OWNER`S MANUAL
Contents
1. 1 1 Top nut assembly See page 5 1 2 03316 01 2 Spring support NR Vi i 04744 95 2 Spring 25 5 260 9 5 2 amp m 1 8 04744 10 2 Option spring 25 5 260 10 0 usc lm 04744 90 2 Option spring 25 5 260 9 0 i i 1 4 01438 04 4 Guide ring 1 5 o1460 06 2 Preload tube 157 mm 7 i 13 1 6 01900 06 2 Fork leg outer Sa e ay 1 7 00191 06 2 Sticker OHLINS i 1 8 01683 04 2 Bushing upper 14 1 9 01684 04 2 Bushing lower i H g 4 1 10 04758 01 2 Washer 1 11 04720 02 2 Seal Vt 15 1 12 04759 01 2 Circlip 5 1 EC qar WD 1 13 01901 04 2 Rodextensioner UJ 1 14 02302 08 2 Guide sleeve 5 17 M ircli 4 amp i 18 g 145 01499 01 2 Circii E P 9 8 1 16 01582 17 4 Spacer 10 mm i e u 20 e 1 17 01440 01 2 Bump rubber i 201 C5 1 18 01032 08 2 Back up ring 22 8 1 19 01027 07 2 X ring 28 i 24 1 20 01651 10 2 Sealhead 6 25 1 21 00438 02 2 O ring C S 1 22 01056 04 2 Bushing A 27 E 1 23 00438 41 2 O ring E A eu 7 1 24 01582 15 2 Spacer 15 mm TI TIE 8 1 25 01582 16 2 Spacer 8mm 2L 1 26 01653 07 2 Sleeve 1 27 01585 01 2 Top out spring 3 5 N mm 1 28 02368 022. 7 1 Put the fork leg in horizontal position in a vice with soft jaws NOTE Do not mix up the two valves they must be installed in their intended valve housing We recommend you to remove one valve at a time to keep them apart 7 2 Remove one valve Use a 17 mm wrench Make the necessary changes 7 3 Add some Ohlins front fork oil 01309 into the valve housing Reinstall the valve Make the necessary changes on the other valve in same order 7 4 Add gas pressure to the reservoir according to chapter Assemble the front fork x2 0 660 Col 2 6 x 16 Owners manual FGR 800 Oil level adjustments 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 spring force at the beginning of the fork travel but will have a great effect at the end of the travel When the oil level is raised The air spring in the later half stage of travel is stronger and make the front fork more progressive When the oil level is lowered The air spring of the travel is reduced and thus the front fork less progressive NOTE Adjust the oil level according to the figure with the fork leg fully compressed without spring and preload tube For correct oil level see specification card Force 4000
3. 3500 3000 2500 2000 1500 1000 500 Oil level adjustment Air spring characteristics The air inside of the front fork works as a spring The graph at the bottom of this page shows the spring force related to stroke when the oil level is changed between 140 mm and 200 mm Standars oil level is 180 mm Use tool 01765 03 Push to a stop hlins Front Fork oil 01309 01 The edge of the outer fork leg Oil level Oil Level Stroke mm 17 Troubleshooting Owners manual FGR 800 Below you will find a few examples of how to adjust for the most common road holding problems in Road Racing driving 1 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 Put on more preload Change to a harder spring e f a lot of stroke remains after riding drop the oil level See oil level chart Make sure the front fork have no friction Rear ride height is too high too much rear spring preload Lower the rear end by taking off preload from rear shock spring 2 The front wheel is jumping during the last part of braking e f a lot of stroke remains the oil level is too high Lower the oil level f the fork is bottoming install harder springs and keep the
4. Technology om me emt ATF Reman See Cm A mm ADVANCED SUSPENSION TECHNOLOGY 4 gt 1 vvv Owner s Manual 07280 15 Issued 2007 12 11 Ohlins Racing AB AA OL
5. legs according to Chapter Assemble the Front Fork 12 Owners manual FGR 800 Work shop section 5 Disassemble the shaft Remove the fork leg from the motorcycle 5p Remove the top cap and shaft assembly L 16 aki wrencl according to steps 1 7 in chapter Disassemble the Front Fork Then continue below Soft jaws 00727 02 5 1 Put the shaft assembly in a vice using soft jaws 00727 02 Remove the piston top out spring and sleeve in one unit Use a 16 mm wrench iU Piston CAUTION Do not tighten the jaws too hard the shaft can be Topout spring damaged Fig 5 1 Sleeve Spacer amp 5 2 O ring Remove the spacer and the o ring 9 Fig 5 2 Remove the seal head from the shaft Check the Suppor tnd e support ring x ring and the o ring Replace them a uf if necessary Use plenty of white grease when Seal head e installing a x ring i O ring S 5 5 Fig 5 3 l Wrap some teflon tape around the shaft thread to protect the x ring from damages Apply some red grease on the tape and the shaft end Reinstall the seal head on the shaft 5 6 Use a brass wire brush to clean the shaft from tape Reinstall the o ring spacer sleeve topout spring and piston Tighten the piston with torque 8 Nm Use Loctite 2701 and a 16 mm wrench HOC 13 Work shop section 6 Assemble the front fork Owners manual FGR 800 6 1 Tool Cylind 00720 02 Open the compression and rebound adjus
6. oil level 3 The front end feels unpredictable and un safe in the middle of the corner between braking and getting on power Not enough rebound damping Add more damping Too much rebound damping If it at the same time feels harsh reduce rebound damping Too much compression damping Also gives a harsh feeling Reduce compression damping 4 The front end loses grip coming out of a corner Not enough rebound damping Add more rebound damping Too much preload Reduce preload Rear end is too soft Install harder rear spring Front end is too high Lower the front end by pulling the fork legs through the triple clamps As mentioned in the beginning the whole bike setup affects the front fork Try to understand the feelings and work step by step NOTE We advise to change only one thing at a time and do everything step by step 18 Owners manual FGR 800 Technical information Technical information G 30 Nm 2701 Front fork length 740 mm E 2 Stroke 130 mm 5 Free spring length 260 mm 10 Nm RG Recommended settings 20 Nm Q Compression 15 clicks Rebound 12 clicks NUS N E Spring preload range 0 18 mm 0 18 turns g l E E El EN INAS Spring rate NE SE HON 9 5 N mm mark 95 STD 04744 95 e ETE E D A S
7. 0 This Ohlins superbike front fork is equipped with the following external adjusters Spring preload adjustment Adjust the spring preload by turning the 14 mm wrench nut on the top of the fork leg Use a 14 mm wrench The adjustment range is 0 18 mm n 1 turn on the adjustment nut will change Increase 1mmiin spring preload spring preload Recommended static sag is 25 30 mm spring preload Rebound adjustment and Compression adjustment Adjust the rebound or compression damping by turning the adjuster screw s at the fork bottom Use tool 00794 01 The adjustment range from closed valve clockwise to maximum open valve counter clockwise is 20 clicks Turn clockwise for closed valve Recommended adjustment clicks from closed position See specification card Turn counter clockwise for maximum open valve Rebound adjuster Compression adjuster Tool 00794 01 N Owners manual FGR 800 Setting up your fork Basic Guidelines How to set up your Ohlins front fork The front fork is just one part of your motorcycle To get it to work properly set up your motorcycle according to your vehicle service manual 1 Put your motorcycle on a workstand and install the Ohlins front fork according to your vehicle service manual NOTE The lower triple clamp must not be tightened to more than 12 15 Nm This is also important for the steering damper bracket when located
8. 2 Shaft 502 5 mm 1 29 00338 60 2 O ring E 1 30 02061 04 2 TTX piston 1 31 00338 05 2 O ring 1 32 01447 01 2 Piston ring 8 31 32 a i Note The number of pieces is valid for 1 pair of Front fork legs 998 pagoa 20 Owners manual FGR 800 Spare parts list See page 3 O ring I c Oylinder tube extension 2 1 00638 06 2 2 04809 01 2 3 00338 20 2 O ring mo mo ro rm rnmj n 2 4 04807 01 Volume spacer 2 5 01486 09 Cylinder tube 170 mm 2 6 01703 01 Fork leg inner 528 mm 2 7 2 8 01565 04 1 Stroke indicator Right leg 2 9 00338 63 2 10 04759 02 2 11 00382 08 2 12 01678 14 O ring Circlip Fender bracket Du DO 2 2 2 Screw 2 2 2 13 01682 28 Fender bracket ring 2 14 01902 27 1 Fork bottom Left leg 01902 28 1 Fork bottom Right leg 6 2 15 00382 07 2 Screw 2 16 00438 33 2 O ring 2 17 00191 17 2 Sticker 2 18 01240 08 4 Bolt Titanium 2 19 00161 10 2 Reservoir end assy 2 20 02806 01 2 Gas piston 2 21 01447 02 2 Piston ring 2 22 00338 25 4 O ring 2 23 00196 01 2 Sticker Warning 2 24 02812 02 2 Reservoir tube 125 mm 2 25 00338 72 2 O ring 2 26 01669 02 4 Caliper sleeve Standard 01669 03 4 Caliper sleeve Optional 2 27 2 2 Valve assy See page 6 2 28 00329 13 2 Ci
9. 6 Oil level adjustments 17 Setting up your fork 7 Troubleshooting 18 1 Change the spring 8 Technical info 19 2 Disassemble the front fork 9 Spare parts list 20 Disassemble the shaft Change spring see page 13 see page 8 Replace seal see page 11 e Replace reservoir see page 12 Replace inner outer fork leg see page 12 Revalve see page 16 Owners manual FGR 800 Work shop section Tools Pos Art No Description Remarks 1 00727 02 Vice with soft jaws 2 Wrench 14 mm Wrench 17 mm Wrench 19 mm 3 Allen key 4 Wire with hook 5 Heat gun 6 Teflon tape 7 Brass wire brush 8 00797 01 Sleeve pin 9 01797 04 Seal head tool 10 01765 03 Pull up tool 11 00720 02 Measure pin 12 00720 03 Pin tool 13 00786 05 Soft jaws clamp o 43 14 00786 07 Soft jaws clamp o 29 15 00715 01 Sharp screw driver 16 02810 01 Pull up holder tool 17 01781 01 Gas filling device 18 01309 01 hlins front fork oil 19 00146 01 hlins red grease 20 00147 01 hlins white grease 21 Rag 22 Waste oil container 23 01757 01 Attachment bar tool 24 01759 07 Bushing tool 01759 08 Bushing tool 25 01758 04 Bar guide Loctite 648 Loctite 222 O External adjustments Owners manual FGR 80
10. AE Optional springs available mAy ls y N S O 8 0 N mm mark 80 04744 80 N SA 3 8 5 N mm mark 85 04744 85 INNS ANIMAS 9 0 N mm mark 90 04744 90 supplied SARIN 10 0 N mm mark 10 04744 10 supplied SA E 10 5 N mm mark 05 04744 05 S 11 0 N mm mark 11 04744 11 E NES EN Oil capacity i See specification card Use Ohlins high performance front fork oil R amp T 01309 only 20 Nm RG WG AS E N I NR Torque E q le Lower triple clamp bolt 12 15 Nm Nid A Upper triple clamp bolt 18 22 Nm S S EI Grease pos hlins Front Fork Red Grease RG 00146 01 mp Ohlins Front Fork White Grease WG 00147 01 Res 8 fo Service intervals g a This product is designed for racing use only T S A frequently service and maintenance is recommended Recommended service every 10 hours RG 160 Nm 2701 Disposal LO Nm 2701 Discarded products should be handed over to an authorized Ohlins Service Centre for proper disposal 2 Ri 20 Nm 7 Nn 222 19 Spare parts list Owners manual FGR 800
11. OWNER S MANUAL Ohlins front fork Superbike FGR 800 Safety precautions Owners manual FGR 800 Important information concerning safety is distinguished in this manual by the following notations AN This Safety alert symbol means Caution Your safety is involved Failure to follow warning instructions could result in severe or fatal injury to anyone working with inspecting or using the suspension or to bystanders CAUTION Caution indicates that special precautions must be taken to avoid damage to the suspension NOTE This indicates information that is of importance with regard to procedures 1 Installing a suspension that is not approved by the vehicle manufacturer may affect the stability of your vehicle hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an hlins dealer for advice 2 Please study and make certain that you fully understand the contents in the mounting instruction s and the owner s manual s before handling this suspension kit If you have any questions regarding installation procedures contact an hlins dealer 3 The vehicle service manual must be referred to when installing the hlins suspension Introduction All of hlins advanced suspension products are adapted to the brand and model This means that length travel spring action and damping charac terist
12. around the upper front leg Too high torque may deform the front fork leg Guidelines Setting the Spring preload 2 The spring preload is very important since it affects the height of the motorcycle and the fork angle Consequently handling characteristics can be changed even negatively Procedure We recommend you to have an assistant for this procedure 3 Put the motorcycle on a stand Make sure that the shock absorber is fully extended Measure the distance from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 Make a similar measurement on the front axle for example from the bottom of the upper fork crown to the front wheel axle Make sure that the front fork is fully extended F1 Take the same measurements with the rider and equipment on the motorcycle It is important that the rider has a correct riding posture so that the weight is balanced on the front and rear wheel in the same way as when riding R3 F3 The measurements should not differ from the following Rear 30 5 mm R1 R3 Front 30 5 mm F1 F3 R1 Bike on a stand O R3 er Ay Bike with rider on Work shop section 1 Change the spring Owners manual FGR 800 1 1 Release the spring preload completely by turning the adjustment nut counter clockwise as far as possible Use a 14 mm wrench or socket 1 2 Loosen the screws that hold the fork legs in the u
13. assembly Pull the pull up tool and push the seal head tool at the same time to contract the top out spring Install tool 02810 01 on tool 01765 03 to keep the contraction Apply red grease to the seal head thread 6 8 Assemble the complete shaft assembly into the cylinder tube Tighten it by hand 6 9 Remove tool 02810 and move tool 01765 03 and tighten the seal head to 20 Nm Use tool 01797 04 and 01765 03 6 10 Once again contract the top out spring using tool 02810 01 tool 01765 03 and tool 01797 04 Check the gas pressure again according to the spec card 6 11 Tighten the gas filling screw and o ring with 3Nm 6 12 Push tool 01765 03 to a stop and adjust the oil level according to chapter Oil level adjustment NOTE Use hlins Front fork oil 01309 01 only 6 13 Reinstall the preload tube spring and spring support 6 14 Reinstall the top cap assembly to the shaft Tightening torque 20 Nm 6 15 Reinstall the top cap into the outer fork leg Use tool 00797 01 Tightening torque 10 Nm Adjust the preload compression and rebound 15 Tool 01765 03 Tool 02810 01 Tool Top out spring eI O JN S x Tool 01797 04 01765 03 Tool 02810 01 r NY Fig 6 14 Fig 6 15 Work shop section 7 Revalve Owners manual FGR 800 Release the gas pressure from the reservoir according to chapter Disassemble the front fork Then continue below
14. bly from the fork leg ee 01765 03 Fig 2 10 2 12 45 01797 04 Drain all oil from the fork leg ud 2 13 1 Disassemble the shaft assembly according to 0 Chapter Disassemble the shaft Shaft Fork leg assembly q N Fig 2 11 Owners manual FGR 800 Work shop section 3 Change the seals NOTE This worksection can not be done while the fork still is installed on the motorcycle Remove the top cap and shaft assembly according to Chapter Disassemble the Front Fork Then continue below 3 1 Remove the outer fork leg clean the seal and check the condition If the seal is in good condition apply some red grease 00146 01 to the seal before reassembling the fork A damaged seal must be replaced 3 2 Remove the circlip the seal and finally the washer 3 3 Apply a thin layer of Ohlins red grease 00146 01 to the washer and to the sealing surfaces of the fork seal Install the washer and the seal into the outer fork leg Install the circlip into the groove NOTE It is important to use the correct grease in order to achieve optimum fork function 3 4 Apply some Ohlins fork oil 01309 01 on the inner fork leg s outer surface Slide on the outer fork leg carefully on to the inner fork leg completely down Be careful Do not damage the fork seal 3 5 Reassemble the fork legs according to Chapter Assemble the Front fork 11 hlins fork oil Inner fork le
15. g 3 Washer Je 3 Circlip 2 Seal 5 1 Washer CD Outer fork leg Work shop section 4 Replace inner outer fork leg Owners manual FGR 800 NOTE This worksection can not be done while the fork still is installed on the motorcycle Outer fork leg Remove the top cap and shaft assembly according to Chapter Disassemble the Front Fork Then continue Pad below 4 1 Remove the outer fork leg 4 2 Use a heat gun to warm up the fork bottom Install tool 00786 02 just above the lower 95 mm oil bleed hole to unscrew and remove the inner fork leg Clean the thread thoroughly from Loctite We recommend to change the o rings 00786 02 4 3 Use a heat gun to carefully warm up the reservoir tube bottom Use tool 00786 07 to unscrew and remove the reservoir tube Clean the threads thoroughly from Loctite We recommend to change the o rings 4 4 Install the new reservoir tube using tool 00786 07 Use Loctite 222 on the threads Tightening torque 25 Nm 4 5 Install the new inner fork leg using tool 00786 02 Use Outer fork leg Loctite 2701 on the threads Tightening torque 160 Nm 4 6 Apply some hlins fork oil 01309 01 on the inner fork leg s outer surface Slide on the outer fork leg carefully on to the inner fork leg completely down Be careful Do not damage the fork seal hlins fork oil 4 7 Reassemble the fork
16. ics are tested individually just for the motorcycle that you have decided to fit with hlins suspension Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension or vehicle or injury to persons if the instructions for fitting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to NOTE hlins products are subject to continual improvement and development Consequently although these instructions include the most up to date information available at the time of printing there may be minor differences between your suspension and this manual Please consult your hlins dealer if you have any questions with regard to the contents of the manual NOTE During storage and transportation especially at high ambient temperature the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material This is not unusual and is in no way detrimental to the suspension Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Owners manual FGR 800 hlins front fork FGR 800 hlins Front Fork FGR 800 The FGR800 is very essence of front fork technology and is based on last years succesful predecessor FGR700 This pressurized front fork eq
17. pper triple clamps 1 3 Loosen the top cap assembly from the outer fork leg Use tool 00797 01 1 4 Remove the top cap assembly from the shaft Use a 14 mm wrench on the top cap and a 19 mm on the shaft 1 5 Remove the spring support and the spring Use a wire with a hook and carefully pull up the preload tube 1 6 Check the oil level according to Chapter Oil level adjustment NOTE Use hlins Front fork oil 01309 01 only 1 7 Reinstall the preload tube the new spring and the spring support 1 8 Reinstall the top cap assembly to the shaft with tightening torque 20 Nm 1 9 Reinstall the top cap into the outer fork leg with the front wheel off the ground use tool 00797 01 and tighten with torque 10 Nm Tighten the upper triple clamps and adjust the preload according to Chapter External adjustments 14 mm wrench Tool 00797 01 14 mm wrench Spring CO amp support 19mm E wrench Spring Fig 1 4 Fig 1 5 Preload tube 00797 01 Owners manual FGR 800 Work shop section 2 Disassemble the front fork NOTE This worksection can not be done while the fork still is installed on the motorcycle 2 1 Fasten the fork leg in a vice with soft jaws 2 2 Release the spring preload completely by turning the adjustment nut counter clockwise as far as possible Use a 14 mm wrench or a socket NOTE Do not use the preload adjuster to
18. rclip 2 29 00338 59 2 O ring 2 30 01050 01 2 Screw Note The number of pieces is valid for 1 pair of Front fork legs 15482 05 spacer must be fitted when 01902 27 28 is used 21 Spare parts list Owners manual FGR 800 Pos Part No Pos Description Type Remarks 3 1 03312 02 2 Adjuster 3 2 03309 01 4 Thin Shim 3 3 00338 72 2 O ring 3 4 03318 05 2 Housing 3 5 00338 02 2 O ring 3 6 03317 01 6 Wave washer 3 7 03309 02 2 Thick shim 3 8 03313 01 2 Nut 2 3 9 03315 01 Preload socket Note The number of pieces is valid for 1 pair of Front fork legs 22 Owners manual FGR 800 Spare parts list Pos PartNo Pos Description Type Remarks 4 1 01657 01 4 Nut Aluminium 4 2 00153 01 4 Washer 4 3 01672 01 4 Spring collar 4 4 01671 03 4 Spring 8 N mm 4 5 01669 01 4 Sleeve 4 6 00530 22 4 Shim 4 7 02406 01 4 Piston 4 8 00338 11 4 O ring 4 9 Shim stack See spec card 4 10 Clamp washer See spec card 4 11 01658 05 4 End piece 4 12 00438 02 4 O ring 4 13 01242 11 4 Adjustment needle 4 14 00884 02 8 Ball 02 5 mm 4 15 01474 01 4 Spring 4 16 00338 53 4 O ring 4 17 01473 02 4 Circlip Note The number of pieces is valid for 1 pair of Front fork legs 23 13 wl Ne C 16 15 Q3 17 Fig 4 gt 4 Porra www ohlins se Advanced Suspension
19. ters WES x by E completely Pour hlins front fork oil 01309 01 to nly M the top edge of the reservoir Carefully continue to fill until the oil level is the same in the reservoir and the cylinder tube 6 2 Push the gas piston with the teflon band and o ring installed to the reservoir bottom Use tool 00720 02 Do not allow the gas piston to be pushed back over the circlip groove Make sure that there is no air between the piston and the oil 6 3 Fill the inner fork leg with oil to approximately 20 f 30 mm above the cylinder tube 6 4 Carefully pump the gas piston up and down 10 20 times to bleed the system 6 5 Check the o ring on the reservoir end cap and replace it if necessary Install the reservoir end cap into the reservoir tube using tool 00720 03 Reinstall the circlip Make sure that it stops in the intended groove NOTE Nitrogen N2 gas Use pressure gauge 01781 01 J Use of inflammable gas for pressurising the shock absorber can be hazardous Use nitrogen gas N2 only 6 6 Dip the needle of the gas tool 01781 01 in red grease and insert the needle through the gas filler valve Charge with gas to the correct pressure according to the spec card NOTE Ensure that there is no leakage of gas or fluid 14 Owners manual FGR 800 Work shop section 6 Assemble the front fork 6 7 Install seal head tool 01797 04 and pull up tool 01765 03 on the shaft
20. tighten or loosen the top cap assembly 2 3 Loosen the top cap assembly from the outer fork leg Use tool 00797 01 2 4 Remove the top cap assembly from the shaft assembly Use a 14 mm wrench on the top cap and a 19 mm wrench on the shaft 2 5 Remove the spring support and the spring Use a wire with a hook to carefully pull up the preload tube 2 6 Remove the screw and the o ring from the reservoir end 14 mm wrench 00797 01 Spring upport Preload tube Fig 2 5 Reservoir end Work shop section 2 Disassemble the front fork Owners manual FGR 800 NOTE Before releasing the gas pressure count and x Tool note the adjuster settings Also check that the gas Injection 00720 03 pressure is correct Then the adjusters should be needle LU Circlip set in a fully open position Releasing high pressure gas from the front fork can be hazardous Do not perform any kind of service until gas pressure is completely released 2 7 Release the nitrogen gas by inserting an injection needle in the reservoir end through the rubber valve 2 8 Press down the reservoir end to remove the circlip Use tool 00720 03 Teo 00720 02 2 9 Remove the reservoir end Use tool 00720 03 Gas piston 2 10 Remove the gas piston use tool 00720 02 2 11 Use tool 01797 04 and 01765 03 to remove the shaft assem
21. uipped with TTX technology is the very latest in front fork technology The new improved FGR800 comes fully packed with technical solutions and experiences gained from MotoGP WSB and AMA racing Features New fork bottoms and inner fork legs for improved rigidity New valve specification with better dynamic behavior for faster damping response resulting in improved feedback of the tire contact feeling New bushings with new material and less play for smoother action New volume spacer for less fluid in the fork to reduce flex in the fluid for improved damping response Improved internal seals and surfaces for simplyfied maintenance NOTE Read through the whole work section and make sure that you understand all the steps in the procedure before you begin Make sure that you have all the proper tools needed for the section you are about to work on before you begin Clean all parts thoroughly after disassembling Contact an hlins dealer if you have any questions regarding the front fork Work shop section Contents Owners manual FGR 800 Contents Safety precautions 2 3 Replace the seal 11 Ohlins front fork FGR800 3 4 Replace inner outer fork leg 12 Work shop section 5 Disassemble the shaft 18 Contents 4 6 Assemble the front fork 14 Tools 5 7 Revalve 16 External adjustments
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