Owners Manual
Contents
1. Flow in rebound valve Make sure that you have the correct springs and the correct spring pre load before making any adjustments And always start with the Ohlins recommended settings NOTE See Mounting Instructions for recommended settings NOTE Higher click numbers give less damping force When making adjustments keep notes make adjustments one at a time and in small steps The adjusters should normally not be adjusted in steps of more than 2 clicks at a time and not outside the usable click range When you think you have made an improvement go back to what you started with and double check to be sure Pay attention to changes in conditions like tires temperatures etc Air spring 4 A change in oil level will effect the damp ing forces not in the early stage of fork travel but a great deal in the later stage Force In general compression damping changes should be used to influence the bike s stability and re sponse while rebound damping changes should be used to influence comfort and traction When you need more damping force you should mainly try to increase compression damping and use as little rebound damping as possible This usually means that you gain comfort and performance in handling Oil level adjustment As the air trapped between the oil and the top nut acts as an air spring a change in oil level will effect the damping forces Not in the early stage of fork travel but a grea2. Place the motorcycle on a stand so the front fork and the rear end are in fully extended position e Measure the distance eg from the lower edge of the rear mudguard or from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 e Make asimilar measurement on the front axle e g from the bottom of the upper fork crown to the front wheel axle F1 Bike with rider on e Allow the motorcycle without rider to apply load on the springs and repeat the measuring procedure R2 F2 Then take the same measurements with the rider and equipment on the motorcycle R3 F3 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 Recommendations The difference should not deviate from the following sizes if no other recommended settings are given in the Mounting Instructions Free sag R1 R2 F1 F2 Rear MX Off Road 30 5mm Front MxX Off Road 30 5mm Ride height R1 R3 F1 F3 Rear MX 100 5 mm Off Road 30 of the total stroke Front MxX Off Road 80 5mm Compression stroke Fine tuning the bike Learning how to use the adjusters will take time but you quickly appreciate them once you know the tricks Even the specialists sometimes need a specialist With the adjusters you optimize the suspension for your riding style and the track you are com peting on
3. The same basic guidelines go for both the front fork and the rear shock absorber Too much compression damping will give you a harsh ride as your bike Jumps along the track With too much rebound damping your bike will have difficulties with several bumps in a row The suspension will not extend fast enough between bumps your bike will ride lower and lower and eventually the suspension will bottom External adjusters On the Ohlins front fork the adjusters are bleed valves completely separated from each other The compression bleed valve controls the flow Flow in rebound valve ja in the cartridge tube during the compression stroke the rebound bleed valve controls the flow during the rebound stroke CAUTION Using too much force when closing the adjust ers will destroy important sealing surfaces Both the adjusters have a normal right hand thread Click position zero 0 is when the adjusters are turned clockwise to fully closed The adjustment range from fully closed until maximum open valve anticlockwise is 20 clicks In order not to click in the wrong direction always first close the adjuster then dial in the new setting Making adjustments To make improvements using the adjusters it is important to understand the function of the front fork and the shock absorber and through testing learn how they effect the handling of your bike ENV A ih Nj Rebound stroke
4. wheel Balls and springs Pre load adjustment 1 Put the bike on a stand and loosen the screws in the top fork crown that hold the fork legs NOTE On most MX bikes you have take of the handle bar off before you can unscrew the top cap Remove the adjustment wheel and the springs and balls of the adjuster 2 Unscrew the top cap use tool 1860 01 Put a box under the front wheel so that the springs are visible Damper rod extender wrench Damper rod assy 3 Remove the top cap from the damper rod extender Use a 17mm wrench and tool 1860 01 New spring C Original support spring Adjustment support 4 5 Remove the original spring support Fit the spring support and the top cap Tighten Install a new spring support to achieve the right the top cap and lock nut to a torque of 20 Nm static sag CAUTION The piston shaft must bottom in the top cap before the lock nut is tightened Refit the adjustment wheel Tighten the bolt in the top fork crown to 20 Nm NOTE The top nut only have to be tightened by hand without extending tool Changing springs 6 Follow instructions 1 4 on previous page and remove the spring Do not install the spring support spacer Compression adjuster NOTE Closing the compression and the rebound valves will keep the damper rod extended making it easier to install the new spring Check the oil level according to page 6 and 10 Pu
5. 1 02063 02 Pcs Y an a an en S vedeva ry rl SN TRO S dee Top cap releasing tool Description Type remarks Screw Adjustment knob Circlip O ring Adjustment screw Ball Spring Screw O ring Top cap O ring Adjustment rod Lock nut Spring guide Circlip Cylinder tube cap Bushing Washer Shaft Spring L Q Rebound adjuster Spare parts Pos 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Part No 00438 31 02356 03 02322 01 02320 03 00530 18 01149 01 02335 01 01447 02 00641 xx 00153 01 00430 05 01473 02 00338 53 01242 0x 00884 04 01248 01 00438 02 02413 xx 04107 x0 00438 52 02414 01 02415 01 00438 03 00520 23 04105 01 05009 12 Pes re yr an a ar en ary ere ese mm me ek me A JA A N Aaa Description O ring Rebound needle Spring Piston holder Shim Wave washer Shims Rebound piston Piston ring Shim Shim Clamp washer Washer Lock nut Circlip O ring Adjustment needle Ball Spring O ring Base valve Spring O ring Poppet valve Shim Valve seat O ring Shim Wave washer Circlip Type remarks see spec card see spec card see spec card see spec card see spec card see spec card see spec card see spec card see spec card Compression adjuster 13 General handling set up Front end falls into the curves oversteering especially in sa
6. Owners Manual Ohlins motocross front forks GasGas Including Fine tuning General handling set up LE AES O as ey ae te Spare parts 7 ci ad int ego te pe rea aa gt eee Magna nic pa Sae x N hoto by Bruno Pechaud ADVANCED SUSPENSION TECHNOLOGY Safety signals Important information concerning safety is distinguished in this manual by the following notations The Safety alert symbol means Caution Your safety is involved WARNING 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 pre cautions must be taken to avoid dam age to the suspension NOTE This indicates information that is of importance with regard to procedures hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Introduction All of hlins advanced suspension products are adapted to the brand and model This means that length travel spring action and damping charac teristics are tested individually just for your motorcycle Before installation hlins Racing AB can not be held responsible for any damage whatsoever to front fork or vehicle or injury to persons if the instructions for fitting and maintenance are not followed exactly Similar
7. el in the legs By using different combinations of springs and air springs you can alter the characteristic of the fork For example a soft spring in combination with a small air spring high oil level makes the fork progressive see Fine tuning the bike Marking All Ohlins front forks are marked You will find the part number on the inside of the fork bottom Recommended settings The front fork in your kit is adjusted to the Ohlins recommended setting for your bike We advise you to use this as your start setting Bike on a stand Settings Basic settings Always ensure that the basic setting made by Ohlins is correct It is adapted to the make and model in its original state and for a rider of average weight WARNING Incorrect spring action can produce a fork angle that is too steep or too flat This in turn will give a tendency for oversteering or understeering which could seriously affect the handling characteristics of the motorcycle The original setting of the front fork when delivered from hlins should always be a base when the settings are changed by use of the adjustment devices Bike on the ground Setting the spring pre load Measuring Pre load on the spring springs is very important because it affects the height of the motorcycle and the fork angle Consequently handling characteristics can be changed even negatively Proceed as follows it will be much easier if done by two persons
8. ll out the damper rod as far as possible and then close the compression and the rebound valve clockwise L gt 460 mm 8 Install the new spring NOTE Check the free length of the spring Original length is 467 mm If the spring length is under 460 mm the spring must be changed Follow instruction 5 on previous page Adjust the compression and the rebound valves according to specification card Fit the fork legs to the motorcycle Tightening torques top fork crown 20 Nm and bottom fork crown 10 Nm 10 Technical specifications Fork lengths and diameters Front fork Motorcycle Length L OA OB FG OEM GasGas 938 mm 53 9 mm 58 4mm Rebound and compression adjustment Refer to mounting instruction for set up data Maximum open rebound and compression valve 20 clicks Free Spring Length All forks 467 mm service limit 460 mm Spring preload Maximum allowed adjustment range 3 13 mm with washers Spring rate depending on models 2328 39 3 9 N mm 2328 41 4 1 N mm 2328 43 4 3 N mm 2328 45 4 5 N mm 2328 47 4 7 N mm Settings Compressing adj 14 clicks Rebound adj 14 clicks Oil level When delivered from factory 115 mm Adjustment range 80 130 mm CAUTION Use only Ohlins high performance front fork fluid No 5 1305 01 Tighten torque Fork top crown bolt 20 Nm Fork bottom crown bolt 10 Nm Compression valve 65 Nm Base val
9. ly the warranty will become null and void if the instructions are not adhered to Contents Safety signals iii 2 WMC TOM sssaaa RER ei 2 Before installation nennen ennn 2 Tuning the suspension 3 BS 0 PRC EAE EEA 3 SCHIO 4 Setting the spring preload 4 Fine tuning the bike 5 Preload adjustment ccccssccecssseeeeeseseeeeees T Changing SPINOS civici 9 Technical information 10 Date DANES POR RT 11 General handling set up 14 Maintenance cicicccscieteastientveredsaatentecusigensdeamiiges 15 NOTE Ohlins products are subject to continual improve ment 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 suspen sion and this manual Please consult your Ohlins dealer if you have any questions with regard to the contents of the manual 1 The compression adjuster is located at the bottom of the fork leg Tuning the suspension Motorcycle road holding qualities All motorcycles are designed with a suspension geometry that includes height and fork angle The changing of components can affect this and it is therefore essential that both the rear and the front ends match each other Changing to hlins suspension gives optimum performance only when both the front fork and the rear s
10. nd Steep front fork angle Front end too low in com parison to rear end e Increase the front fork compression damping e Change to harder springs e Lower fork leg approximately 5 mm in the triple clamp Front end ploughs understeers Shallow front fork angle Front end too high in comparison to rear end e Decrease the front fork compression damping e Raise the fork legs approximately 5 mm in the triple clamp e Change to softer fork springs Front end unstable at high speed unstable when accelerating out of curves Front fork angle too steep Front end too low in comparison to rear end e Lower the fork legs approximately 5 mm in triple clamp e Change the front fork springs to harder ones Front end unstable during deceleration Front fork angle too steep during braking Front end too low or rear end too high e Increase the oil level in the front fork e Change to harder fork springs e Increase the front fork compression damping 14 Front suspension Front fork travel is not used to its full capacity Harsh feeling front wheel grip is not satisfactory in bumpy turns Suspension too hard e Decrease the front fork compression damping e Change to softer springs Suspension bottoming too soft during entire travel Spring too weak or compression damping too soft e Increase oil level 5 mm e Increase compression damping e Change to stiffer springs Suspension bottoming bu
11. t can handle smaller bumps Damping force not progressive enough e Increase the oil level Can handle smaller bumps but is too hard during the last part of the travel Damping force is too progressive e Decrease the oil level Front end feels low initially feels soft but is not bottoming The initial spring rate is too soft or spring preload is too low e Increase the spring pre load Feels harsh over small bumps but using full wheel travel Too much spring pre load or too much compres sion damping e Increase the oil level or change to softer springs e Decrease the compression damping e Decrease the spring pre load e Clean the oil seals and scrapers Use Ohlins grease 146 01 for regreasing Can handle the first in a series of bumps but feels hard after a few more bumps Frontal grip insufficient in rough and bumpy turns Too much rebound damping e Decrease the rebound damping Front end rebound too fast after a bump Front wheel grip insufficient in bumpy curves Not enough rebound damping or too much spring pre load e Increase the rebound damping e Decrease the spring pre load Maintenance Telescopic front forks depend on a smooth friction free action Make sure your forks are regularly serviced Do not use strong solvents such as brake cleaner to clean the front forks This will dry out the seals and the steel tubes and cause friction or leakage After every race Clean externall
12. t deal in the later stage A general description of how the oil level air spring effects the damping forces are shown in Fig 4 The air spring gives the Ohlins USD fork a progressive spring rate preventing it from bottoming out hard Stroke By using different combinations of springs and oil levels air springs you can alter the characteristic of the fork and tailor it to suit different tracks and conditions CAUTION The oil level must be the same in both front fork legs Riding a bike with different oil levels will cause instability When the oil level is raised The air spring in the later half of travel is strong and thus the front fork hard When the oil level is lowered The air spring in the later half of travel is soft and thus the front fork soft Oil level DI Oil level is measured from the top of the outer leg with the top nut off the fork fully compressed and no pre load washer or spring installed Oil level CAUTION Adjust the oil level with the fork leg fully com pressed and no pre load washer or spring installed NOTE See Mounting Instructions for recommended oil level The oil level is measured from the top of the outer leg with the top nut off Fig 6 Changes in oil level should be made in small steps We recommend a change of 5 mm ata time and not outside the range of 80 130 mm Adjustment
13. uspension interact properly It is of the greatest importance that the front and rear loaded heights are within the specified values In the Mounting Instructions see section Setting the spring pre load 2 The rebound adjuster is located at the top of the fork leg Design Ohlins new upside down USD front fork is designed to combine the advantages of com fortable safe conventional forks and rigid light USD forks The result is a unique combination of being rigid precise in corners and during hard braking yet comfortable forgiving during over landing and in big bumps Your new Ohlins USD front fork has aluminium outer legs and 46 mm steel inner legs with a polished surface for lowest possible friction The new USD fork features the Ohlins cartridge damping system The fork is fully adjustable with external adjuster for compression and rebound damping The compression adjuster is located at the bottom of the fork leg Fig 1 the rebound adjuster at the top Fig 2 Spring pre load is adjusted with spring supports of different heights Fig 3 and optional springs are available to suit different tracks and riders 3 Spring pre load is adjusted with different spring supports Optional springs are available In the legs there are also air springs the air trapped above the oil that work together with the real spring You adjust the air spring by raising or lowering the oil lev
14. ve Cylinder tube cap cartridgetube 65 Nm Compression valve 8 mm nut 8 Nm Rebound valve 8 mm nut 8 Nm Grease Ohlins Front Fork grease 00146 01 Red grease Service Intervals Every 20 hours Pos DI DS Go Poy 10 11 12 13 14 15 16 We 18 19 20 21 22 23 24 25 Spare parts Part No 02400 01 02403 01 02337 01 02319 01 02328 39 02328 41 02328 43 02328 45 02328 47 02324 01 02409 02 02373 01 02325 03 02332 05 01552 01 02336 01 02015 01 02014 01 02339 01 02022 01 02315 83 02309 80 00438 30 02314 01 02372 21 02372 22 02314 02 00195 01 Pcs NDI N O N A AA Description Type remarks Top Cap Bump rubber Slide washer Spring support Spring washer see spec card Spring front fork 3 9 N mm 4 1 N mm 4 3 N mm 4 5 N mm 4 7 N mm Fork leg outer Guide sleeve Bushing lower Sleeve Cover Sticker Ohlins Washer Seal Circlip Scraper Cylinder tube cartridge Bushing upper Fork leg inner Cover fork leg pair O ring Bolt Fork bottom left Fork bottom right Bolt fork bottom Base valve assy Sticker Ohlins white transparent 11 12 Spare parts Pos Tool 1860 01 Part No 00828 01 00820 02 01473 06 00338 79 02405 01 00884 01 00883 01 01050 01 00338 59 02395 01 00438 17 02366 13 02402 01 02401 01 01499 02 02399 01 00110 01 02340 01 02393 0
15. y and spray with an all purpose oil after washing with detergent Check externally for damage Put a little Ohlins red grease 146 01 on the steel tubes and work it in by pushing the fork up and down Every 20 hours Dismantle the fork and check all parts for wear and damage replace if necessary NOTE Discarded Ohlins products should be handled over to an authorized work shop or distributor for proper disposal 15 More info www ohlins com Precision Makes the Difference If You are look in performance this is the looking for the ultimate right site Surf around and find out what the ultimate in suspension is all about ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your Ohlins dealer 07295 11 Issued 02 10 03 Teknisk Illustration 1000 ex
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