Owners Manual - Öhlins - Advanced Suspension Technology
Contents
1. 180 500 190 250 Oil level Air spring height 0 Stroke mm NOTE Adjust the oil level in mm according to the figure with the fork fully compressed and with the spring and the pre load tube removed For the right recommended level please see the mounting in struction Front spring kit Technical information Fork length Spring rate CAUTION See Mounting instructions See Mounting instructions Use only Ohlins high performance front fork fluid 1309 01 Stroke Optional springs are available in following rates See Mounting instructions 04744 80 8 0 N mm Loctite glue Free spring length 04744 85 8 5 N mm 542 on Fork bottom thread See mounting instructions 04744 90 9 0 N mm 04744 95 9 5 N mm Tightening torque Rebound adjustment 04744 10 10 0 N mm Triple clamp bolt 15 18 Nm Basic setting 9 12 clicks Maximum open valve 20 clicks Oil Level Grease Please see Mounting instructions for the specific Ohlins front fork grease 00146 01 red grease Compression adjustment front fork Basic setting 6 16 clicks Maximum open valve 20 clicks Spring preload adjustment 0 15 mm 0 15 turns Inspection and maintenance Clean the front fork externally with a soft deter gent Use compressed air Be careful that all dirt and debris is removed Keep the front fork clean and always spray it with oil QS 14 WD40 or CRC 5 56 or similar after washing the vehicle CAUTION Never us2. from closed position 3 Static sag B A Setting up your fork Here are some basic guidelines for setting up your Ohlins 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 in conformance with its 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 of the outer tube is 15 18 Nm Dismantle the front wheel and brakes 2 Unscrew the adjustment housing on top of the fork use tool 797 04 on both upper tubes and slide the fork up and down gently to make sure everything works correctly Assemble the adjustment housing again and set your initial preload of the spring by using a 12 mm or a 17 mm wrench until you get a static sag of 25 30 mm Each turn gives 1 mm in preload Maximum preload is 15 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 Measure again The difference between these two figures is the static sag 5 The clicks are a bleed function separate for rebound and compression damping Rebound adjustment is made on the top centre of the fork an
3. If You are right site looking for the ultimate in performance this is the Surf around and find out what the ultimate in suspension is all about Read this years Newsletters Softail for Harley Davidson The First Volvo S6OR with CES hlins Teams amp Riders 2003 The ultimate suspension site Find out everything about your suspension Download mounting instructions manuals and brochures And a lot more ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your Ohlins dealer 07282 04A OM Front Fork 43 Issued 05 12 20 Teknisk Illustration AB
4. in the same position as when the fork was reassembled 16 Reinstall the top nut assy CAUTION Some models of top nut are equipped with a flat key that must be guided into the slot of the top nut assy 17 Fasten the adjustment housing in the fork leg Make sure that the fork leg is fully extended when tightening the adjustment housing 18 Install the fork legs on the motorcycle and adjust the pre load compression and rebound according to the instructions at page 4 See Mounting instructions for specific measurment Oil level Oil level adjustment Compared to 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 damping force in the early stage of fork travel but will have a great effect in the later stage When the oil level is raised 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 refer to a general card description to facilitate under standing of the difference when the oil level is changed 8 Air spring characteristics Force N Oil level mm 1000 160
5. Owners Manual Ohlins road amp track front fork FG 43 Including Adjusters Changing springs Technical information Service Tools 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 Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Introduction All of Ohlins advanced suspension products are adapted to the brand and model This means that length travel spring action and damping char acteristics are tested individually just for the motorcycle that you have decided to fit with Ohlins suspension Before installation Ohlins 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 inst
6. d compression adjustment at the bottom part of the fork You start to count from fully closed clockwise and set it to the recommended click use a 3 mm Allen key For recommended start setting please refer to the mounting instruction F1 R1 Bike on a stand Setting the spring pre load 6 Pre load on the spring springs is very important because it affects the height of the motorcycle and the fork angle Consequently handling char acteristics can be changed even negatively Proceed as follows it will be much easier if done by two persons 1 Place the motorcycle on a stand 2 Lift up the rear end to a fully extended position 3 Measure the distance e g from the lower edge of the rear mud guard or from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 Bike on the ground Make a similar measurement on the front axle e g from the bottom of the upper fork crown to the front wheel axle The fork must also be fully extended F1 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 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 A F3 3 R3 Bike with rider on T The measurements may not differ
7. e detergents that can damage the sur faces of the front fork Use of thinner and brake cleaner will dry the surfaces too much NOTE Make certain that your front fork is always filled with Ohlins High Performance Front Fork Oil 1309 01 10 Inspection points see opposite page 1 Check the front fork for leakage 2 Check the front fork tubes for external damages 3 Fastening of caliper bracket and fender bracket 4 Fastening to the vehicle Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for additional service please get in touch with an authorised Ohlins service workshop There they have the necessary tools and know how for whatever you need NOTE Regular maintenance and inspection contribute to the prevention of functional disturbances Recommended inspection and maintenance intervals Normal use Once a year or every 5000 km Race track Every ten hours Once every 2nd year or 20 000 km general Change front fork oil use Ohlins front fork oil 1309 01 only NOTE Discarded Ohlins products should be handled over to an authorized work shop or distributor for proper disposal Inspection points Service tools 4701 01 Tool Kit 786 05 ies 4702 02 CI tool amp too Cartridge tool 797 04 Top nut tool 4705 01 787 03 Clamp tool Top nut holder 11 More info www ohlins com Precision Makes the Difference
8. ebound damping adjuster e Compression damping adjuster Spring pre load adjustment Use 14 mm wrench to turn the upper adjustment screw NOTE On some models adjustments are made with 12 mm wrench These models has two larger nuts below the adjustment screw and the top nut assy Maximum adjustment range is 18 mm One turn of the adjustment screw will cause 1 mm change in spring preload Adjust so the front forks are lowered 25 30 mm from the top unloaded position 3 mm allen key Clockwise turn closes increase rebound damping Counter clockwise turn opens reduced rebound damping Rebound adjustment Adjust the rebound rate on the adjustment screws positioned at the top centre of the front forks Use a3 mm allen key with a spherical head use tool 794 01 Adjustment range from closed valve clockwise to maximum open valve counter clockwise is 20 clicks See mounting instruction for recom mended adjustment clicks from closed position Counter clockwise opens reduces compression damping Clockwise closes increase compression damping 3mm allen key Compression adjustment Adjust the compression rate on the lower part of the front forks compression valve Use a 3 mm allen key with spherical head use tool 794 01 Adjustment range from closed valve clockwise to maximum open valve counter clockwise is 20 clicks See mounting instruction for recommended adjustment clicks
9. from the following sizes Without rider Rear 10 20 mm R1 R2 Front 15 30 mm F1 F2 With rider Rear 25 40 mm R1 R3 Front 35 50 mm F1 F3 9 11 12 Vice with SOP aes w soft jaws SS RS A SSS SSS Say SSF SSS F Tool 797 04 H P Top nut assy Outer fork leg Changing springs 8 Loosen the screws that hold the fork legs in the upper triple clamps 9 Loosen the top nut assy page 7 about two turns use tool 797 04 10 Remove the fork legs from the motorcycle 11 Grip a fork leg in a vice Use soft jaws 12 Unload the spring completely by turning the adjustment screw anticlockwise Use a 12 mm or a 14 mm wrench Unloading the spring CAUTION Do not damage the O ring and do not drop the flat key into the fork leg Carefully remove the adjustment housing 13 Remove the adjustment driver the pre load tube and spring CAUTION The pre load tube can be positioned above or below the spring depending on type of front fork Take note when dissasembling 14 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 13 15 Cal _ Adjustment Wire with driver Pre load tube 15 Install the new spring the adjustment driver and the preload tube Be careful to put all parts back
10. o 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 det rimental to the suspension Ohlins front fork FG 43 The Ohlins 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 air volume oil level offers a possibility to adjust the characteristics of the fork to suit different tracks and riders For example a soft spring in combination with a small air volume high oil level gives progressive action of the front forks For better understanding please refer to our oil level chart see page 8 A telescopic front fork depends on 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 Ohlins red grease 146 01 regularly on the steel tube and work it in by pushing the forks up and down Increase spring pre load Reduce spring pre load 14 mm wrench Adjusters Your Ohlins front fork 43 is provided with the following adjusters e Spring pre load e R
11. ructions are not adhered to Contents IMO OWI EEE EA 3 PRON SUCN texgacer sn nues 4 Setting up your fork jcaccsivetnsnnniacontiandanteceateensies 5 Setting the pre load cccceeeeseeeeeeeeeeeeeeneeees 6 Changing SPrINGS ne oo FA Oil level adjustment ccceeeeesseeeeeeeeeee ease 8 Technical information siennes 9 Inspection amp maintenance 10 Service TOO S Sn nan 11 WARNING 1 Installing a suspension that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an Ohlins dealer or other qualified person for advice 2 Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this suspension kit If you have any questions regarding proper installation procedures con tact an Ohlins dealer or other qualified person 3 The vehicle service manual must be referred to when installing the Ohlins suspension 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 t
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