Ohlins FG 470 Manual de usuario
Owner’s Manual
Öhlins Superbike Front Fork FG 470
Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:
This 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 sus-
pension, 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 impor-
tance with regard to procedures.
Introduction
All of Öhlins advanced suspension products
are adapted to the brand and model. This
means that length, travel spring action and
damping characteristics, are tested individ-
ually just for the motorcycle that you have
decided to fit with Öhlins suspension.
Before installation
Öhlins Racing AB can not be held respon-
sible for any damage whatsoever to sus-
pension 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.
!
!WARNING!
1. Installing a suspension, that is not ap-
proved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage whatsoever
that may occur after fitting the suspension.
Contact an Öhlins dealer or other qualified
person for advice.
2. Please study and make certain that you
fully understand all the mounting instructions
and the owner´s manuals before handling
this suspension kit. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer or other qualified
person.
3. The vehicle service manual must be
referred to when installing the Öhlins sus-
pension.
NOTE!
Öhlins products are subject to continual
improvement and development. Conse-
quently, 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 Öhlins
dealer if you have any questions with re-
gard to the contents of the manual.
NOTE!
During storage and transportation, espe-
cially at high ambient temperature, the oil
and grease used for assembling may run
out inside the packing and damage the ex-
panded polystyrene packing material. This
is not unusual and is in no way detrimental
to the suspension.
© 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
Öhlins Front Fork FG 470
This Super Bike front fork is an improved
version of FG 370 with pressurised damp-
ing system. FG 470 is based on 4 years
experience from factory road racing. The
pressurised damping system improves the
front fork function at high frequency move-
ments. The immediate damping responses
improve the tyre feeling and also give more
possibilities for adjustments. Of course
the combination of spring and air-gap (oil
level*) still 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
more progressive action of the front forks.
NOTE!
Gas pressure should not be changed or
used as an alternative to adjust the damp-
ing.
For better understanding, please refer to
our oil level chart see page 17.
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 cause friction.
For tighten torque, loctite and grease see
page 19.
Contents
Before installation
Öhlins front fork FG 470
Adjusters
Setting up your forks
Changing springs
Changing seals
Dismantling the forks
Assembly of the forks
Oil level adjustment
Troubleshooting
Technical information
Spare parts list
Service tools
*
Front fork 470 is equipped with an external reservoir, pressurized
with nitrogen. A dividing piston separates the oil from the gas.
3
...........................................................2
.................................................3
...........................................................................4
......................................................5
...........................................................6
...............................................................7
.....................................................8
..................................................12
......................................................17
............................................................18
...................................................19
.............................................................20
...............................................................23
Adjusters
Your Öhlins super bike front fork is pro-
vided with the following external adjusters:
• Spring pre-load adjuster
• Rebound damping adjuster.
• Two type of compression
damping adjuster:
- Reservoir valve adjuster in the
lower part of the fork leg.
- Main valve bleed circuit.
NOTE!
The rebound damping adjuster is located at
the top of the right hand fork leg. The Main
valve bleed circuit (compression adjuster) is
located at the top of the left hand fork leg.
Spring pre-load adjustment
Use a 17-mm wrench to turn the upper
adjustment screw. The adjustment range
is 0-18mm. On the adjustment screw one
turn will change 1mm in spring pre-load.
Recommended static sag is 25-30 mm.
Compression adjustment main valve.
Adjust the compression damping on the
adjustment screw positioned at the top of
the left hand fork leg. Use a hex key with
spherical head (use tool 794-01).
Adjustment range from closed valve
(clockwise) to maximum open valve
(counter clockwise) is 20 “clicks”. Recom-
mended adjustment “click”, from closed
position: See specification card.
Rebound adjustment
Adjust the rebound damping on the adjust-
ment screw positioned at the top centre of
the right hand fork leg. Use a hex key with
a spherical head (use tool 794-01).
Adjustment range from closed valve (clock-
wise) until maximum open valve (counter
clockwise) is 20 “clicks”. Recommended
adjustment “click”, from closed position:
See specification card.
Compression adjustment reservoir valve
(Base valve)
Adjust the compression damping (shaft
displacement) on the lower part of the fork
legs. Use a normal screwdriver. Adjustment
range from closed valve (clockwise) to
maximum open valve (counter clockwise)
is 20 “clicks”. Recommended adjustment
“clicks”, from closed position:
See specification card.
Top cap
Increase spring pre-load
Reduce spring pre-load
17 mm wrench
Spring pre-load adjustment
Compression adjustment
Left Hand Fork Leg
Tool 794-01
Clockwise turn
closes = increase
compression
damping
Counter clockwise
turn opens = reduced
compression damping
Rebound adjustment
Right Hand Fork Leg
Tool 794-01
Clockwise turn
closes = increase
rebound damping
Counter clockwise
turn opens = reduced
rebound damping
Compression adjusment reservoir valve (Base valve))
Clockwise turn closes =
increase compression damping
Counter clockwise turn opens =
reduced compression damping
Screwdriver
4
Setting up your forks
Here is 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 and fit the
Öhlins front fork.
NOTE!
The lower triple clamp must not be tight-
ened to more than 12-15 Nm. This is also
important for the steering damper bracket,
when located around the upper front leg.
To high torque might deform the front fork
leg.
2
Set your initial pre-load of the spring, by
using a 17mm socket or wrench, until you
get a static sag of 25-30 mm. Each turn
gives 1mm in pre-load, maximum pre-load
is 18mm.
Setting the spring pre-load generally on
the bike
3
Pre-load on the spring/springs is very
important, since it affects the height of
the motorcycle and the fork angle. Con-
sequently, handling characteristics 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 upper
position.
3 Measure the distance, e.g. from the ower edge of
the rear mud guard or from a point marked by a
piece of tape, immediately above the rear whee
axle, to the wheel axle. (R1)
4 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 be fully
extended. (F1)
5 Allow the motorcycle (without rider) to apply load
on the springs and repeat the measuring proce-
dure. (R2, F2)
6 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)
4
The measurements may not differ from the
following sizes:
Without rider:
Rear: 5-15 mm (R1-R2)
Front: 25-30 mm (F1-F2)
With rider:
Rear: 30-40 mm (R1-R3)
Front: 35-50 mm (F1-F3)
Increase spring pre-load
Reduce spring pre-load
17 mm wrench
A-D. Bike on a stand E. Bike on the ground F. Bike with rider on
R1
F1
R2
F2
R3
F3
Spring pre-load adjustment
5
Changing springs
12
17 mm socket
1.
Unload the spring pre-load completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 17 mm
wrench or socket.
2.
Loosen the screws that hold the fork legs
in the upper tripple clamps.
3.
Remove the Top nut assembly. Use tool
797-01.
4.
Remove the top nut assembly from the
piston shaft. Use a 17 mm wrench to the
top and tool 4705-01 to hold the nut on the
lower side of the top nut.
5.
Remove the adjustment driver and the
spring. Use a wire with a hook and care-
fully pull out the preload tube.
6.
Check the oil level according to page 17.
NOTE!
Use Öhlins Front fork oil 1305-01 only.
7.
Refit the Pre-load tube. Install the new
spring and refit the adjustment driver.
8.
Refit the top nut assembly to the piston
shaft. Tighten the jam nut to 20 Nm.
9.
Refit the top nut into the fork leg, with
the front wheel off the ground (use tool
797-01). Tighten the upper triple clamps
and adjust the preload, compression and
rebound according to above instructions.
CAUTION!
The top nut should only be tightened by
hand into the fork leg.
Tool 797-01
Tool 4705-01
17 mm socket
8 9
Preload tube
Adjustment driver
Spring
5 6
Check the oil level
1305-01
Tool 797-01
CAUTION!
20 Nm
34
6
Tool 1765-03
1800
1st, Circlip
2nd, Seal
3rd, Washer
Changing seals
1.
Remove the fork legs from the motorcycle.
Put the fork legs in upright position for
about 5 minutes to allow the oil to settle.
2.
Fasten the fork leg in a vice. Use soft jaws.
3.
Carry out instructions 1 to 5 in “Changing
springs”, page 6.
4.
Drain the cylinder tube from oil.
5.
Remove the outer tube, clean the seal and
check the condition. If the seal is in good
condition apply some red grease (146-01)
to it. A damaged seal must be replaced!
6.
First remove the circlip, then the seal and
finally the washer.
7.
Apply a thin layer of Öhlins red grease
(146-01) to the washer and to the sealing
surfaces of the fork seal. Install the seal
and the washer in the outer tube. Fit the
circlip into the groove.
NOTE!
It is important to use the correct grease in
order to achieve optimum fork function.
8.
Apply some front fork oil (1305-01) to the
inner tube surface and carefully mount the
outer tube (slide it completely down).
!WARNING!
Be careful not to damage the fork seal!
9.
Repeat instructions 6 to 9 in “Changing
springs” on page 6. Refit the front fork.
2 4
5 6
7Circlip
Washer
Seal
NOTE!
!
WARNING!
8
7
Dismantling the Forks
1.
Remove the fork legs from the motorcycle.
Put the fork legs in upright position for
about 5 minutes to allow the oil to settle.
2.
Fasten the fork leg in a vice. Use soft jaws.
3.
Unload the spring pre-load completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 17 mm
wrench or socket.
4.
Loosen the top nut assembly. Use tool
797-04.
5.
Remove the top nut assembly from the
piston shaft. Use a 17 mm wrench to the
top and tool 4705-01 to hold the nut on the
lower side of the top nut.
6.
Remove the adjustment driver and the
spring. Use a wire with a hook and care-
fully pull out the preload tube.
7.
Remove the screw and o-ring from the
reservoir end cap.
NOTE!
Before the gas pressure is relieved the
adjuster settings must be counted and
noted. Even check that the gas pressure is
correct. Follow that, the adjusters should
be set in a fully open position.
8.
Relieve the nitrogen gas by inserting an
injection needle into the reservoir end cap
through the rubber valve.
17 mm socket
Tool 797-04
Tool 4705-01
17 mm socket
23
4 5
6 7
8
NOTE!
!
WARNING!
Preload tube
Adjustment driver
Spring
8
!WARNING!
Releasing high pressure gas from the
shock absorber can be hazardous. Do not
perform any kind of service until gas pres-
sure is completely released.
9.
Remove the circlip.
10.
Use tool 720-03 to lift up the reservoir end
cap. Install the tool 720-02 into the gas
piston.
11.
Use tool 1797-04 and 1765-03 to unscrew
the seal head from the cartridge tube.
Remove the piston rod unit.
12.
Fasten the piston rod in a vice. Use soft
jaws (727-02). Remove the nut with a 13
mm wrench or socket. Remove the valve
from the piston rod.
Place all parts, including the shims, in their
correct position on the work bench. Clean
all parts thoroughly and dry with com-
pressed air.
NOTE!
The right hand fork leg is the rebound leg.
The left hand fork leg is the compression
leg.
910
11
Tool 1797-04 Piston rod unit
Seal head
12
Compression Valve LH-Leg
Rebound Valve RH-Leg
13 mm socket
Nut
Soft jaws
(727-02)
Notes
NOTE!
Tool 720-03
Tool 720-02
9
Tool 1765-03
13.
Remove the Piston holder. Use a 14 mm
wrench.
14.
Remove the Topout spring, the Sleeve, the
Spacer and the O-ring.
15.
Remove the Seal head. Check the O-ring
and the X-ring. Change them if necessary.
16.
Remove the needle and change the O-ring
if necessary.
17.
Drain the cylinder tube from oil.
18.
Remove the gas piston in the reservoir, use
tool 720-02.
19.
Drain the reservoir from oil.
20.
Use a 17 mm wrench to unscrew the
complete compression valve at the bottom
of the fork.
21.
Remove the piston from the compres-
sion valve. Place the shims in their correct
position on the work bench. Clean all parts
thoroughly, change O-rings if necessary
and dry all parts with compressed air.
15 16
21
17
19
18
20
O-ring
Seal head
X-ring
O-ring
Rebound neendle
Notes
14 mm Wrench
13
Piston holder
Topout spring
Sleeve
Spacer
O-ring
14
10
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