öhlins front fork fgr 300
Contents
1. 260 270 0 10 20 30 40 50 60 Stroke mm 70 80 90 100 110 120 130 25 Troubleshooting The whole motorcycle setup affects the front fork Make sure you understand how the front fork works and make adjustments step by step amp Note Adjust only one thing at a time Below you will find a few examples of how to ad Just for the most common stability 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 A The fork is working too low in the travel and reach es the progressive hard part at the end of the trav el Try one of the following Increase preload Change to a harder spring If a lot of stroke remains after riding drop the oil level See oil level chart Make sure the front fork has no friction B Rear ride height is too high too much rear spring preload Try one of the following Lower the rear end by taking off preload from rear shock spring The front wheel is jumping during the last part of braking Try one of the following gt If a lot of stroke remains the oil level is too high Lower the oil level If the fork is bottoming install harder springs and keep the oil level 3 The front end feels unpredictable and unsafe in the middle of the corner between braking and get ting on power Try o2. For the new FGR 300 hlins engineers set out a target to improve the already successful FGR 200 front fork in several areas as development never stands still in racing Design The outer tube is now reinforced making the FGR 300 stiffer and more robust This pressurized front fork equipped with 23mm TTX technology is the very latest in front fork tech nology New features on the FGR 300 Stronger outer tubes Stiffer outer tube Lighter design New settings for better control 9 Note The front fork is just one part of your motorcycle To make it work properly set up your motorcycle according to your vehicle service manual 1 Mount hlins Front Fork Put your motorcycle on a workstand and mount the hlins front fork with the splines facing out from the motorcycle see figure below Follow in structions in your vehicle service manual Lower triple clamp Tightening torque max 12 15Nm m Caution Ifthe Steering damper bracket is located around the upper front leg do not exceed 12 15Nm Too high torque may deform the front fork leg affect ing the function negatively amp Note See Chapter Technical Information for technical data for the FGR 300 2 Check Ride Height 9 Note The following procedure should be performed on a flat surface We recommend that the following procedure should be performed by two persons 2 1 Put the motorcycle on a stand Ensure t
3. hlins Front Fork Superbike Owner s Manual Spare Parts List Workshop Manual ADVANCED SUSPENSION TECHNOLOGY It was the 1970 s a young man named Kenth h lin spent most of his spare time pursuing his fa vourite sport motocross A careful observer Kenth s attention was continually drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension hlins Racing was established in 1976 and just two years later the company won its first World Championship title Despite being in the business for 30 years the search for perfection and new functions is still the main focus of the company Congratulations You are now the owner of an hlins Front Fork More than two hundred World Championships and other major world titles are definitive proof that hlins products offer out standing performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible experience from our 30 years within the racing sport The product that you now have in your possession is pure racing breed that is built to withstand By installing this front fork on your bike you have made a clear statement you are a serious rid er with a focus on gett
4. 2 TTX piston 25 mm 1 28 00638 25 2 O ring 1 29 01447 02 2 Piston ring Note Pcs pieces applies for one pair of Front Fork legs Figure 2 Inner tube and Fork Bottom Pos PartNo Pcs Description Notes ye 2 1 04809 04 2 Cylinder tube ext 2 2 00438 75 2 O ring 2 23 00576 11 2 O ring 2 4 04807 04 2 Vol Spacer y 2 5 01656 14 2 Cylinder tube 158mm 2 6 01703 02 2 Inner tube 528mm 2 7 01565 04 1 Stroke indicator Right 2 8 00338 54 1 O ring Green 2 9 04759 02 2 Circlip 5 Ein 2 10 01682 55 2 Fender bracket ring NN eee IE 2 11 01678 14 2 Fender bracket d pe 2 12 00382 08 2 Screw UJ 2 13 00338 63 2 O ring C 2 14 0190229 1 Fork bottom Left 01902 30 3 Fork bottom Right pem 2 15 01240 08 4 Screw Titanium 6 o 2 16 04810 01 2 Stop screw 2 17 00382 07 2 Screw 2 18 00438 33 2 O ring 2 19 01669 02 4 Caliper sleeve 2 20 01669 03 4 Spacer Optional 2 21 2 2 Valve assy See fig 4 2 22 01050 01 2 Screw 2 23 00338 59 2 O ring 2 24 00557 01 2 Circlip 2 25 00338 25 2 O ring 2 26 00161 12 2 Reservoir end assy 2 27 02806 01 2 Gas piston 2 28 01447 02 2 Piston ring 2 29 00338 25 2 O ring 2 30 02814 03 2 Reservoir tube 95 mm 2 31 00338 72 2 O ring lt O Note Pcs pieces applies for one pair of Front Fork legs 10 Pos PartNo Pcs Description Notes 3 1 04732 11 2 Top C
5. outer surface of the Seal 3 7 Mount the Washer and the Seal into the Outer tube Mount the circlip into the groove 3 8 Apply some hlins Front Fork fluid 01309 01 on the inside of the seal and the outside of the inner tube do not use grease inside the seal Slide the Outer tube carefully on to the Inner tube A Warning Be careful Not to damage the Fork seal To reassemble Front Fork go to Chapter 6 Assemble Front Fork Outer tube 18 4 1 Loosen the upper clamp screws and loosen the top cap turn use tool 00797 08 Remove the Front fork from the motorcycle 4 2 Remove Top cap and Shaft assembly according to Chapter 2 Disassemble Front Fork 4 3 Remove the Outer tube 4 4 Mount clamp tool 00786 05 on the Inner tube Make sure both are clean as high as possible above the lower 85 mm oil bleed hole Use a heat gun to heat up the fork bottom Loosen and re move the Inner tube Clean the thread from all Loctite We recommend to replace the O ring 00338 63 4 5 Loosen and remove the Reservoir tube Use Clamp tool 00786 07 Use a heat gun to heat up the fork bottom Clean the thread thoroughly from Loctite We recommend to replace the O ring 00338 72 4 6 Mount the new Reservoir Using clamp tool 00786 07 Loctite 222 on the thread Tightening torque 25 Nm 4 7 Mount the new Inner tube Use clamp tool 00786 05 and ma
6. ap Assy 3 2 03312 09 2 Adjuster 3 3 03083 01 4 Spring 3 4 00884 06 4 Ball 3 5 00338 72 2 O ring 3 6 03309 01 4 Thin Shim 3 7 03318 11 2 Housing 3 8 00338 02 2 O ring 3 9 03317 01 8 Spring washer 3 10 03313 01 2 Nut 3 11 03315 05 E Preload socket amp Note Pcs pieces applies for one pair of Front Fork legs 11 Figure 4 Valve 1 Pos PartNo Pcs Description Notes NIE 4 1 01657 01 Nut Aluminium ED 2 4 2 00153 01 Washer eB 3 4 3 01672 01 Spring collar amp 4 4 Spring See spec card e a 4 5 01669 04 4 Sleeve 4 6 Shim See spec card F 4 7 02406 02 Piston 4 8 00338 11 O ring CB F 4 9 Shim stack See spec card SS 4 10 Clamp washer See spec card 4 11 01658 09 2 End piece Compression E 7 01658 10 2 End piece Rebound 4 12 00438 02 4 O ring 8 4 13 01242 16 4 Adjustment needle C 4 14 00884 02 8 Ball 02 5 mm Ce 9 4 15 01474 01 4 Spring 4 16 00338 53 4 O ring 4 17 01473 02 4 Circlip lt O Note Pcs pieces applies for one pair of Front Fork legs 12 Pos PartNo Description Notes 2 3 1 00146 01 hlins red grease 2 00147 01 Ohlins white grease Sa 3 00715 01 Sharp screw driver 4 00720 02 Measure pin 5 00720 03 Pin tool 5 6 gt 6 00727 08 Soft jaws 7 00786 05 S
7. e down Front Fork is very sensitive to variations in oil level compared to the conventional type fork Therefore adjust the oil level with spe cial care A change in the fork oil level will not af fect 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 which makes the front fork more progres sive When the oil level is lowered The air spring of the travel is reduced which makes the front fork less progressive 9 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 specifica tion card O Note The diagram below shows the air spring force for one fork leg 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 100 mm and 260 mm Oil level according to spec card hlins Front fork fluid 01309 01 Push to a stop Use tool 01765 03 The edge of the outer tube Oil level Force vs Stroke 250 200 m a Ss 150 160 170 180 Force N m e Ss 190 200 210 220 230 50 20 250
8. hat the shock absorber is fully extended 2 2 Measure the distance from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 2 3 Make a similar measurement on the front axle for example from the bottom of the upper triple clamp to a fixed point for example the front wheel axle F1 Make sure that the front fork is fully extend ed 2 4 Put the motorcycle on the ground so that the front and the rear suspensions are slightly compressed Repeat the measuring procedures R2 and F2 2 5 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Correct rid ing position is important so that the weight is bal anced on the front and rear wheel in the same way as when riding Repeat the measuring procedure R3 F3 3 The measurements should not differ from the fol lowing Rear 30 5 mm R1 R3 Front 35 5 mm F1 F3 R1 R2 E e e lt 3 4 If the measures differ significantly from the meas ures in step 3 you need to set the spring preload see below CO Note The spring preload is very important since it af fects the height of the motorcycle and the fork an gle Consequently handling characteristics can be changed even negatively If the measures still differ you may need to change spring Contact an hlins dealer for advice ADJUST SPRING PRELOAD REBOUND AND COMPRESSION Ad
9. ing the maximal handling ability and outstanding feedback from your bike Along comes the fact that your front fork will be a long lasting friend delivering the very best of com fort and performance every time you go for a ride Go explore AFETY PRECAUTION SAFETY SYMBOLS General Warnings O Note The shock absorber front fork steering damper is an important part of the vehicle and will affect the stability amp Note In this manual mounting instructions and other technical documents important infor mation concerning safety is distinguished by the following symbols A Read and ensure you understand the informa tion in this manual and other technical documents provided by hlins before using the product amp Note hlins Racing AB can not be held responsible for any damage to the shock absorber front fork steering damper vehicle other property or injury to persons if the instructions for mounting usage and maintenance are not followed exactly A Warning After installing the hlins product take a test ride at low speed to ensure your vehicle has main tained stability A Warning If the suspension makes an abnormal noise or the function is irregular or if you notice any leak age from the product stop the vehicle immedi ately and return the product to an hlins Service Centre A Warning The Safety Alert Symbol means Warning Your safety is i
10. ized use without the written permission of hlins Racing AB is prohibited Introduction ooooccccocncncocnnncocnnnnnnnnnnnonnnnnnnnrononnnnnnonennnons 1 Safety Precautions nennen 2 Ohlins Front Fork FEGR200 4 Setting up the Front Fork uuueerssssnnnnnennnenenennnnn nennen 5 Adjust Spring Preload Rebound and Compression 6 Technical Information ooooccinicciccccccccncccnncnnncnnnnninnnnnnns 7 spare Parts List ae 9 Workshop Section s occi core ee touto rea roe seeks ae 13 Hol 14 1 Replace Spririg erant nee 15 2 Disassemble Front Fork usuusse 16 3 Replace Seal etre 18 4 Replace Inner Outer tube ee 19 5 Disassemble haft 21 6 Assemble Front Fork s sssssesssesneennsenneerrererreneee 22 T RevalVQin incidi talxtescet co ixice arn ferc reat 24 ei Ed A 25 Troubleshooting uiii teo iere 26 The product in your hand is an artwork prepared by our dedicated craftsmen at our Swedish facil ity in Upplands V sby Sweden Its predecessors have battled their way on numerous race tracks in World Superbike Supersport Superstock and AMA and the legacy continues in your front fork Thousands of hours have been spent together with some of the best teams in the world to find the optimal design and functionality to give you as much performance as possible You will feel the difference be sure
11. just Spring Preload 1 Use a 14 mm wrench 2 Turn the nut on the top of the fork leg Turn clockwise to increase spring preload turn counter clockwise to decrease it 1 turn on the adjustment nut will change spring preload 1 mm 1 turn 2 clicks 1 click mm spring preload Recommended static sag F1 F2 25 30 mm Rebound and Compression Adjusters 1 Use tool 00794 01 2 Turn the adjuster screw s at the fork bottom Turn the adjuster clockwise to fully closed 3 Turn counter clockwise and count the clicks to set the adjuster Recommended adjustment clicks from closed position See spec card Spring Preload A turn 1 click 72mm change Rebound and Compression Rebound Adjuster Compression Adjuster N 2 Turn clockwise to close valve Turn counter clockwise to open valve FGR 300 Front fork length stroke 750 130 mm Free spring length 260 mm Adjustment Range Compression 26 clicks Rebound 26 clicks Spring preload 0 18 mm 0 18 turns The adjustment range from closed valve clock wise to maximum open valve counter clockwise approx 26 clicks Spring rate 10 0 N mm mark 10 STD 04744 10 Optional springs 8 0 N mm mark 80 04744 80 8 5 N mm mark 85 04744 85 9 0 N mm mark 90 04744 90 9 5 N mm mark 95 04744 95 10 5 N mm mark 05 04744 05 11 0 N mm mark 11 04744 11 supplied Oil capacity See specificatio
12. ke sure both tool and tube are clean Install the tool as high as possible above the lower 5 mm oil bleed hole Apply Assembly grease on the O ring on the Cylinder tube extension 4 8 Apply a thin layer of Ohlins Front Fork flu id 01309 01 on the inside of the Inner tubes low er half Carefully slide the Inner tube over the O ring and on the Fork bottom thread Loctite 2701 on the threads Tightening torque 160 Nm bleed hole 7 Jii Te Loctite 19 4 9 Apply some hlins fork fluid 01309 01 on the In ner tubes outer surface and inside the seal do not use grease inside the seal Slide the Outer tube carefully on to the Inner tube A Warning Be careful Not to damage the Fork seal To reassemble Front Fork go to Chapter 6 Assemble Front Fork Inner tube Outer tube 20 5 1 Loosen the upper clamp screws and loosen the top cap turn use tool 00797 08 Remove the Front fork from the motorcycle 5 2 Remove Top cap and Shaft assembly according to Chapter 2 Disassemble Front Fork 5 3 Put the Shaft assembly in a vice Use Soft Jaws Clamp 00727 08 Mm Caution Do not tighten the jaws too hard the Shaft can be damaged 5 4 Remove Piston Top out spring and Sleeve in one unit Use a 20 mm wrench 5 5 Remove Spacers and O ring 5 6 Remove the Seal head from the Shaft Check the Seal a
13. lu llu Le ue c Ny ly z ville 02 2 a aa au n oO m N OG be ie vg a z c g B E y 3 C c Mo c ES OQ o C ZE ZE Ex gt o C Q Q 2c o C onm 0 c a E SES au oO o o oC Io E u X EE d qu Z o 9 mou uc HH s2e3538338 rar SD E H II 1 H II 1 u n c4 m o 2 o oa aD UY N zd c mete X cQ Dco gh 25 26 L 97 ein 28 amp 29 Pos PartNo Pcs Description Notes 1 1 04732 11 2 Top nut assembly See page 11 1 2 03316 02 2 Spring support 1 3 04744 10 2 Spring installed 25 5 260 10 0 04744 95 2 Spring supplied 25 5 260 9 5 04744 05 2 Spring supplied 25 5 260 10 5 04744 11 2 Spring supplied 25 5 260 11 0 1 4 01438 04 4 Guide ring 1 5 01460 35 2 Preload tube 169 mm 1 6 01900 13 2 Outer tube 510 mm 1 7 01683 04 2 Bushing upper 1 8 01684 04 2 Bushing lower 1 9 04758 01 2 Washer 1 10 04720 02 2 Seal 1 11 04759 01 2 Circlip 1 12 01901 08 2 Shaft extension 1 13 00338 76 2 O ring 1 14 21666 01 2 Guide sleeve 1 15 01582 22 2 Spacer 1 16 01580 04 2 Bump rubber 1 17 01651 15 2 Seal head 1 18 00438 02 2 O ring 1 19 15428 01 2 Seal 1 20 01056 09 2 Bushing 1 21 01582 24 2 Spacer 15 mm 1 22 00638 81 2 O ring 1 23 01653 09 2 Sleeve 1 24 21733 03 2 Top out spring 1 25 21734 01 2 Shaft 525 5 mm 1 26 00338 39 2 O ring 1 27 02061 07
14. n card Use hlins Front Fork flu id 01309 only Torque Lower triple clamp bolt 12 15 Nm 1 2 1 Upper triple clamp bolt 18 22 Nm 1 2 1 Front axle Clamp bolt 17 19 Nm 1 2 1 Axle tolerances 30mm 0 06 O Note If your vehicle also is equipped with an hlins Steering Damper outer tube clamp Tighten to 12 15Nm Service intervals This product is designed for racing use only Service and maintenance is recommended eve ry 20 hours Disposal Discarded products should be handed over to an authorized hlins Service Centre for proper disposal gt 5 E S E gt mna CH IL N Ve e E E i EM E E B E E S E z z zZ m e le lt 1 gt o gt gt o N MO N oC Jogo REN d E SSSY SSH SINN Xx NI CH Thin layer of WG inside ring FG 4 3 u Eeer Va Na AR Jag Jy O OO ze SE SS N E ojoj oloo E E Ee a TF TA d Ze SJ p E E No so o l
15. nd the O ring Replace if necessary m Caution Do not use sharp tools 5 7 Wrap Teflon tape around the Shaft thread to pro tect the Seal Apply Assembly grease on the tape and the Shaft end Remount the Seal head on the shaft 5 8 Use a brass wire brush to clean the Shaft from tape 5 9 Remount the O ring Spacer Sleeve Top out spring and Piston Use a 20 mm wrench Loctite 243 Tightening torque piston 10 Nm Piston Top out spring i 65 Sleeve amp Spacer cb O ring e 0 VOR ap o Seal head c O ring gt Seal Bushing 88 P CO Leg 21 9 Note Use hlins Vacuum Filling Machine for best result 6 1 Open the Compression and Rebound adjusters to fully open 6 2 Fill hlins Front Fork fluid 01309 01 up to the edge of the Reservoir Carefully continue to fill un til the oil level does not drop 6 3 Use Measuring Pin 00720 02 Carefully push the Gas piston with the Teflon band and O ring installed to the Reservoir bottom 9 Note Ensure that there is no air between the Piston and the oil 6 4 Fill the inner tube with hlins Front Fork fluid 01309 01 to approximately 20 30 mm above the cylinder tube extension 6 5 Carefully pump the Gas piston up and down 10 20 times to bleed the system 6 6 Check the O ring 00338 25 on the Reserv
16. ne of the following 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 Try one of the following Not enough rebound damping Add more re bound 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 26 hlins Owner s Manual FGR300 Part No 07280 20_0 Issued 2012 12 04 hlins Racing AB Your hlins retailer hlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands V sby Fax 46 0 8 590 025 80 Sweden www ohlins com
17. ng facing up and Spring support 6 18 Remount Top cap assembly on the Shaft Tightening torque 20 Nm 6 19 Apply hlins Functional grease 00159 02 on the Top cap thread and O ring 6 20 Use Sleeve Pin 00797 08 Remount the Top cap into the Outer tube fork leg fully extended Tightening torque 10 Nm 6 21 Adjust Preload Compression and Rebound Tool 02810 01 Tool 01797 04 spring Ai Tool 01765 03 KC C om N s x Tool 01797 07 23 7 1 Release Gas pressure from the Reservoir See Chapter 2 step 2 9 7 2 Put the fork leg in horizontal position in a vice with soft jaws O Note Do not mix up the two valves they must be in stalled in their intended valve housing We rec ommend to remove one valve at a time to keep them apart 7 3 Remove one Valve Use a 17 mm wrench If you only intend to change setting without changing oil please make sure to fill oil at the same time as you remove the valves if not you can get an air trap below the adjuster 7 4 Perform necessary service 7 5 Add some hlins Front Fork fluid 01309 01 into the Valve housing Remount the Valve Tightening torque 20 Nm 7 6 Remove the other Valve Perform necessary serv ice Remount the Valve see step 7 5 To pressurize Front Fork go to Chapter 6 Assemble Front Fork 24 The Upsid
18. nvolved A Warning The Warning Symbol means Failure to fol low warning instructions can result in se vere or fatal injury to anyone working with inspecting or using the shock absorber or to bystanders qu Caution The Caution Symbol means Special pre cautions must be taken to avoid damage to the shock absorber O Note The Note Symbol indicates information that is important regarding procedures Product Specific Warnings A Warning The product warranty shall only apply if the prod uct has been operated and maintained in accord ance with recommendations in this manual If you have any questions regarding usage service inspection and or maintenance please contact hlins O Note When working with the hlins product always read the Vehicle Service Manual O Note This Manual shall be considered a part of the product and shall therefore accompany the prod uct throughout its life cycle This product was developed and designed exclu sively for a specific vehicle model and shall only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer A Warning This product contains pressurized nitrogen gas N Do not open service or modify this product without proper education authorized h lins dealer distributor and proper tools hlins Racing AB All rights reserved Any reprinting or unauthor
19. oft jaws clamp 043 gt 00786 07 Soft jaws clamp 29 8 00794 01 Screwdriver Allen key 3mm 8 9 9 00797 08 X Sleeve pin 10 01309 01 hlins Front Fork fluid ah 01757 01 Attachment bar tool 12 01758 04 Bar guide 13 01759 07 Bushing tool Dismantling 01759 08 Bushing tool Installation 14 01765 03 Pull up tool 15 01781 01 Gas filling device 16 01797 04 Seal head tool 17 01797 07 Seal head tool 18 02810 01 Pull up holder tool 19 00159 02 Functional grease 19 00159 02 Assembly grease Brass wire brush Heat gun Torque Wrench 3 8 Loctite 648 Loctite 222 Loctite 2701 Rag Teflon tape Torx wrench T20 Vice Waste fluid container Wire with hook Wrench 14mm Wrench 17mm Wrench 19mm Wrench 20 mm 14 9 Note This procedure can be performed with the front fork on the vehicle front wheel off the ground 1 1 Release spring preload Use a 14mm wrench Turn the Adjustment nut counter clockwise until stop make a note of position Mm Caution Do not use the Preload adjuster to tighten or loosen the Top cap assembly 1 2 Loosen the screws attaching the fork legs in the upper triple clamp 1 3 Loosen Top cap assembly from the Outer tube Use Sleeve Pin tool 00797 08 lower the front so that the front fork is fully compressed 1 4 Remove Top cap assembly from the Shaft Use a 14 mm wrench on the top cap and a 19 mm wrench on the Shaft 1 5 Remove Spring support and Spring Use a
20. oir end cap Replace if necessary 6 7 Use Pin tool 00720 03 Mount the Reservoir end cap into the Reservoir tube 6 8 Remount the Circlip Ensure that it stops in the in tended groove A Warning Use nitrogen gas N only Using inflammable gas to pressurize the front fork can be hazard ous Use Pressure Gauge 01781 01 6 9 Dip the needle of Pressure Gauge 01781 01 in Assembly grease and insert the needle through the Gas filler valve Charge with gas to the correct pressure according to the spec card O Note Ensure that there is no leakage of gas or fluid 22 6 10 Mount Seal Head tool 01797 04 and Pull up tool 01765 03 on the Shaft assembly Pull the pull up tool and push the Seal head tool at the same time to contract the Top out spring 6 11 Mount Pull up Holder tool 02810 01 on Pull up tool 01765 03 to keep the contraction Ap ply hlins Functional grease 00159 02 on the Seal head thread and the O ring 6 12 Insert the Shaft assembly all the way down into the Cylinder tube Tighten by hand 6 13 Check Gas pressure again according to the spec card 6 14 Tighten the Gas filling screw and O ring Tightening torque 3 Nm 6 15 Remove Pull up Holder tool and Pull up tool Use tool Seal Head tool 01797 07 Tightening torque 20 Nm 6 16 Check oil level according to chapter Oil level 6 17 Remount Preload tube Spring marki
21. ter settings open the Adjust ers to fully open MB ol 00797 08 Ze Reservoir end 16 A Warning Releasing high pressure gas can be hazardous Do not perform any kind of service until gas pres sure is completely released 2 9 Release gas pressure Insert tool 01781 01 in the Reservoir end through the Rubber membrane 2 10 Use Pin tool 00720 03 Press the Reservoir end down to remove the Circlip clean the circlip groove with a rag 2 11 Remove the Reservoir end Use Pin tool 00720 03 2 12 Remove Shaft assembly from the fork leg Use Seal Head tools 01797 04 and 01765 03 2 13 Drain all oil from the fork leg 2 14 Remove Gas piston Use Measure Pin 00720 02 To Replace Seal go to Chapter 3 Replace Seal To Disassemble Shaft assembly go to Chapter 5 Disassemble Shaft Shaft assembly 17 3 1 Loosen the upper clamp screws and loosen the top cap turn use tool 00797 08 Remove the Front fork from the motorcycle 3 2 Remove Top cap and Shaft assembly according to Chapter 2 Disassemble Front Fork 3 3 Remove the Outer tube 3 4 Clean the Seal and check for damage 3 5 If seal is damaged replace by removing the circlip Seal and Washer 3 6 Apply a thin layer of Assembly grease on the Washer and the
22. wire with a hook and carefully pull up Preload tube 1 6 Check oil level according to Chapter Oil level 1 7 Remount Preload tube new Spring marking fac ing up and Spring support 1 8 Remount the Top cap assembly on the Shaft Tightening torque 20 Nm 1 9 Apply hlins Functional grease 00159 02 on the Top cap thread and O ring 1 10 Remount Top cap into the outer tube with the fork fully extended Use Sleeve Pin tool 00797 08 See figure 1 3 Tightening torque 10 Nm 1 11 Tighten the upper triple clamp and reset the preload see page 5 15 2 1 Loosen the upper clamp screws and loosen the top cap 72 turn use tool 00797 08 Remove the Front fork from the motorcycle 2 2 Fasten the Fork leg in a vice with soft jaws 2 3 Release spring preload Use a 14 mm wrench Turn the Adjustment nut counter clockwise until stop make a note of position qu Caution Do not use the Preload adjuster to tighten or loosen the Top cap assembly 2 4 Loosen Top cap assembly from the Outer tube Use Sleeve Pin tool 00797 08 push down the outer tube 2 5 Remove Top cap assembly from the Shaft Use a 14 mm wrench on the top cap and a 19 mm wrench on the Shaft 2 6 Remove Spring support and Spring Use a wire with a hook and carefully pull up Preload tube 2 7 Remove Screw and O ring from the Reservoir end Use a Torx wrench T20 2 8 Count and note Adjus
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