Ohlins FG 470 Bedienungsanleitung

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.

Any reprinting or unauthorized use

without the written permission of

Öhlins Racing AB is prohibited.

Printed in Sweden.

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.

...........................................................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

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.

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.

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

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)

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

Spring pre-load adjustment

Changing springs

17 mm socket

Unload the spring pre-load completely

by turning the adjustment nut counter

clockwise as far as possible. Use a 17 mm

wrench or socket.

Loosen the screws that hold the fork legs

in the upper tripple clamps.

Remove the Top nut assembly. Use tool

797-01.

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.

Remove the adjustment driver and the

spring. Use a wire with a hook and care-

fully pull out the preload tube.

Check the oil level according to page 17.

NOTE!

Use Öhlins Front fork oil 1305-01 only.

Refit the Pre-load tube. Install the new

spring and refit the adjustment driver.

Refit the top nut assembly to the piston

shaft. Tighten the jam nut to 20 Nm.

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

Tool 1765-03

1800

1st, Circlip

2nd, Seal

3rd, Washer

Changing seals

Remove the fork legs from the motorcycle.

Put the fork legs in upright position for

about 5 minutes to allow the oil to settle.

Fasten the fork leg in a vice. Use soft jaws.

Carry out instructions 1 to 5 in “Changing

springs”, page 6.

Drain the cylinder tube from oil.

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!

First remove the circlip, then the seal and

finally the washer.

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.

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!

Repeat instructions 6 to 9 in “Changing

springs” on page 6. Refit the front fork.

2 4

5 6

7Circlip

Washer

Seal

NOTE!

WARNING!

Dismantling the Forks

Remove the fork legs from the motorcycle.

Put the fork legs in upright position for

about 5 minutes to allow the oil to settle.

Fasten the fork leg in a vice. Use soft jaws.

Unload the spring pre-load completely

by turning the adjustment nut counter

clockwise as far as possible. Use a 17 mm

wrench or socket.

Loosen the top nut assembly. Use tool

797-04.

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.

Remove the adjustment driver and the

spring. Use a wire with a hook and care-

fully pull out the preload tube.

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.

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

4 5

6 7

NOTE!

WARNING!

Preload tube

Adjustment driver

Spring

!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.

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

Tool 1797-04 Piston rod unit

Seal head

Compression Valve LH-Leg

Rebound Valve RH-Leg

13 mm socket

Nut

Soft jaws

(727-02)

Notes

NOTE!

Tool 720-03

Tool 720-02

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

O-ring

Seal head

X-ring

O-ring

Rebound neendle

Notes

14 mm Wrench

Piston holder

Topout spring

Sleeve

Spacer

O-ring

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