"service manual"
Contents
1. When working on this product always consult this Owners Manual This Manual shall be considered a part of the product and shall therefore accompany the product throughout its life cycle Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distin guished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the front fork or to bystanders Mm Caution The Caution Symbol means Special precautions must be taken to avoid damage to the front fork Note The Note Symbol indicates information that is important regarding 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 Contents Page Safety Precautions 2 Recommended Tools 3 How to Install 4 Replace Spring 6 Set up 8 Measure Spring Preload 9 Adjustments 10 Diagram Oil Volume Force 10 Spring Guide 11 Inspection and Maintenance 12 Recommended Tools Ohlins Front fork Installation See your Vehicle Owner s Manual for proper instructions for OEM front fork removal and installation Ohlins Front Fork Service Tools Fork Cap Tool oct2. advisable to have an hlins dealer remove and install the steering stem 7 Consult your vehicle service manual for instructions on how to install lower and upper triple clamp and how to achieve the correct steering bearing free play 8 Install the front fork legs into the triple clamps Use to start with the same height position as measured in step 3 Rotate the fork legs in the triple clamps to achieve good access to the adjusters in the fork leg top cap We recommend turning the adjuster access point towards the rear of the motorcycle O logo readable from riding position 9 Install the upper fork leg sticker rotated to your liking and install lower plastic fork leg protectors Tighten top and bottom triple clamp bolts Tightening torque Top triple clamp M8 20Nm Bottom triple clamp M8 15Nm Fork protectors M6 7Nm How to Install 10 Reinstall the brake caliper and the front wheel Tighten brake caliper bolts Tighten front wheel nut and left side fork bottom bolts Make sure front fork legs are parallel before tightening the right side fork bottom bolts Tightening torque Brake caliper M8 25Nm Front wheel axle 50Nm Fork bottom M8 15Nm Note It is very important that the triple clamps are tightened to the correct torque 11 Make sure that all removed parts are re installed according to instructions in your vehicle service manual Replace Spring Note We advise you to loosen not r
3. oil flow and the Front Fork function Adjustments Compression damping adjuster The compression adjuster is located at the top of the fork leg Adjust by turning the screw with a 3 mm allen key Rebound damping adjuster The rebound adjuster is located at the bottom of the fork leg Adjust by turning the screw with a 3 mm allen key To Reset The adjusters have a normal right hand thread Turn the damping adjusters gently clockwise to fully closed pos zero 0 To open turn counter clockwise and count the clicks until you reach the recommended number For recommended clicks see Set up data in Supplementary Mounting Instruction M Caution Do not use force when checking zero position delicate sealing surfaces can be damaged Compression damping adjuster Diagram Oil Volume Force more oil less oil Force Stroke 10 Spring Guide Spring Guide Rider s weight Spring rate kg pounds N mm Motocross Enduro 250 70 154 4 1 4 4 75 165 4 3 4 5 80 176 4 5 4 8 85 187 4 6 4 9 90 198 4 7 5 0 95 209 4 8 5 1 Motocross Enduro 450 70 154 4 3 4 6 75 165 4 4 4 7 80 176 4 5 4 8 85 187 4 6 4 9 90 198 4 7 5 0 95 209 4 8 5 1 Rider s weight Rider wearing all riding equipment 11 Inspection and Maintenance Preventive maintenance and regular inspection reduces the risk of functional disturbance Breat
4. triple clamps are tightened to the correct torque Note Make sure that all removed parts are reinstalled as they were before the installation of the Ohlins Kit Replace Spring Set up A Warning Before riding always ensure that the basic settings made by Ohlins are intact Take notes adjust in small steps and make only one adjustment at a time Step 1 Check Sag and Ride Height Note The following procedure should be performed on a flat surface 1 Put the motorcycle on a workstand so that both wheels are off the ground and the suspension is unloaded 2 Mark for example with a piece of tape a point immediately above the rear wheel axle 3 Measure the distance from the marked point to a fixed point for example the wheel axle See figure below R1 4 Measure the distance from the bottom of the upper triple clamp to a fixed point for example the front wheel axle F1 5 Put the motorcycle on the ground so that the front and the rear suspensions are slightly compressed Repeat the measur ing procedures R2 and F2 6 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Repeat the measuring procedures R3 and F3 R1 i Se Se K S SA A A Recommended Measures If no other recommendations are given in the Vehicle Manual follow the measures below Free sag R1 R2 Rear 30 45 mm Ride height R1 R3 F1 F3 Rear 100 115 mm Front 40
5. 50 mm Step 2 Adjust spring preload 1 If your measurements differ significantly from the recommendations in the table above adjust the spring preload See section Spring Preload in this manual 2 Ifthe ride height still differs from the recomendations you may need to change spring Contact an Ohlins dealer for advise A Warning Incorrect spring rate may produce a fork angle that is too steep or too flat This in turn will give a tendency for over or understeering which could seriously affect the handling characteristics of the motorcycle Measure Spring Preload Five Steps to measure and adjust spring preload 1 Measure A Fork outer tube should be slid down to stop and cartridge left at free length internal gas pressure extends cartridge Measure B Measure C Calculate preload Preload B A C Adjust preload according to the desired value according to set up data by add ing removing preload washers below the spring ak wh For recommended Spring Preload see Supplementary Mounting Instruction Fork springs may differ in length Therefore we recommend you to check the preload on each fork leg and if necessary install preload washers to get the correct value Preload less than 0 mm will make the fork springs loose when the front wheel is off the ground which increases wear inside the fork M Caution Preload washers must be placed below the spring otherwise they will restrict
6. Ohlins Front Fork for Motocross and Enduro Owner s Manual ADVANCED SUSPENSION TECHNOLOGY Safety Precautions Note The front fork is a very important part of the vehicle and will therefore affect the stability Read and make sure that you understand the information in this manual and the mounting instructions before you use this product If you have any questions regarding installation or maintenance please contact your Ohlins dealer Ohlins Racing AB can not be held responsible for any damage to the front fork vehicle other property or injury to persons if the instructions for installing and maintenance are not followed exactly A Warning This product was developed and designed exclusively 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 This product contains pressurized nitrogen gas N Do not open service or modify this product without proper education authorized Ohlins dealer distributor and proper tools A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability A lf the suspension makes an abnormal noise or the function is irregular or if you notice any leakage from the product please stop the vehicle immediately and return the product to an Ohlins Service Centre Note
7. agon 50mm e Socket 12mm for Ohlins shaft end Pliers for security snapring Tool 01890 01 Plug Bushing removal tool 01702 04 with top part 01702 13 Bushing Seal mounting tool 01799 04 How to Install A Warning It is advisable to have an Ohlins dealer install the front fork When installing consult your Vehicle Service Manual 1 Put the motorcycle on a workstand so that the front wheel is off the ground A Warning Make sure the vehicle is securely supported so that it will not tip 2 Remove the front wheel plastic fork leg pro tectors and brake caliper Note Note the fork height position see step 3 3 Measure the distance from the top of the upper triple clamp to the centre of the front wheel axle according to figure make a note 4 Loosen the upper triple clamp by loosening the screws 5 Loosen the lower triple clamp by loosening the screws 6 Remove the front fork legs from the motorcy cle VEHICLE SERVICE MANUAL Upper triple clamp Lower triple cla clamp p Lower triple clamp Note On some models you will need to install Ohlins triple clamps provided in the kit See your vehicle service manual for instructions how to remove the upper and lower triple clamp OEM steering stem and steering bearing need to be removed from OEM lower triple clamp and installed to the Ohlins triple clamp M Caution It is
8. correctly fitted into the groove of the outer tube Remove and Inspect Cartridge and Check Pressure 1 Follow steps 1 4 in Replace spring to disas semble the fork tubes 2 Remove cartridge and inspect for wear or damage replace parts if necessary M Caution When compressing the damper cartridge fully fluid might escape from top cap side hole 3 Check pressure Compress the cartridge fully When releasing the internal pressure should push back the cartridge to full length distinct stop A Warning It is advisable to have an hlins dealer perform service on the damper cartridge 4 Follow instructions from previous chapters to install front fork to the vehicle 14 Inspection and Maintenance Maintenance Intervals Do not use strong solvents such as brake cleaner to clean the front fork This will dry out the seals and the tubes and cause friction or leakage After every race Clean externally and spray with an all purpose oil after washing with detergent Check externally for damage Every 20 hours Dismantle the fork and check all parts for wear and damage replace if necessary After brake in Every race Every 20 hrs As required Inspect and adjust x x x Clean and lubricate scrapers x x Replace seal and scraper x Replace oil x x Replace bushings x x Service damper cartridge x x Disposal Discarded hlins products shoul
9. d be handed over to an authorized hlins workshop or distributor for proper disposal 15 Owner s Manual Part No 07295 31_0 Issued 2011 01 17 Ohlins Racing AB Your Ohlins retailer Ohlins 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
10. emove the top cap from the outer tube when the fork leg is still fixed by the lower triple clamp 1 To remove the fork follow steps 1 6 in chapter How to Install 2 Unscrew the top cap from the outer tube 3 Remove the security snapring at the bottom of the fork with a pair of pliers Loosen the bottom end of the cartridge kit by turning it clockwise 4 Install the tool 01890 01 oil plug by pushing it into the fork bottom The plug will keep the oil in the fork while changing the spring 5 Remove the cartridge kit from the fork leg and change the spring Note the plastic preload washer s Note The preload washers must be placed below the spring at the bottom end of the fork leg 6 Install the cartridge kit into the fork leg and push out the oil plug tool 01890 01 7 Tighten the shaft end counter clockwise into the fork bottom Tightening torque 18 Nm 8 Install the security snapring Preload washer lastic optional 65 Note When removing spring and cartridge kit there will be a loss of front fork fluid Therefore we recommend adding 15 ml Ohlins Front Fork fluid into each fork leg 9 Tighten the Ohlins fork top cap gently Use a 50 mm octagon Fork Cap Tool Tightening torque maximum 10 Nm 10 Install the front fork and all other removed parts according to step 8 10 in chapter How to install Note It is very important that the
11. her plug Aerate the front fork at regular intervals 1 Put the motorcycle on a workstand so that the front wheel is off the ground 2 Loosen the breather plug to release excessive pressure in the front fork Cleaning the scrapers The scrapers protects the fork tube from dust and dirt After some use dirt may end up behind the scrapers If this dirt is not removed the oil sealing rings may start leaking How to clean 1 Lift scrapers out of the outer tubes with a screwdriver and slide them down 2 Clean the scrapers the outer tubes and the inner tubes thoroughly 3 Lubricate inner surface with a thin layer of Ohlins grease 00159 01 and Ohlins Front Fork Fluid 01312 01 leave outside dry Reinstall the scrapers by pushing them into the outer tubes Inspect and or Replace Seals and Bushings Disassemble 1 Follow steps 1 4 in Replace spring to disas semble the fork legs 2 Remove cartridge spring and plastic preload washers drain the front fork fluid 3 Remove scraper with a screwdriver and remove the seal circlip Note The fork legs have one fixed bushing and one sliding bushing Be careful when disassembling the fork legs use Ohlins tool 01702 04 Breather plug Scraper Inspection and Maintenance 4 Fasten the fork legs horizontally in a vice with soft jaws Use a hot air gun to warm up the 4 outer tube where the bushings are located 5 To remove the b
12. ushings Use Ohlins N tool 01702 04 to separate inner tube from J BE outer tube Install the tool at the top of the T N outer tube Rotate the tool to press out the the Ly ky or inner tube with seals and bushings Outer tube Inner tube 47 6 Remove the seals and bushings and check them for wear and damage Replace if neces sary Outer tube M Caution When removing and installing scraper and oil seal use thin plastic tape on the edges ofthe inner tube to avoid damage to the seals Bushing y Washer Assemble Seal 7 EL crip Apply a thin layer of hlins grease 00159 01 and hlins Front Fork Fluid 01312 01 on the sealing surface of the scraper ring and the Scraper fork seal Leave outer surface of the scraper ring dry Install the scraper ring circlip oil Inner tube seal support ring and the bushing on the 7 inner tube ae Scraper Circlip Seal Washer Bushing Bushing k 13 Inspection and Maintenance 8 Fasten the outer tube in a vice with soft jaws Install the inner tube Use tool 01799 04 to install the lower bushing Note Use a hot aii t the outer tub 4 hof inetaigihn buche Ehre NV g gs 4 01799 04 9 FT Bushing Use tool 01799 04 flip it around to install the AI seal in the outer tube Install the circlip and jj f the scraper kn Mm Caution Make sure the circlip is
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