FGR 710 - Ohlins
Contents
1. 1 1 Top nut assembly See page 16 1 2 03316 01 2 Spring support 21610 55 2 Spring 4 0 163 5 5 21610 50 2 Option spring 4 0 158 5 0 1 3 21610 60 2 Option spring 4 2 154 6 0 21610 65 2 Option spring 4 2 157 6 5 21610 70 2 Option spring 4 4 148 7 0 1 4 21611 01 2 Guide ring 1 5 01460 50 2 Preload tube 1 6 01550 03 2 Forkleg outer 1 7 01683 03 2 Bushing 1 8 01684 03 2 Bushing 1 9 02463 01 2 Washer 1 10 02461 01 2 Seal MX 1 11 02465 01 2 Circlip 1 12 21606 01 2 Cylinder tube 1 13 02469 03 2 Fork leg inner 1 14 01902 17 1 Fork bottom LH Left 1 15 01902 18 1 Fork bottom RH Right 1 16 01046 02 4 Screw 1 17 01669 01 2 Sleeve 1 18 01473 02 2 Circlip 1 19 00338 53 2 O ring 1 20 01242 03 2 Adjustment needle 1 21 01474 01 2 Spring 1 22 00884 02 4 Ball Note The number of pieces is valid for 1 pair of Front fork legs 15 A 1 S UU CC N 1 1 ah O 1 1 Spare parts list Pos PartNo Pos Description Remarks Top nut assembly 2 1 01473 01 2 Circlip 1 2 2 00577 01 2 O ring 2 O 4 5 2 3 01467 02 2 Adjustment screw 2 4 00884 04 4 Ball 2 5 01474 01 2 Spring 2 6 03312 01 2 Adjuste2. Reinstall the preload tube Install the spring and the spring support 5 7 Reinstall the top nut assembly to the piston shaft Tightening torque 20 Nm 5 8 Reinstall the top nut into the outer fork leg Use tool 00797 01 and tighten with torque 10 Nm Adjust the spring preload compression and rebound damping a 1 E T a Tool 00797 01 11 Oil level adjustment Compared with 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 the spring force at the beginning of the fork travel but will have a great effect at the end of the travel When the oil level is raised The air spring in the later half stage of travel is stronger and make the front forks more progressive When the oil level is lowered The air spring of the travel is reduced and thus the front fork less progressive The oil level works most efficient at the end of the fork travel Air spring characteristics shown is a general card description to understand the difference when the oil level is changed NOTE Adjust the oil level according to the figure with the fork leg fully compressed with springs and preload tube taken out For the correct oil level see specification card
3. Change to a harder spring If a lot of stroke remains after riding drop the oil level See oil level chart Make sure the front forks have no friction Rear ride height is to high too much rear spring preload Lower the rear end by taking off preload from rear shock spring 2 The front wheel is jumping during the last part of braking e If a lot of stroke remains the oil level is too high Lower the oil level f the fork is bottoming put in harder springs and keep the oil level 14 3 The front end feels unpredictable and un safe in the middle of the corner between braking and getting on power Not enough rebound damping Put on more damping Too much rebound damping If it at the same time feels harsh take off some rebound damping Too much compression damping Also gives a harsh feeling Take off some compression damping 4 The front end loses grip coming out of a corner Not enough rebound damping Put on some more rebound damping Too much preload Take off some preload Rear end is too soft Put on a harder rear spring Front end is too high Lower the front end by pulling the fork legs through the triple clamps As mentioned in the beginning the whole bike setup affects the front forks Try to understand the feelings and work step by step NOTE We advise to change only one thing at a time and do everything step by step Spare parts list
4. 12 hlins Front Fork fluid 01311 01 Push to a stop use tool 01765 03 The edge of the outer fork leg Check the oil level Fig 5 4 Technical information Front Fork length 615 mm Stroke 100 mm Free spring length 260 mm Recommended settings Compression 10 clicks Rebound 12 clicks Spring preload 4 turns from fully compressed position Preload range 0 15 mm 0 15 turns Spring rate 21610 55 5 5 N mm Optional springs available 21610 50 5 0 N mm 21610 60 6 0 N mm 21610 65 6 5 N mm 21610 70 7 0 N mm Oil capacity See specification card Use hlins high performance front fork oil no 4 01311 01 only Torque Lower triple clamp bolt 12 15 Nm Upper triple clamp bolt 18 22 Nm Grease hlins Front Fork Red Grease 00146 01 Service intervals This product is designed for racing use only Recommended service every 10 hours Disposal Discarded products should be handed over to an authorized hlins Service Centre for proper disposal 13 Troubleshooting Below you will find a few examples of how to adjust for the most common road holding problems in Road Racing driving 1 The front wheel chatters entering a corner the problem goes away as soon as you let the brakes off or when you get on the power This is caused by the fact that the fork is working too low in the travel and reaches the progressive hard part at the end of the travel Put on more preload
5. Nut es 1 Note The number of pieces is valid for 1 pair of Front fork legs gt O os 1 Bor 12 17 Spare parts list Compression valve assembly Pos PartNo Pos Descrption Remarks 4 1 00520 26 2 Shim 4 2 21609 01 2 Base valve 4 3 Washer See spec card 4 4 Shim stack See spec card 4 5 01670 04 2 Piston 4 6 00438 02 2 O ring 4 7 01669 01 2 Sleeve 4 8 00530 22 2 Shim 4 9 01671 02 2 Spring 4 10 01672 01 2 Spring collar 4 11 00120 01 2 Washer 4 12 01675 01 2 Nut Note The number of pieces is valid for 1 pair of Front fork legs N o 1 1 co 1 o 1 1 N 1 1008600 Fig 4 18 www ohlins com Your hlins retailer hlins Racing AB Box 722 SE 194 27 Upplands V sby Sweden Phone 46 0 8 590 025 00 Fax 46 0 8 590 025 80 www ohlins com AFIS S ISO 9001 S CERTV Ohlins Owner s Manual FGR 710 Part No 07280 14 3 Issued 2009 02 16 2009 hlins Racing AB
6. the product throughout its life cycle Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distinguished 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 m Caution The Caution Symbol means Special precautions must be taken to avoid damage to the front fork lt Note The Note Symbol indicates information that is important regarding procedures O hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden hlins Front Fork FGR 710 hlins Front Fork FGR710 The hlins 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 gap oil level gives a possibility to adjust the Be characteristics of the fork to suit different tracks and riders KL For example a soft spring in combination M A with a small air gap high oil level gives a N progressive action of the front forks 77 ts A telescopic front fork is depending on a smooth friction free action Mak
7. 19 mm and 24 mm 5 Wire with hook 6 Seal head tool 01797 08 7 Heat gun 8 Brass wire brush 9 Sleeve pin 00797 01 10 Inner fork leg tool 00786 02 11 Attachment bar 01757 01 12 Pull up spring tool 01765 03 13 Rag 14 hlins red grease 00146 01 15 hlins front fork oil 01311 01 16 Waste oil container Loctite 2701 6 Work section 1 Change the spring 1 1 Release the spring preload completely by turning the adjustment nut counter clockwise as far as possible Use a 14 mm wrench or socket 1 2 Loosen the screws that hold the fork legs in the upper triple clamps 1 3 Loosen the top nut assembly from the fork leg Use tool 00797 01 1 4 Remove the top nut assembly from the piston shaft Use a 14 mm wrench on the top nut and a 19 mm on the shaft 1 5 Remove the spring support and the spring Use a wire with a hook and carefully pull out the preload tube 1 6 Check the oil level according to Chapter Oil level adjustment NOTE Use hlins Front fork oil 01311 01 only 1 7 Reinstall the preload tube the new spring and the spring support 1 8 Reinstall the top nut assembly to the piston shaft with tightening torque 20 Nm 1 9 Reinstall the top nut into the outer fork leg with the front wheel off the ground use tool 00797 01 and tighten with torque 10 Nm Tighten the upper triple clamps and adjust the preload according to Chapter External adjustme
8. e 2295 e ar e ja oo o ug NA YI e e T ha FGR 710 Owner s Manual ADVANCED SUSPENSION TECHNOLOGY FGR 710 Safety Precautions 9 Note The front fork is a very important part of the vehicle and will 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 an hlins dealer lt hlins 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 After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability AN If 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 hlins Service Centre 9 Note When working on this product always consult your Vehicle Service Manual This Manual shall be considered a part of the product and shall therefore accompany
9. e sure your front forks are serviced regularly and do not use strong solvents such as brake cleaner to clean the front forks This will dry out the seal and steel tubes and cause J Dee friction Regularly put some hlins red _ grease 00146 01 on the steel tube and work in by pushing the forks up and down Contents hlins Front Fork RR 125cc FGR 710 3 External adjustments 4 Setting up your forks 5 Work section Tools 6 7 8 1 Change the Spring 2 Disassemble the Front Fork NOTE Read through the whole work section and 5 siu 2 5 make sure that you understand all the steps 5 Assemble the Front Fork 11 in the procedure before you begin Oil level adjustment 12 Make sure that you have all the proper Technical Information 13 tools needed for the section you are about Troubleshooting 14 to work on before you begin Spare parts list 15 e Clean all parts thoroughly after disassembly e Contact an Ohlins dealer if you have any questions regarding the front fork FGR 710 External adjustments The hlins FGR 710 Front Fork is equipped with the following external adjusters Spring preload adjuster Rebound damping adjuster Compression damping adjuster Spring preload adjuster 14 mm wrench Adjust the spring preload by turning the nut on top of the fork leg Use a Increase 14 mm wrench spring preload Adjustment range 0 18 mm 4 On the adjustment nut on
10. e turn will change 1 mm in spring preload Recommended static sag is 15 25 mm spring preload 2 Rebound adjuster Adjust the rebound damping by turning the screw at the top of the front fork Use Tool 00794 01 tool 00794 01 Adjustment range from closed valve clockwise until maximum open valve counter clockwise 20 clicks Recommended adjustment click from closed position See specification card 3 Compression adjuster Adjust the compression damping by turning the screw at the fork bottom Use a flat screwdriver Adjustment range from closed valve clockwise to maximum open valve counter clockwise 20 clicks Recommended adjustment click from closed position See specification card FGR 710 Setting up your forks Basic Guidelines How to set up your hlins front forks The front forks are just one part of your motorcycle and to get it to work properly you have to adjust the front and rear suspension together 1 Put the motorcycle on a workstand and install the hlins front fork NOTE The lower triple clamp must not be tightened to more than 12 15 Nm This is also important for the steering damper bracket when located around the upper front leg Too high torque may deform the front fork leg Guidelines Setting the Spring preload 2 The spring preload is very important since it affects the height of the motorcycle and the fork ang
11. le Consequently handling characteristics can be changed even negatively 14 mm wrench Increase spring preload spring preload R1 Bike on a stand Procedure We recommend you to have an assistant for this procedure 1 Put the motorcycle on a stand 2 Make sure that the shock absorber is fully extended 3 Measure the distance 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 4 Make a similar measurement on the front axle for example from the bottom of the upper fork crown to the front wheel axle Make sure that the front fork is fully extended F1 5 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 should not differ from the following With rider Rear 30 5 mm R1 R3 Front 30 5 mm F1 F3 Without rider Rear Just top out 0 mm R1 R2 Front 15 25 mm F1 F2 NOTE An RR125 cannot afford to loose the momentum that the sag would give in a straight line loss of top speed Bike on the ground Bike with rider on 5 FGR 710 Tools and oils Recommended tools and oils 1 Vice 2 Soft jaws 00727 02 one pair 3 Hexagon screwdriver 00794 01 4 Wrench 14 mm 17 mm
12. nts Spring SY support E Spring Fig 1 4 wrench 00797 01 Fig 1 9 Work section 2 Dissasemble the front fork NOTE This worksection can not be done while the forks still are installed on the motorcycle 2 1 Put the fork legs in upright position for about 5 minutes to allow the oil to settle 2 2 Fasten the fork leg in a vice with soft jaws 2 3 Release the spring preload completely by turning the adjustment nut counter clockwise as far as possible Use a 14 mm wrench or a socket NOTE Do not use the preload adjuster to tighten or loosen the top nut assembly 2 4 Loosen the top nut assembly Use tool 00797 01 2 5 Remove the top nut assembly from the piston shaft Use a 14 mm wrench to the top nut and a 19 mm wrench to the shaft 2 6 Remove the spring support and the spring Use a wire with a hook and carefully pull up the preload tube 2 7 Use tool 01797 08 together with an 24mm wrench to unscrew the piston rod unit from the fork leg 2 8 Use tool 01765 03 to remove the piston rod unit 2 9 Drain all oil from the fork leg Make sure that washer 04729 02 falls out Piston rod unit Fig 2 8 Spring support E Spring 24 mm wrench Fig 2 7 Fork leg Work section 3 Change the seals NOTE This worksection can not be done while the forks still are installed on the motorcycle Remove the t
13. op nut and piston rod unit according to Chapter 2 Disassemble the Front Fork Then continue below 3 1 Remove the outer fork leg clean the seal and check the condition If the seal is in good condition apply some red grease 00146 01 to the seal before reassembling the fork A damaged seal must be replaced 3 2 Remove the circlip the seal and finally the washer 3 3 Apply a thin layer of hlins red grease 00146 01 to the washer and to the sealing surfaces of the fork seal Install the washer and the seal into the outer fork leg Install the circlip into the groove NOTE It is important to use the correct grease in order to achieve optimum fork function 3 4 Apply some hlins fork oil 01311 01 on the inner fork legs outer surface Slide on the outer fork legs carefully on to the inner fork legs completely down Be careful Do not damage the fork seal 3 5 Reassemble the fork legs according to Chapter 5 Assemble the Front fork E 7 mp 3 Washer Tire lever or eguivalent Fig 3 2 3 Circlip CO 2 Seal A Outer fork 1 Washer CD leg d ML ji Inner fork Ohlins fork oil Fig 3 4 Work section 4 Replace the inner fork legs NOTE This worksection can not be done while the forks still are installed on the motorcycle Remove the top nut and piston rod unit according to Chapter 2 Disassemble the Fron
14. r 2 7 03309 01 4 Shim t 0 1mm 2 8 00338 72 2 O ring 2 9 03318 09 2 Adjustment housing 2 10 00338 92 2 O ring 2 11 03317 01 6 Spring 2 12 03309 02 2 Shim t 0 38mm 2 13 03313 01 2 Nut 2 14 03315 01 2 Preload socket 2 15 00382 06 2 Screw 2 16 00338 56 2 O ring Note The number of pieces is valid for 1 pair of Front fork legs e 1 CD 1 i l N 1 ow 1 Fig 2 16 Spare parts list EEE i 3 1 02366 16 2 Adjustment rod 3 2 03314 12 2 Shaft extension 1 3 3 00338 76 2 O ring 3 4 02302 10 2 Spring guide 3 5 01582 12 4 Spacer 3 6 01582 10 2 Spacer 3 7 01580 01 2 Bump rubber 2 3 8 21607 01 2 Tubetop cap Rebound valve assembly 3 9 00110 01 2 Bushing m E m m 3 10 00438 28 2 O ring 3 pco 3 11 01582 12 4 Spacer EA 13 O I 3 12 02367 09 2 Shaft H 3 13 00438 31 2 O ring 14 3 14 01698 10 2 Rebound needle ar I I 3 15 02322 01 2 Spring 3 16 01654 11 2 Piston holder l 15 3 17 Shim stack See spec card 3 18 02061 03 2 Piston rebound 5 3 19 01447 02 2 Piston ring 16 3 20 Shim stack See spec card 6 i i n 3 21 Washer See spec card 3 22 00153 01 2 Washer a E 3 23 01675 01 2
15. t Fork Then continue below 4 1 Remove the outer fork leg Inner fork leg 4 2 Use a heat gun to warm up the fork bottom Use tool 00786 02 to unscrew and remove the inner fork leg Clean the threads thoroughly from Loctite 4 3 Install the new inner fork leg using tool 00786 02 Use Loctite 2701 on the threads Tighten with torgue to 160 Nm 4 4 Apply some hlins fork oil 01311 01 on the inner fork legs outer surface Slide on the outer fork legs on to the inner fork legs completely down Be careful Do not damage the fork seal 4 5 Reassemble the fork legs according to Chapter 5 Assemble the Front Fork Ohi Ins fork oil Inner fork leg 10 Outer fork leg N Outer fork leg Tool 00786 02 Work section 5 Assemble the front fork 5 1 Assemble the compression valve assembly to the cylinder tube Smear some red grease on washer 04729 02 and stick it to the bottom of the base valve 5 2 Assemble the piston rod unit into the fork leg and tighten with 20Nm Use tool 01797 08 5 3 Pour hlins Front Fork Oil 01311 01 into the inner fork leg approximately 20 25 mm above the cylinder tube 5 4 Pull the rod up and down and make sure that there is no air left Use tool 01765 03 5 5 Push tool 01765 03 to a stop and check the oil level according to Chapter Oil level adjustment NOTE Use Ohlins Front Fork oil 01311 01 only 5 6
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