Ohlins Exercise Bike FG 9700 User's Manual

Racing manual
Öhlins super bike front fork FG 9700
Including:
Setting up
your fork
Changing
springs
and seals
Service
the fork
Trouble
shooting
Technical
info
Spare parts
& tools
Traction, handling,
comfort and safety
1
Contents
Öhlins super bike
front fork FG 9700
Introduction __________________
Setting up your forks
Spring preload adjustment ______
Rebound adjustment
Compression adjustment
Changing springs
Changing seals
Dismantling the forks __________
Assembly of the forks
Troubleshooting
Oil level adjustment ___________
Technical information
Spare parts __________________
Tools
Introduction
2
3
4
5
6
Safety signals
Particularly important information is
distinguished in this manual by the
following notations:
The Safety Alert Symbol means:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or
death to the shock absorber operator,
a bystander or a person inspecting or
repairing the shock absorber.
CAUTION!
A CAUTION indicates special precautions that must be taken to avoid
damage to the shock absorber.
NOTE!
A NOTE provides key information to
make procedures easier or clear.
The Öhlins front forks use a Cartridge
system for damping. This gives a damping force which depends on the speed
of the piston in the cartridge system.
The combination of spring and airgap (oil level) gives a possibility to adjust the characteristic of the fork to suit
different tracks and riders.
For example a soft spring in combination with a small air-gap (high oil
level) gives a progressive action of the
front forks.
For better understanding, please refer to our oil level chart.
A telescopic front fork is depending
on a smooth friction-free action.
Make sure your front forks are serviced regularly and don’t use strong solvents such as brake cleaner to clean
the front forks. This will dry out the seals
and steel tubes and cause friction.
Regularly, put a little Öhlins grease
(148-01) on the steel tube and work it
in by pushing the forks up and down.
Öhlins Racing AB can not be held
responsible for any damage to spare
parts or person if the mounting-, maintaining- and servicing instructions are
not followed exactly.
Also no guarantee can be given for
the performance and reliability if these
instructions are not followed.
Setting up your forks
We would like to give you some basic
guidelines, how to set up your Öhlins
front forks. However you must remember that the front forks are just one part
of your motorcycle and to get it to work
properly, the whole motorcycle has to
be set up according to your bikes
manual.
1
Put your bike on a front stand so you
can fit the front forks.
Maximum torque on the bottom triple
clamp and steering damper bracket (if
it is located on the diameter on the outer
tube) is 15-18 Nm.
Fit the front wheel and brakes.
2
Unscrew the adjustment housing on top
of the fork (use tool 797-01) on both
upper tubes and slide the fork up and
down gentle to make sure everything
works correctly.
3
© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
2
Assemble the adjustment housing
again and set your initial preload of the
spring by using a 12 mm socket until
you get a ”static sag” of 25-30 mm.
Each turn gives 1 mm in preload, maximum preload is 18 mm.
4
The best way to check the ”static sag”
is to put the bike on the ground in running condition.
Measure the distance between the bottom of the outer tube to the fork bottom.
Then lift the front end of the bike, so
the fork is fully extended.
Take the measurement again. The difference between those two figures is
”static sag”.
5
The ”clickers” are a ”bleed function”
separate for rebound and compression
damping.
Rebound is on the top centre of the fork
and compression at the bottom part of
the fork.
You start to count from fully closed
(clockwise) and set it to the recommended ”click” (use tool 794-01).
For recommended start setting please
refer to the specification card.
Spring preload adjustment
Using a 12 mm wrench, turn the upper
adjustment screw.
Maximum adjustment range is 18 mm.
One turn on the adjustment screw will
cause 1 mm change in spring preload.
Changing springs
1
11
Loosen the screws that hold the fork
legs in the upper triple clamps.
12
2
Loosen the adjustment housings (pos
7, page 7) about two turns (use tool
797-01).
3
Remove the fork legs from the motorcycle.
4
Compression adjustment
Adjust the compression rate on the
lower part of the front forks (compression valve). Use a hex key with spherical head (use tool 794-01).
Adjustment range from closed valve
(clockwise) to maximum open valve
(anticlockwise) is 20 ”clicks”.
Recommended adjustment ”clicks”,
from closed position (see specification
card).
Fasten the adjustment housing in the
fork leg.
13
Unload the spring completely by turning the adjustment screw completely
anticlockwise. Use a 12 mm wrench.
Install the fork legs on the motorcycle
and adjust the preload, compression
and rebound according to the above
instructions.
Remove the blue locking nuts.
6
CAUTION!
Changing seals
Do not damage the o-ring and do not
drop the flat key into the fork leg.
Put the fork legs upright for 15 minutes.
Carefully remove the adjustment housing.
Fasten the fork leg in a vice. Use soft
jaws.
7
2
Remove the preload tube and spring.
(The free spring length see page 5).
Unload the spring preload completely by
turning the adjustment screw completely
anticlockwise. Use a 12 mm wrench.
8
Install the tool 1765-01 on top of the
preload adjustment screw.
Recommended adjustment ”click”, from
closed position (see specification card).
Tighten the upper gently against the
lower nut.
5
Rebound adjustment
Adjustment range from closed valve
(clockwise) until maximum open valve
(anticlockwise) is 20 ”clicks”.
Tighten the lower lock nut gently, and
then unscrew it 1/4 of a turn.
Make sure that the fork leg is fully extended when tighten the adjustment
housing.
Install the new spring and check the
oil level.
Use a hex key with a spherical head
(use tool 794-01).
Loosen the preload tube, and bring it
to its correct position in the adjustment
housing.
Fasten a fork leg in a vice. Use soft
jaws.
Adjust so the front forks lowers 25-30
mm from the top, unloaded position.
Adjust the rebound rate on the adjustment screws positioned at the top centre of the front forks.
Install the two blue nuts.
Pull out the piston rod as far as possible and turn the compression adjustment screw fully clockwise.
This will keep the piston rod in top position, which will make the continued
assembly easier.
1
Make a note of the number of turns.
Remove the two blue lock nuts.
3
Carefully remove the adjustment housing.
CAUTION!
Do not damage the o-ring and do not
drop the flat key into the fork leg.
4
9
Remove the preload tube.
Install the preload tube.
5
Install the tool 1766-01 on top of the
preload tube and fasten it below the
edge of the preload adjustment screw
(pos 18, page 7).
Slide the outer fork leg up until the top
bushing is just above the inner leg.
(Approx. 140 mm from complete bottom position.
Remove the tool and continue the assembling.
This is to make sure there is no oil
above the top bushing).
10
6
Install the adjustment housing.
Slide the outer tube completely down.
(Fork seal touching fork bottom).
CAUTION!
The flat key must be guided in the slot
of the adjustment housing.
The o-ring must be greased, or it
might be damaged.
7
Push the piston rod down so that it is
in level with the top of the outer tube.
3
NOTE!
compressed air.
When measuring the oil level, always
have the spring installed.
Assembly of the forks
Measure the oil level using the top of 1
the outer tube as the zero mark. Note
the measurement.
8
Remove the spring and tip the oil in a
clean container.
9
Remove the outer tube, clean the seals
and check for damaged, if the seals are
damaged remove and replace.
Apply a thin layer of Öhlins green
grease (148-01) on the scraper ring
and on the sealing surfaces of the fork
seal.
Install the seals in the outer tube.
Please note that it is important to use
the correct grease in order to achieve
optimum fork function.
2
Install the piston and the shims on the
piston rod and the compression valve.
10
Tighten the 6 mm lock nuts with a
torque of 0.6 Nm.
12
Carefully mount outer tube (slide completely down) install spring and set the
oil level.
13
Go on with 9 to 13 according to page 3
"Changing springs".
Dismantling the forks
1
Carry out 1 to 7 of page 3 "Changing
springs".
A
The front wheel ”chatters” entering
a corner, the problem goes away, as
soon as you let the brakes off, or
when you get on the power.
This is caused by the fact that the fork
is working too low in the travel and
reaches the progressive, hard part at
the end of the travel.
1
Put on more preload.
2
If the seals are OK, then apply with
Öhlins grease (green grease 148-01).
Apply Öhlins fork oil on the seals and
on the inner tube.
are common in Road Racing and how
to solve them.
Check the piston ring for damages. Replace if necessary.
3
Install the compression valve assembly into the valve housing.
4
Apply some front fork oil 1305-01 on
the inner steel tube surface and install
the outer aluminium tube.
Measure the correct amount of 130501 oil according to the specification
card.
CAUTION!
Change to a harder spring.
3
If a lot of stroke remains after riding,
drop the oil level. See oil level chart.
4
Make sure the front forks have no friction.
5
Rear ride height is to high, too much
rear spring preload.
Lower the rear end by taking off preload
from rear shock spring.
B
The front wheel is jumping during
the last part of braking.
1
Be careful not to damage the fork leg
seals.
If a lot of stroke remains, the oil level is
too high. Lower the oil level.
5
2
3
Raise the outer tube approximately 120
mm and fill the oil.
If the fork is bottoming, put in harder
springs and keep the oil level.
Pull up the outer tube and remove the
seals.
Install the complete piston rod into the
cartridge tube.
C
4
6
Fasten the inner tube on the fork bottom in a vice. Use soft jaws!
Lightly tighten the seal head using tool
1797-01.
The front end feels unpredictable
and unsafe in the middle of the corner (between braking and getting on
power).
5
7
1
Unscrew the seal head (pos 24, page
7) from the cartridge tube and remove
the piston rod unit (use tool 1797-01).
Not enough rebound damping. Put on
more damping.
Drain the remaining oil.
Pump the piston rod up and down and
the oil will be sucked into the cartridge
tube. Close the “clickers” and check the
function.
6
8
Remove the complete compression
valve use a 17 mm wrench.
Pull the piston rod out as far as possible and close the compression valve
screw completely (clockwise).
2
Free the fork leg from the vice and drain
the oil.
7
Remove the piston and the shims from
the piston rod and compression valve.
Place the shims in their correct position on the work bench.
8
Clean all parts thoroughly and dry with
4
9
Go on with 8 to 13 according to page 3
"Changing springs".
Trouble shooting
We like to give a few examples which
2
Too much rebound damping. If it at the
same time feels harsh, take off some
rebound damping.
3
Too much compression damping. Also
gives a harsh feeling. Take off some
compression damping.
D
The front end loses grip coming out
of a corner.
Air spring characteristics
Not enough rebound damping. Put on
some more rebound damping.
Oil level 100 mm
Oil level 120 mm
2
Too much preload. Take off some
preload.
120
100
80
50
0
60
As mentioned in the beginning, the
whole bike setup affects the front forks.
Try to understand the feelings and work
step by step.
200
150
100
20
Front end is too high. Lower the front
end by pulling the fork legs through the
triple clamps.
400
350
300
250
0
4
Force kgf
3
Rear end is too soft. Put on a harder
rear spring.
Oil level 110 mm
Oil level 130 mm
500
450
40
1
Stroke mm
NOTE!
Our advice is to change only one thing
at a time and do everything step
by step.
stage of the fork travel, but will have a
great effect at the later stage.
When the oil level is raised:
Oil level adjustment
Compared with conventional type of
front forks, the upside down front forks
are very sensitive to variations in oil
level. Therefore, adjust the oil level with
special care.
A change in the fork oil level will not
affect the damping force at the early
The air spring in the later half stage of
travel is stronger, and thus the front
forks harder.
When the oil level is lowered:
The air spring in the later half stage of
travel is lessened, and thus the front
forks are softer.
The oil level works most effectively
at the end of the fork travel.
Air spring characteristics shown, is a
general card description to understand
the difference when the oil level is
changed.
NOTE!
Oil level
Adjust the oil level in mm according to
the figure with the fork fully compressed
and with the spring mounted.
For the right STD-level, please see
the specification card.
Optional springs supplied:
1596-10, 10.0 N/mm (marking -10).
1596-90, 9.0 N/mm (marking -90).
Optional springs:
1596-85, 8.5 N/mm (marking -85).
1596-80, 8.0 N/mm (marking -80).
Oil Capacity:
Please see specification card.
CAUTION!
Use only Öhlins high performance
front fork fluid No. 5 (1305-01).
Loctite glue:
542 on Fork Bottom thread.
Tighten torque:
Triple Clamp bolt 15-18 Nm.
Grease:
Öhlins front fork grease 148-01 (green
grease).
Service interval:
Every
10
hours.
Notes
Technical information
Fork length:
730 mm.
Stroke:
120 mm.
Free spring length:
230 mm.
Rebound adjustment:
Base setting 9-12 ”clicks”.
Maximum open valve 20 ”clicks”.
Compression adjustment:
Base setting 6-16 ”clicks”.
Maximum open valve 20 ”clicks”.
Spring preload adjustment:
0-18 mm (0-18 turns).
Spring rate:
1596-95, 9.5 N/mm (marking -95).
5
Spare parts
Fig.
1-01
1-02
1-03
1-04
1-04
1-04
1-05
1-06
1-07
1-08
1-09
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
1-19
1-20
1-21
1-22
1-23
Part No.
Description
00338-65
01460-33
01438-02
01596-90
01596-10
01596-95
01689-02
01627-01
01626-01
01552-01
01524-01
01553-01
01565-01
00338-63
01656-01
01525-02
01046-19
01240-01
01591-01
00430-04
01564-01
00194-10
01593-01
01593-02
01239-03
01666-01
01666-02
O-ring
Preload tube
Guide ring
Spring, 230/0.90
Spring, 230/1.0
Spring, 230/0.95
Fork leg outer
Bushing
Bushing
Washer
Seal
Circlip
Stroke indicator
O-ring
Cylinder tube
Fork leg inner
Bolt
Bolt
Fender bracket
Nut
Fender bracket
Sticker
Caliper bracket LH
Caliper bracket RH
Bolt
Fork bottom LH
Fork bottom RH
Service tools
6
Part No.
Description
0787-04
0797-01
0786-03
1797-01
0794-01
1765-02
1766-01
Cylinder tube tool (cartridge)
Pin sleeve tool
Inner tube tool
T-handle
Hex key with spherical head
Pull-up top-out spring tool
Preload tube pusher
Pieces
2
2
2
2
2
2
2
2
2
2
2
2
1
1
2
2
4
4
2
4
2
2
1
1
4
1
1
Spare parts
Fig.
Part No.
Description
2-01
2-02
2-03
2-04
2-05
2-06
2-07
2-08
2-09
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-23a
2-24
01059-04
01059-05
01437-01
01403-01
01437-01
00338-22
01468-02
01437-01
01403-01
01404-01
01408-01
01473-01
00577-01
01467-01
01474-01
00884-04
01673-01
01469-05
01407-02
01648-01
01499-02
01649-01
01582-11
01580-01
01651-01
00110-01
01582-10
00438-28
01653-01
01585-01
01644-01
01508-01
00338-14
01508-01
01654-02
00530-16
01669-01
01672-01
01671-02
00530-22
02061-01
01447-02
00641-01
01674-01
01657-01
01473-02
00338-53
01242-05
01474-01
00884-02
00438-02
01658-02
01652-02
01670-01
00338-11
01669-01
00530-22
01671-01
01672-01
00120-01
01657-01
Nut
Nut
Thrust washer
Thrust needle bearing
Thrust washer
O-ring
Adjustment housing
Thrust washer
Thrust needle bearing
Thrust washer
Adjustment driver
Circlip
O-ring
Adjustment screw
Spring
Ball
Adjustment needle
Adjustment screw
Flat key
Lock nut
Circlip
Stop screw
Spacer
Bump rubber
Seal head
Bushing
Spacer
O-ring
Sleeve
Topout spring
Shaft
Back-up ring
O-ring
Back-up ring
Piston holder
Shims
Sleeve
Spring collar
Spring
Shim
Piston
Piston ring
Shim, see spec.card
Washer
Washer
Nut
Circlip
O-ring
Adjustment needle
Spring
Ball
O-ring
End piece
Washer
Shim, see spec.card
Piston
O-ring
Sleeve
Shim
Spring
Spring collar
Washer
Nut
07280-05
Owner´s manual
2-25
2-26
2-27
2-28
2-29
2-30
2-31
2-32
2-33
2-34
2-35
2-36
2-37
2-38
2-39
2-40
2-41
2-42
2-43
2-44
2-45
2-46
2-47
2-48
2-49
2-50
2-51
2-52
2-53
2-54
2-55
2-56
2-57
2-58
2-59
2-60
2-61
1
Pieces
2
2
2
4
2
2
2
2
4
2
2
2
2
2
2
4
2
2
2
2
2
2
2
2
2
- 2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
6
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
7
Öhlins distributors
Motorcycles
SLOVENIA
Moto ZIP trgovina d.o.o, KRANJ, Tel: +386 64 26 85 15, Fax: +386 64 26 85 14
SOUTH AFRICA
Technical Motor Products, MIDRAND, Tel. +27 11 805 2471, Fax. +27 11 315 0472
SPAIN
Zacatin S.A., TORREJON DE ARDOZ, Tel. +34 1 677 7897, Fax. +34 1 677 6123
SWITZERLAND
3W Motorsport, WINTERTHUR, Tel. +41 52 315 3188, Fax. +41 52 315 3754
TAIWAN
Henly Company Ltd, TAIPEI 10422, Tel. +886 2 5375 600, Fax. +886 2 5631 357
TURKEY
Demaks Motor-Servis Hizmetleri A.S., ISTANBUL,Tel. +90 216 442 1580,Fax. +90 216 442 2380
U.K.
Harris Performance Prod. Ltd., HERTFORD, Tel. +44 1992 551 026, Fax. +44 1992 587 052
USA and CANADA
LeMans Corporation, JANESVILLE, WI 53547, Tel. +1 608 758 1111, Fax. +1 608 758 1144
service
Pettersson Pro Suspension, ANAHEIM, CA 92807, Tel. +1 714 630 4777, Fax. +1 714 630 4788
service
TUF Racing Products, DEKALB, IL 60115, Tel. +1 815 756 3588, Fax. +1 815 756 3528
(MX & Enduro steeringdampers)
Scotts Performance MC Products, MONTROSE, Tel. +1 818 248 6747, Fax. +1 818 248 4529
Öhlins Authorized Dealers in SWEDEN
Claessons Motor AB, Bromölla, Tel. 0456-230 30, Fax. 0456-232 31
R G Motor AB, Helsingborg, Tel. 042-16 96 60, Fax. 042-16 18 15
DML Pro Bike, Värnamo, Tel. 0370-271 00, Fax 0370-271 61
LEJ Motor AB, Skövde, Tel. 0500-48 11 95, Fax. 0500-46 17 14
Carlbarks Motor AB, Kumla, Tel. 019-57 07 01, Fax. 019-58 12 74
Beviks Motor AB, Linköping, Tel. 013-36 25 00, Fax. 013-36 25 10
BIKE Trollhättan AB, Trollhättan, Tel. 0520-700 75, Fax. 0520-762 84
Stötdämparexperten AB, Stockholm, Tel. 08-650 10 07, Fax. 08-650 10 09
Schneiders MC AB, Upplands Väsby, Tel. 08-590 310 80, Fax. 08-590 725 53
MB Racing AB, Västerås, Tel. 021-81 17 77, Fax. 021-81 17 78
Revelj Racing, Hede, Tel. 0684-120 59, Fax. 0684-122 75
Two Wheels I Umeå AB, Umeå, Tel. 090-187 595, Fax 090-18 77 61
Heds Motor AB, Boden, Tel. 0921-175 10, Fax.0921-162 20
Traction, handling,
comfort and safety
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00, fax +46 8 590 025 80.
E-mail: info@ohlins.se
8
07280-05 (99 ed1) Teknisk Illustration AB, OHL763 rm super bike front fork, 99 01. 500 ex.
AUSTRALIA
Steve Cramer Proucts, BRAESIDE, Tel. +61 3 9587 1466, Fax. +61 3 9587 2018
AUSTRIA
Motopart Handelsges. m.b.H., WIEN, Tel. +43 1 667 6628, Fax. +43 1 667 0696
CANADA
S. Hansen Racing Products, EDMONTON, Tel. +1 403 466 8653, Fax. +1 403 465-9483
CROATIA
Moto ZIP trgovina d.o.o, KRANJ, Tel: +386 64 268 515, Fax: +386 64 268 514
DENMARK
F.I. Motorcykler ApS, SORÖ, Tel. +45 57 833 348, Fax. +45 57 834 855
FINLAND
Mauri Penttilä Racing, HYVINKÄÄ, Tel. +358 19 437 100, Fax. +358 19 489 872
FRANCE
P.F.P - Öhlins France, Arpajon-Sur-Cere, Tel. +33 471 481 534, Fax. +33 471 642 593
GERMANY
Zupin Moto-Sport GmbH, TRAUNREUT, Tel. +49 8669 85760, Fax. +49 8669 2328
GREECE
Vassilis Dulaveris, ATHENS, Tel. +30 1-923 6051, Fax. +30 1-924 9957
HONG KONG
Power Motorcycle Specialist, KOWLOON, Tel. +852 3903 949, Fax. +852 3919 434
ICELAND
Baldurssons Trading, AKUREYRI, Tel: +354 8545 3136, Fax: +354 462 2777
ITALY
Motorquality S.p.A., SESTO S GIOVANNI (MI), Tel. +39 02 249 511, Fax. +39 02 2495 1232
JAPAN
Carrozzeria Japan Co., Ltd., SAITAMA-PREF; 336, Tel. +81 48 863 1801, Fax. +81 48 863 1802
The NETHERLANDS, BELGIUM, LUXEMBURG
Wim Kroon Import V.O.F., HV MILL, Tel. +31 485 453 911, Fax. +31 485 454 848
NORWAY
MC-Spesialisten, SKÄRER, Tel. +47 67 920 380, Fax. +47 67 972 855
NEW ZEALAND
Hawera Motorcycles LMVD, HAWERA TARNAKI, Tel.+64 627 84160, Fax. +64 627 86552
POLAND
P.T.M. SP. zo.o., NIEPORET, Tel. +48 22 774 8978, Fax. +48 22 774 8978
PORTUGAL
Motoni, AMADORA, Tel. +351 1 472 8160, Fax. +351 1 471 4809
RUSSIA
Alpine Ltd, MOSCOW 121 552, Tel. +7 95 149 5069, Fax. +7 95 141 2310
SINGAPORE
Sporting Motorcycles, SINGAPORE 1232, Tel. +65 250 5508, Fax. +65 253 6312