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1. Front 15 30mm F1 F2 With rider Ride height Rear 25 40mm R1 R3 Front 35 50mm F1 F3 Setting up your front fork tools Description Remarks 1 00727 02 Soft jaws o 12 2 00786 05 Soft jaws 043 3 00787 03 Cylinder tube 29 1 holder 4 00797 08 Pin sleeve socket 5 01757 01 Attachment bar front fork bushing 6 01758 04 Bar guide 7 01759 07 Bushing tool Dismantle 01759 08 Bushing tool Installation 8 01765 05 Pull up tool 01797 07 Seal head tool 10 04705 03 Spanner top cap 11 00794 01 Hexagon screw driver Setting up your front fork Extended stroke The FGRT series of front forks are delivered with a 120 mm stroke but designed with a possibility to be extended up to 10 mm achieving a 130 mm stroke A 120 mm stroke suits the regular driver well but often when running a gt 1000 cc on the race track a 130 mm stroke is desired NOTE When increasing the stroke the overall length of the front fork increases by up to10 mm In order to obtain a correct ride height the fork might need to be raised in the fork crowns It is of great importance that the clearance between front wheel or fender and i e radiator or cowlings is examined along the entire stroke The easiest way to check the free travel is to open both top caps and compress the fork completely while sweeping the handle bar from side to side Tool 0472. N mm Ohlins front fork grease 00146 01 red grease 04744 90 9 0 N mm vom as 33 Nimim Other available documents regarding your 04744 10 10 0 N mm hlins f fork hlins M 04744 05 10 5 N mm Ohlins ront ork see Ohlins Mounting 04744 11 11 0 N instruction Work shop manual Spare part list IIN and Specification card Oil Level Please see the specification card for your specific front fork CAUTION Use only hlins high performance front fork fluid 01309 01 12 Inspection and maintenance Clean the front fork externally with a soft detergent Use compressed air Be careful that all dirt and debris is removed Keep the front fork clean and always spray it with oil OS 14 WD40 or CRC 5 56 or similar after washing the vehicle CAUTION Never use strong detergents that can damage the surfaces of the front fork Use of thinner and brake cleaner will dry out seals increase the risk of friction oil leakage or even malfunction NOTE Make certain that your front fork is always filled with hlins High Performance Front Fork Oil 01309 01 Inspection points see figure 1 Check the front fork for external oil leakage 2 Check the inner fork leg for scratches dents or other defects that might harm the seal bushing 3 Check fastening of fender brackets and brake caliper 4 Check fastening to the vehicle Preventive maintenance and regular inspection reduces the risk of func
3. 05 03 Top cap The basic steps for changing the stroke e Adjust the configuration of the spacers below the seal head J e Replace the preload tube Ca py The procedure is as follows the front fork Cn can still be installed on the motorcycle while changing the overall length but removing it will make the modification a little easier 5 1 If the fork is installed on the motorcycle loosen the upper fork crown Spring 2 Release the spring preload fully counter support clockwise 3 Open the top cap using tool 00797 08 Spring 4 Use tool 04705 03 to get a grip of the lock I nut and remove the top cap Carefully remove tool 04705 03 5 Remove the spring support and the spring Preload tube 6 Use a wire with a hook to pull out the preload tube Setting up your front fork 7 Loosen and remove the shaft assembly using tool 01797 07 Make sure the 0 30 mm shim attached to the base plug follows 8 On the shaft assembly remove the top cap lock nut guide sleeve spacers if any and bump rubber 9 Remove the base plug from the cylinder tube 10 Push the shaft gently through the seal head The shaft with the piston top out spring and spacers is now exposed and ready for modification 11 Install spacers on the shaft according to the specification card spacers amp seal head 12 Install the o ring next to the spacers and push the shaft back through the cylin
4. Owner s Manual hlins Front fork FGRT series Road amp Track e Safety precautions e Introduction amp design e Setting up your front fork e Adjustments e Changing springs Technical information e Inspection and maintenance RQZY Oil level adjustments hlins Racing AB The Story It was the 1970 s a young man named Kenth hlin spent most of his spare time pursuing his favourite sport motocross A careful observer Kenth s attention was continually drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension hlins Racing was established in 1976 and just two years later the company won its first World Championship title Despite being in the business for 30 years the search for perfection and new functions are still the main focus of the company You are now the owner of an hlins front fork More than one hundred World Championships and other major world titles are definitive proof that hlins shock absorbers offer outstanding performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible experience from our 30 years within the racing sport The product that you now have in your possession is pure racing breed that is built to withstand By in
5. ble for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an Ohlins dealer for advice 2 Please study and make certain that you fully understand the contents in the mounting instruction s and the owner s manual s before handling this suspension kit If you have any questions regarding installation procedures contact an Ohlins dealer 3 The vehicle service manual must be referred to when installing the Ohlins suspension CAUTION Ohlins products are subject to continual improvement 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 suspension and this manual Please consult your Ohlins dealer if you have any questions with regard to 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 detrimental to the suspension 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 and Design Introduction The product in your hand is an artwork prepared by our dedicated craftsmen at our Swedish facility in Upplands V
6. der tube and seal head 13 Install the bump rubber spacers according to specification card spacers O bump rubber guide sleeve and top cap lock nut Wind the lock nut all the way down on the shaft or until 25 mm of the thread or more is visible above the nut 14 Install the base plug into the cylinder tube and attach the 0 30 shim to the base plug using red grease 15 Install the shaft assembly into the fork leg using tool 01797 07 Tightening torgue 20 Nm 16 Adjust the oil level according to the specification card procedure see chapter Oil level adjustments NOTE Make sure that the outer tube is slided all the way down before adjusting the oil level OS Tool 01797 07 ZN Shim 0 3 mm S WH El Shaft assembly La Se ASD X gt Cylinder tube Top cap lock nut Guide sleeve Spacer s Bump rubber Seal head D 02 i Spacers Setting up your front fork 17 Install the new preload tube see specification card for correct art No 18 Install the spring with the marking facing up and the spring support 19 Install tool 01765 05 on the shaft and wind the preload nut to contract the springs 20 Use tool 04705 03 to maintain the contraction and replace tool 01765 05 with the top cap Make sure the shaft bottoms in the top cap before tightening the
7. for additional fine tuning Springs are available in 0 5 N mm intervals from 8 N mm to 11 N mm but the rate can be set to 0 25 N mm increments by using two different rates A method used on the race track Example Using 9 5 N mm in the right fork leg and 10 0 N in the left fork leg gives an average spring rate of 9 75 N mm Set the spring preload The spring preload is very important since it affects the height of the motorcycle and the fork angle Conseguently handling characteristics can be changed even negatively with an incorrect adjustment Before setting the preload the sag shall be measured according to procedures below e Lift up rear end so that the shock absorber is fully extended e Measure the distance from the wheel axle to a point marked with e a piece of tape immediately above the rear wheel R1 e Lift up the front of the motorcycle so that the front fork is fully extended e Measure the distance i e between the scraper and the fork bottom F1 e Make similar measurements with the motorcycle in upright position without rider R2 F2 e Make similar measurements with the motorcycle in an upright position with rider R3 F3 It is of great importance that the rider has a correct riding posture and correct riding gear so that the weight is balanced on the suspension same way as when riding The measurements should be within the following intervals Without rider Free sag Rear 10 20mm R1 R2
8. he shaft and pull itup Changing springs 10 Contract the top out spring and the main spring using tool 01765 05 Maintain the contraction by placing tool 04705 05 between the spring support and the lock nut 11 Replace tool 01765 05 with the top cap NOTE Make sure the shaft bottoms in the top cap assembly before tightening the lock nut 12 Tighten the lock nut with tightening torque 20 Nm 13 Apply some red grease on the top cap thread and the o ring 14 Make sure the fork leg is fully extended when tightening the top cap Tightening torque 10 Nm 15 Tighten the upper triple clamp Tightening torque 20 Nm 16 Set the spring preload according to chapter Setting up your front fork The marking facing up Technical information Fork length Please see the specification card for your specific front fork Stroke 120 mm with possibility to lenghten to 130 mm Free spring length 260 mm Rebound adjustment Maximum open valve 20 clicks Compression adjustment Loctite Maximum open valve 25 clicks 2701 Fork bottom thread seal head piston Spring preload adjustment holder top cap main nut 2 12 mm 0 10 turns 243 Piston nut 648 Upper bushing Spring rate Please see the specification card for your Tightening torgue specific front fork Upper triple clamp 20 Nm Lower triple clamp 10 Nm Optional springs Grease 04744 80 8 0 N mm N 04744 85 8 5
9. lock nut Tightening torgue 20Nm 21 Install the top cap into the outer fork leg using tool 00797 08 Use red grease on the thread and o ring and tighten with 10 Nm Make sure the fork leg is fully extended when tightening the top cap 22 If the front fork is installed on the motorcycle tighten the upper fork crown Tightening torgue 20Nm 23 Set the spring preload according to chapter Setting up your front fork Spring support o Spring 1 Tool 01765 05 Preload nut POT A Uy Tool 04705 03 Top cap Tool 00797 08 Adjustments Adjusters Your hlins front fork is eguipped with the following adjusters e Spring preload adjuster e Rebound damping adjuster e Compression damping adjuster Spring preload adjustment Use a 14 mm wrench to turn the upper adjustment screw Maximum adjustment range is 10 mm One turn of the adjustment screw will cause 1 mm change in spring preload The spring has a minimum spring preload of 2 mm giving an adjustment range of 2 12 mm Adjust according to the procedure in chapter Set up Rebound adjustment Adjust the rebound damping on the adjustment screw positioned at the top centre of the fork leg Use a 3 mm allen key Adjustment range from fully closed valve clockwise to maximum open valve counter clockwise is 20 clicks Recommended clicks from closed position according to your mounting instruction for your mo
10. n optimal setting spring and top out spring The new top cap design will send a signal to all curious spectators when you pull over next to your favourite caf or local race track it s a signal that says that the owner of the bike has made his choice to go straight for the podium We now raise the Road Track front fork to a new level A Setting up your front fork Rear mark Front mark F1 R1 R2 K Bike on a stand J Ne Bike on the ground Bike with rider on I Basic guidelines This chapter contains some basic guidelines for setting up your hlins front fork Remember though that the front fork is 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 Fork leg extension Before removing the standard front fork I measure the distance 6 the fork leg is extended above the upper fork crown see figure To obtain a correct ride height with the hlins front fork install the hlins fork legs at the same position as the standard fork Replacing the spring The spring installed in your hlins front fork is chosen after evaluations performed on a test track according to motorcycle characteristics for your specific motorcycle model Due to variations in ride style track conditions body shape etc the spring is often a subject
11. nd the preload tube removed For the recommended oil level see the specification card or mounting instruction for your specific front fork 14 Ohlins Front Fork oil 01309 01 The upper edge of the outer fork leg Oil level Force N 500 475 450 425 4 400 Oil level adjustments AIR SPRING FOR BOTH LEGS 40 50 60 70 80 90 100 110 120 130 Stroke mm Oil level mm 140 150 160 1170 180 190 200 210 220 230 240 www ohlins com Owner s Manual 07282 05 Issued 20080422 hlins Racing AB Annette Asph Oskar Lindberg hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80
12. sby Sweden Its predecessors have battled their way on numerous race tracks in MotoGP and World Superbike and the legacy continues in your front fork Thousands of hours have been spent together with some of the best teams in the world to find the optimal design and functionality to give you as much performance and comfort as possible You will feel the difference be sure Design The DNA of this front fork originates in the most prestigious race series in the world and the front fork is weight optimized as a result of that fact We have used exclusive racing components from our R amp D department to increase the performance of the front fork and a lot of work has been done concerning friction reduction Our engineers that work on a daily basis with the top riders in the world often hear the word feeling and control when they debrief after tests and races We wanted to pour as much of these important factors into your front fork and as a result the new rigid design with new fork bottoms outer and inner tubes gives you an unparalleled feedback when riding For all of you that have your mind set on doing some serious racing we have some really good news The new front fork is easy to rebuild into a 130 mm stroke which we recommend if you want to go for the No 1 spot We have of course optimized the design so that you can easily have it maintained in a proper way and every single front fork is individually tested with a
13. stalling an hlins front fork on your vehicle you have made a clear statement you are a serious rider with a focus on getting the maximal handling ability and outstanding feedback from your vehicle Along comes the fact that your front fork will be a long lasting friend delivering the very best of comfort and performance every time you go for a ride Go explore Safety signals Important information concerning safety is distinguished in this manual by following notations A This Safety alert symbol means Caution Your safety is involved A 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 precautions must be taken to avoid damage to the suspension NOTE This indicates information that is of importance with regard to procedures Before Installation Ohlins Racing AB can not be held responsible for any damage to the Front Fork or vehicle or injury to persons if the instructions for installing and maintenance are not followed exactly Similar the warranty will become null and void if the instructions are not adhered to Safety precautions A 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 responsi
14. tional disturbance If there is any need for additional service please get in touch with an authorised hlins service workshop There they have the necessary tools and knowhow for whatever you need Recommended inspection and maintenance intervals Normal use Once a year or every 5000 km Race track Every ten hours 13 Once every 2nd year or 20 000 km Change front fork oil use hlins front fork oil 1309 01 only Remove outer fork leg and inspect the bushings seals and the full length of the inner fork leg Replace the seals and bushings if necessary Proceed according to hlins Work shop manual NOTE Discarded hlins products should be handled by an authorized work shop or distributor for proper disposal Oil level adjustments 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 fork harder When the oil level is lowered The air spring in the later half stage of travel is lessened and thus the front fork is softer Oil level diagram Adjust the oil level in mm according to the diagram here beside with the spring a
15. torcycle model Compression adjustment Adjust the compression damping on the fork bottom compression valve Use a 3 mm allen key Adjustment range from fully closed valve clockwise to maximum open valve counter clockwise is 25 clicks Recommended clicks from closed position according to your mounting instruction for your motorcycle model 10 Spring preload adjuster de C Increase Rebound adjuster Decrease Increase Compression adjuster The springs can easily be changed replaced with the front fork installed on the motorcycle Follow this instruction to change the spring 1 Loosen the upper fork crown 2 Release the spring preload fully counter clockwise 3 Loosen the top cap assembly from the outer fork leg using tool 00797 08 Carefully slide the outer fork leg down completely 4 Remove the top cap assembly from the shaft using tool 04705 03 5 Remove the tool the spring support and finally the spring 6 Screw the top cap lock nut all the way down on the shaft Approximately 25 mm free thread above the lock nut NOTE We recommend you to check the oil level since the removal of a spring often affects the oil level The oil level is measured without spring or preload tube according to chapter Oil level adjustments 7 Replace the spring with the marking facing up 8 Put the spring support on top of the spring 9 Use tool 01765 05 to grab t
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