damping. Put on more<br />
damping.<br />
Too much rebound damping. If it at the same time<br />
feels harsh, take off some rebound damping.<br />
Too much compression damping. Also gives a<br />
harsh feeling. Take off some compression<br />
damping.<br />
17<br />
4.<br />
The front end loses grip coming out of a<br />
corner.<br />
Not enough rebound damping. Put on some more<br />
rebound damping.<br />
Too much preload. Take off some preload.<br />
Rear end is too soft. Put on a harder rear spring.<br />
<strong>Front</strong> end is too high. Lower the front end by<br />
pulling the fork legs through the triple clamps.<br />
As mentioned in the beginning, the whole<br />
bike setup affects the front forks. Try to<br />
understand the feelings and work step by<br />
step.<br />
NOTE!<br />
We advise to change only one thing at a<br />
time and do everything step by step.<br />
1<br />
4
Technical Information<br />
<strong>Front</strong> <strong>Fork</strong> length 740 mm<br />
Stroke 130 mm<br />
Free spring length 260 mm<br />
Recommended setting<br />
Compression 15 clicks<br />
Rebound 12 clicks<br />
Spring preload 4 turns<br />
from closed position<br />
Range 0-18 mm (0-18 turns)<br />
Spring rate<br />
04744-95 9.5 N/mm (mark -95)<br />
Optional springs supplied<br />
04744-10 10.0 N/mm (mark -10)<br />
04744-90 9.0 N/mm (mark -90)<br />
Optional springs available<br />
04744-85 8.5 N/mm (mark -85)<br />
04744-80 8.0 N/mm (mark -80)<br />
Oil capacity<br />
Please see specification card<br />
Use <strong>Öhlins</strong> high performance front fork<br />
fluid no. 5 only 01311-01<br />
Torque<br />
Lower triple clamp bolt 12-15 Nm<br />
Upper triple clamp bolt 18-22 Nm<br />
Grease<br />
<strong>Öhlins</strong> <strong>Front</strong> <strong>Fork</strong><br />
Red Grease 00146-01<br />
White Grease 00147-01<br />
18<br />
Service Intervals<br />
This product is designed for racing use<br />
only.<br />
Recommended service every 10 hours.<br />
Disposal<br />
Discarded products should be handed over<br />
to an authorized <strong>Öhlins</strong> Service Centre for<br />
proper disposal.
Spare parts list, <strong>FGR</strong> <strong>700</strong><br />
1 -<br />
2 -<br />
3 -<br />
4 -<br />
5 -<br />
4 -<br />
6 -<br />
7 -<br />
8 -<br />
9 -<br />
10 -<br />
11 -<br />
- 12<br />
- 13<br />
- 14<br />
- 15<br />
- 16<br />
- 17<br />
- 18<br />
- 19<br />
- 20<br />
- 21<br />
- 22<br />
- 23<br />
- 24<br />
- 25<br />
- 26<br />
- 27<br />
- 28<br />
Pos. Part No. Pcs. Description Type/remarks<br />
1 - - Top nut assembly See page 21<br />
2 03316-01 2 Spring support<br />
3 04744-95 2 Spring<br />
25.5/260/9.5<br />
04744-10 2 Option spring<br />
25.5/260/10.0<br />
04744-90 2 Option spring<br />
25.5/260/9.0<br />
4 01438-04 4 Guide ring<br />
5 01460-06 2 Preload tube<br />
6 01900-06 2 <strong>Fork</strong> leg outer<br />
7 01683-02 2 Bushing, upper<br />
8 01684-02 2 Bushing, lower<br />
9 04758-01 2 Washer<br />
10 04720-02 2 Seal<br />
11 04759-01 2 Circlip<br />
12 01901-04 2 Rod extensioner<br />
13 02302-08 2 Guide sleeve<br />
14 01499-08 2 Circlip<br />
15 01440-01 2 Bump rubber<br />
16 01651-04 2 Seal head<br />
17 01027-04 2 X-ring<br />
18 00438-02 2 O-ring<br />
19 01056-04 2 Bushing<br />
20 00438-41 2 O-ring<br />
21 - - Spacer See spec. card<br />
22 01653-07 2 Sleeve<br />
23 01585-01 2 Topout spring<br />
24 02368-02 2 Shaft<br />
25 00338-60 2 O-ring<br />
26 02061-04 2 TTX-piston<br />
27 00338-05 2 O-ring<br />
28 01447-01 2 Piston ring<br />
19<br />
Note! The number of pieces is<br />
valid for 1 pair of <strong>Front</strong> fork legs
Spare parts list, <strong>FGR</strong> <strong>700</strong><br />
42<br />
46 -<br />
Continues from page 2<br />
29 -<br />
30 -<br />
31 -<br />
32 -<br />
33 -<br />
34 -<br />
39 -<br />
43 -<br />
44 -<br />
45 -<br />
35 -<br />
36 -<br />
37 -<br />
38 -<br />
41<br />
47<br />
40<br />
- 48<br />
- 57<br />
- 56<br />
- 55<br />
- 54<br />
- 53<br />
- 52<br />
- 51<br />
- 50<br />
- 49<br />
Pos. Part No. Pcs. Description Type/remarks<br />
29 04806-01 2 Seal ring<br />
30 00638-06 2 O-ring 33x3 NBR 70<br />
31 04804-01 2 Sleeve seal ring<br />
32 04805-01 2 Cylinder Tube Extension<br />
33 01486-09 2 Cylinder tube 20/170 Al<br />
34 01<strong>700</strong>-02 2 <strong>Fork</strong> leg inner<br />
35 00338-72 2 O-ring<br />
36 01565-04 1 Stroke indicator<br />
37 00338-63 1 O-ring<br />
38 04759-02 2 Circlip<br />
39 01678-14 2 Fender bracket<br />
40 01682-28 2 Fender bracket ring<br />
41 00382-08 2 Screw<br />
42 01902-15 2 <strong>Fork</strong> bottom<br />
43 00382-07 2 Screw<br />
44 00438-33 2 O-ring<br />
45 00191-17 2 Sticker “Ö”<br />
46 01240-08 4 Bolt Titanium<br />
47 00196-01 2 Sticker “Warning”<br />
48 01669-02 4 Caliper sleeve Standard<br />
48 01669-03 4 Caliper sleeve Optional<br />
49 00338-72 2 O-ring<br />
50 02804-01 2 Reservoir tube<br />
51 00338-25 2 O-ring<br />
52 01447-02 2 Piston ring<br />
53 02806-01 2 Gas piston<br />
54 00161-08 2 Reservoir end kit<br />
55 01152-01 2 Circlip<br />
56 00338-59 2 O-ring<br />
57 01050-01 2 Screw<br />
58 - - Valve assy See page 22<br />
20<br />
Note! The number of pieces is<br />
valid for 1 pair of <strong>Front</strong> fork legs
1 -<br />
2 -<br />
3 -<br />
4 -<br />
5 -<br />
2 -<br />
6 -<br />
7 -<br />
8 -<br />
9 -<br />
Top nut assembly<br />
Spare parts list, Top nut assembly<br />
Pos. Part No. Pcs. Description Type/remarks<br />
1 03312-02 2 Adjuster<br />
2 03309-01 4 Thin Shim<br />
3 00338-72 2 O-ring<br />
4 03318-05 2 Housing<br />
5 00338-02 2 O-ring<br />
6 03317-01 6 Wave washer<br />
7 03309-02 2 Thick shim<br />
8 03313-01 2 Nut<br />
9 03315-01 2 Preload socket<br />
21<br />
Note! The number of pieces is<br />
valid for 1 pair of <strong>Front</strong> fork legs
14 -<br />
1 -<br />
2 -<br />
3 -<br />
4 -<br />
5 -<br />
6 -<br />
7 -<br />
8 -<br />
9 -<br />
10 -<br />
11 -<br />
12 -<br />
13 -<br />
Valve assy<br />
- 15<br />
- 16<br />
- 17<br />
Spare parts list, Valve assy<br />
Pos. Part No. Pcs. Description Type/remarks<br />
1 01675-01 4 Nut<br />
2 00153-01 4 Washer<br />
3 - 4 Clamp washer See spec. card<br />
4 - - Shim stack See spec. card<br />
5 02406-01 4 Piston<br />
6 00338-11 4 O-ring<br />
7 00530-22 4 Shims<br />
8 01671-02 4 Spring<br />
9 01669-01 4 Sleeve<br />
10 01672-01 4 Spring collar<br />
11 01658-05 4 End piece<br />
12 00438-02 4 O-ring<br />
13 01242-11 4 Adjustment needle<br />
14 00884-02 8 Ball<br />
15 01474-01 4 Spring<br />
16 00338-53 4 O-ring<br />
17 01473-02 4 Circlip<br />
22<br />
Note! The number of pieces is<br />
valid for 1 pair of <strong>Front</strong> fork legs
Service tools<br />
1<br />
10<br />
4<br />
11<br />
2<br />
15<br />
5<br />
Pos. Part No. Pcs. Description<br />
1 00727-02 1 Soft jaws (one pair)<br />
2 00786-05 1 Inner tube tool<br />
3 00786-07 1 Cartridge tube tool<br />
4 01781-01 1 Gas tool<br />
5 00797-01 1 Top nut socket<br />
6 01757-01 1 Attachment bar<br />
7 01759-07 1 Dismantling bar<br />
8 01759-08 1 Installing sleeve<br />
9 01758-04 1 Guide ring<br />
10 00720-02 1 Measure pin<br />
11 00720-03 1 Pin tool<br />
12 01765-03 1 Pull-up spring tool<br />
13 01797-04 1 Seal head tool<br />
14 02810-01 1 Pull-up spring tool holder<br />
15 00715-01 1 Screwdriver sharp<br />
12<br />
14<br />
23<br />
6-9<br />
3<br />
13
Notes
Notes
Notes
MORE INFO<br />
www.ohlins.com<br />
<strong>Öhlins</strong> Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden<br />
Phone +46 8 590 025 00, Fax +46 8 590 025 80<br />
07280-13_3, Issued 20080114 <strong>Öhlins</strong> Racing AB<br />
07280-13_4 Issued 2008 08 15 <strong>Öhlins</strong> Racing AB