Ohlins SUPERBIKE FG 570 User's Manual
Contents
1. Pos Part No Pcs Description Type remarks 1 2 Topnutassembly See page 24 2 01408 04 2 Adjustment driver 3 04744 95 2 Spring 25 5 260 9 5 04744 10 2 Option spring 25 5 260 10 0 04744 90 2 Option spring 25 5 260 9 0 4 01438 04 4 Guidering 5 01460 37 2 Preload tube 6 01900 05 2 Forkleg outer X 01683 02 2 Bushing upper 8 01684 02 2 Bushing lower 9 04758 01 2 _ Washer 10 04720 02 2 Seal 11 04759 01 2 Circlip 12 02807 01 2 Adjustment rod 13 01901 03 2 Rodextensioner 14 02302 08 2 Guide sleeve 15 01440 01 2 Bump rubber 16 01651 04 2 Sealhead 17 01027 04 2 X ring 18 00438 02 2 O ring 19 01056 04 2 Bushing 20 00438 41 2 O ring 21 02803 01 2 Spacer 22 01653 05 2 Sleeve 23 01585 11 2 Topout spring 24 01698 30 2 Rebound needle 25 00338 14 2 O ring 26 02368 01 2 Shaft 2h gt 1 Compression valve LH See page 25 28 1 Rebound valve RH See page 25 29 01656 02 2 Oylindertube 30 00338 72 2 O ring 31 01699 02 2 Fork leg inner 32 01565 04 1 Stroke indicator 33 00338 63 1 0O ring 34 00194 10 2 Sticker Ohlins 35 04759 02 2 Circlip 36 01682 288 2 Fenderbracketring 37 01678 14 2 Fender bracket 38 00382 088 2 Screw D 39 01902 11 1 Fork bottom Left 4 01902 12 1 Fork bottom Right d 40 01050 01 2 Screw 41 00338 592. 10 22 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 Adamaged seal must be replaced 23 First remove the circlip then the seal and finally the washer 24 Heat the tube where the bushings are posi tioned Use a heat air gun 25 Put the outer tube standing up on a soft suface seal side facing down Remove the bushings by pushing them out Use attach ment bar 1757 01 and dismantling sleeve 1759 07 from the top nut side 26 Heat air gun Tap gently on the attachment bar with a heavy hammer until the bushings are free and can be released from the seal side of the outer tube 27 Check the innertube for damages replace if necessary Use a heat gun to warm up the fork bottom and tool 786 05 to un screw the inner tube of the fork leg 28 Check the reservoir tube for damages replace if necessary Use tool 786 07 to unscrew the reservoir tube 3rd Washer Attachment bar 1757 01 Dismantling sleeve 1759 07 ubber mat C Tool 786 05 O Upper bushing ex Lower bushing em ng Tool 786 07 11 Assembly of the forks 1 Use Tool 786 07 to refit the reservoir tube Tighten to 45 Nm 2 Use Tool 786 05 to refit the inner tube of the fork leg Tighten to 80 Nm 3 Put the outer tube standing up ona soft surface seal side up Fi
3. Cd i ass JE EE o v 2 ogzz N 226 88 pe t as SB e 88 8 PS 388 BS P E 5 9 5 E oga 8 EE z oa i 0 o 5 i ZO N t O N 9 maan O 0 a s o PAP Q zZ gt 2 co e or xr rc Or x N SSE ST 8 7 e m a 8 BT oO TT E XM 4 h e o N 7 N ox D r 0 M Or nn co o o e a Pee t on 7 Apply some front fork oil 1311 01 to the inner tube surface and carefully mount the outer tube slide it completely down 8 Fill up with hlins front fork oil 1311 01 all the way to the edge of the reservoir Con tinue to fill until the oil level is the same in both the reservoir and in the cylinder tube 9 Push the gas piston with teflon band and O ring fitted to the reservoir bottom without allowing it to be pressed back over the circlip groove make sure that there is no air between the piston and the oil Use tool 720 02 Close the compression adjuster 10 Grip the piston shaft with soft jaws 727 02 9 Fit the O ring on the adjustment needle Apply plenty of red grease on the O ring so that the needle slides easily into the piston 8 shaft L 11 Check the X ring and O ring on the seal head Replace if necessary Smear plenty TOSI 0715 01 of white grease on the X ring before you fit it Use tool 0715 01 to get the X ring into the right position 10 po holder Wrap some teflon tape arond the thread of the shaft to protect the seal and O ring from damages Apply some red grease 146
4. 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 deg LLL Notes Tool 1765 03 oN Tool 1797 04 amp 13 mm socket 0 Nut Tool 720 03 Ls 720 02 Piston rod unit Seal head ey Rebound Valve RH Leg N Compression Valve LH Leg 13 13 nn aa Remove the Piston holder Use a 14 mm Jc 9 5 amp wrench 14 L Remove the Topout spring the Sleeve the Spacer and the O ring Piston noider Sleeve amp Spacer O ring 1 E 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 Notes
5. Seal head tool to contract the Top out spring Install tool 2810 01 on tool 1765 03 to keep the contraction Assemble the complete piston rod into the cartridge tube and tight it by hand 3 4 turns NOTE Make sure that the gas piston is pressed down completely 15 Tighten the Seal head to 20 Nm Use Seal head tool 1797 04 and 1765 03 16 Check the O ring on the reservoir cap assy Replace if necessary Apply some red grease on the O ring and push the reser voir cap assy into the chamber using tool 720 03 17 Fit the circlip Make certain that it enters its groove properly 18 Once again contract the top out spring using tool 2810 01 tool 1765 03 and tool 1797 04 NOTE Nitrogen N2 gas Use pressure gauge 1781 01 No TE Tool 1765 03 amp Ba Tool 720 03 15 nitrogen gas N ont 19 Ensure that there is no leakage of gas or Use hlins Front fork oil 1311 01 only The top nut should only be tightened by position 16 Use of inflammable gas for pressurising the soch absorber can be hazardous Use 19 Check the gas pressure stipulated in the spec card Dip the needle of the gas tool 1781 01 in red grease and insert the nee dle through the gas filler valve Charge with gas to the correct pressure according to the spec card NOTE fluid 20 Screw the gas filler screw with O ring Remove tool 2810 01 and
6. gt 7 01759 07 1 Dismantling bar 8 01759 08 1 Installing sleeve 9 01758 04 1 Guidering 10 00720 02 1 _ Measure pin 11 00720 03 1 Pintool 12 04705 01 1 Spanner 13 01765 03 1 Pull up spring tool 14 01797 04 1 Sealhead tool 15 02810 01 1 Pull up spring tool holder 16 00715 01 1 Screwdriver 26 27 More info www ohlins com ADVANCED SUSPENSION TECHNOLOGY hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 07280 11 Issued 06 07 26 hlins Racing AB Mattias Johansson Update Tiina Harakka
7. 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 10 20 mm R1 R2 Front 20 30 mm F1 F2 With rider Rear 25 40 mm R1 R3 Front 35 50 mm F1 F3 Use hlins Front fork oil 1311 01 only The top nut should only be tightened by hand into the fork leg 6 Changing springs 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 triple 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 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 Tool 1765 03 1305 01 Tangy 10 eui
8. the so called rebound leg right leg and one the compression leg left leg Compression adjustment Rebound adjustment Left Hand Fork Leg Right Hand Fork Le Tool 794 01 Tool 794 01 Clockwise turn closes increase rebound damping Clockwise turn closes increase compression damping Counter clockwise turn opens reduce compression damping Counter clockwise turn opens reduce compression damping Clockwise turn closes increase compression damping Start click position in this example Rebound Top right 10 clicks open Rebound base bottom right 16 never adjust Compression top left 12 Compression base bottom left 12 Rebound damping adjustment The rebound damping is adjusted on the top of the right leg Standard click position is 10 clicks open from fully closed position The recommended range of adjustment with this setting is 6 16 clicks open from fully closed position Compression damping adjustment As said earlier the compression damp ing on this Front fork FG 570 has been checked for balance at the factory be fore delivery In order not to change this matched pressure balance between the 25mm valves main piston and the base valves bottom left and right leg please use the following guidelines By changing both the top and bottom compression adjusters at the same time you have a greater chance of keeping the pressure balance between th
9. 0 18 mm 0 18 turns Spring rate 4744 95 9 5 N mm marking 95 Optional springs supplied 4744 10 10 0 N mm marking 10 4744 90 9 0 N mm marking 90 Optional springs 4744 85 8 5 N mm marking 85 4744 80 8 0 N mm marking 80 Oil Capacity Please see specification card Use hlins high performance front fork fluid No 5 1311 01 only Tighten torgue Lower triple clamp bolt 12 15 Nm Upper triple clamp bolt 18 22 Nm Grease Ohlins front fork grease 146 01 red grease Service interval Every 10 hours 22 Tighten torgue Loctite and Grease UN 8J2S sjuiod dn 1 ujog aseaiB ON Duu iSI ejep uojsid ejquiesse aJojaq pou 01 Japjoy uoisid uoenv ZPS 911201 WN Or Bal 104 109 9111907 Buiysng 19ddn 022 81907 WN SL 19U0ISUSI XO poJ jeus uoisid Ajuo puey Ag Buisnoy juewysnipy WN Oz elsnipe uds jjog 1euoisuejxe poy js6ulJ o Jayjo je uo aseas6 pay S 0 Sz ao o zs 8 E m 3 zx 2g mu EJ S a sa 8 s 2 E E z a Ei o 3 gt a z 3 UN mans 1190 ON Buiusnq 19401 ecc 81907 WN Z INN eseo1b pay WN Sp eqni JIOAJISIH 879 8111907 WN 08 eqm Japul AD 323 8111907 UN Z INN uy un eseeib eiuw 8qn JI0A48S81 JO episu Base valve 45 Nm Spare parts list FG 570
10. 01 to the tape and the shaft end Mount the seal head and the O ring Topout spring amp Sleeve amp Spacer 11 Use a brass wire brush to clean the piston rod from tape Mount Spacer Sleeve Top out spring and the Piston holder 12 Tighten the Piston holder to a torque of 15 Nm 13 Refit the Compression Rebound valve Use the picture below to make it right Tighten the 8 mm nut with a torque of 7 Nm m 27 a a pee SK LL SE e BE E E OT gt WF mo q 5 c 5 uj W d 2 E lt g gt x amp 2 FE 5 24 6 u 05923 E s m n O IE F Su ce NES K lt 2 955 85 9 PEN S E oo sts 7 go L SEE 9 6 osy fg 8 32255 8B rrsd GE A T l a z a gt uo lt 434 Lo deg tt o o 1858 8 l8 pen O w 3598 g a 595 ESE 5 gt z Ss x a 0882 E ke nen Ss 299 o 7 5 o o Sues x 6 8 NES OL Ne 95v 5 05 Fca SON otc o 6 Ox oO x 6 SS Yo U 6 Box ES amp S2EET F o 2 999 s 52 amp 22683 BEB i an gt CAUTION The Washers must be positioned correctly Notice that there is a difference between the compression and the rebound valve Also make sure to fit the Wave washer 1149 01 in the correct position convex side facing piston NOTE The right hand fork leg is the rebound leg The left hand fork leg is the compression leg 14 Fit the Seal head tool and the Top out spring tool on the piston rod Pull the Top out spring tool and at the same time push the
11. 2 O ring 42 01240 08 4 Bolt Titan 43 00438 33 2 O ring S 44 00382 07 2 Screw O 45 01669 02 4 Caliper sleeve C 46 2 Base valve See page 24 47 00338 72 2 O ring 48 02804 01 2 Reservoir tube 49 00338 25 2 O ring 50 01447 02 2 Pistonring 51 02806 01 2 Gas piston 52 02811 01 2 Reservoir end kit 53 00338 25 2 O ring 41 O 54 02805 01 2 Reservoir end 755 00338 59 2 O ring j 56 01050 01 2 Screw 57 01152 01 2 Circlip 23 Spare parts list Top nut assey Top nut assy Pos Part No Pcs Description Type remarks 1 04747 02 2 Cap 2 04756 01 2 Adjuster 3 00884 04 4 Ball a 4 04727 01 2 Spring a Vy 5 04722 07 2 O ring cb 6 04748 01 2 Bolt spring adjuster beet 7 04722 04 4 O ring 8 04749 02 2 Plate center 9 02801 01 2 Adjustment housing 10 00338 61 2 O ring wil 04751 02 2 Washer 12 04752 01 2 Washer 13 04753 01 2 Washer 14 04762 03 2 Spring seat o CS Spare parts list Base valve Base valve Pos Part No Pcs Description Type remarks 15 01675 01 2 Nut 16 00153 01 2 Washer 17 00641 02 2 Washer 18 Shim stack See spec card 19 01670 01 1 Piston compression RH 6 holes 01670 03 1 _ Piston compression LH 3 holes 20 00338 11 2 O ring 21 00530 22 2 Shims 22 01693 01 2 Spring 23 01669 01 2 Sleeve 24 01672 01 2 Spring collar 25 01658 01 2 End piece 26 00438 02 2 O r
12. 40240 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 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 Adamaged seal must be replaced 6 First remove the circlip then the seal and finally the washer 7 Apply a thin layer of hlins 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 NOTE It is important to use the correct grease in 7 CO Circlip order to achieve optimum fork function L Seal Apply some front fork oil 1311 01 to the CD waste inner tube surface and carefully mount the a D outer tube slide it completely down l Be careful not to damage the fork seal 9 Repeat instructions 6 to 9 in Changing springs on page 6 Refit the front fork 3rd Washer Dismantling the Forks 4 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 Unl
13. Owners Manual hlins Superbike Front Fork FG 570 Safety signals Important information concerning safety is distinguished in this manual by the following notations This Safety alert symbol means Caution OU ale Dnvolveqg A WARNING Failure to follow warning instructions could result in severe or fatal injury to anyone working with inspecting or using the sus CAUTION Caution indicates that special precautions must be taken to avoid damage to the suspension This indicates information that is of impor tance with regard to procedures u Gate eri MS URGE ary Introduction All of Ohlins 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 Ohlins suspension Before installation Ohlins 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 Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden 1 Installing a suspension that is not ap proved by the vehicle manufacturer may affect the stability of your vehi
14. cated around the upper front leg To high torgue might deform the front fork Jedi nn 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 Spring pre load adjustment 17 mm wrench Increase spring pre load Reduce spring pre load E E Bike on the ground F Bike with rider on 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 seguently 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 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 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
15. cle Ohlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an Ohlins 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 Ohlins dealer or other qualified person 3 The vehicle service manual must be referred to when installing the Ohlins sus pension 2 NOTE hlins products are subject to continual improvement and development Conse guently 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 hlins dealer if you have any guestions with re aard 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 hlins Front Fork FG 570 This Super Bike front fork is an improved version of FG 470 with pressurised damp ing system FG 570 is based on 5 years experience from factory road racing The pressurised damping system improves the
16. cording to the figure with the fork leg fully compressed For the right oil level please see the speci fication card Air spring characteristics Air inside the front fork works as a spring The graph at the bottom of the page shows the spring force related to stroke when the oil level is changed between 140 mm and 200 mm Standard oil level is 180 mm o m Y Push to a stop use tool 1765 03 hlins front fork fluid 1311 01 919 10 94 49940 Oil Level Stroke mm 17 18 Troubleshooting Below are a few examples of how to adjust for the most common road holding prob lems 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 e Put on more pre load e Change to a harder spring e Ifa lot of stroke remains after riding drop the oil level See oil level chart e Make sure the front forks have no friction e Rear ride height is to high too much rear spring pre load e Lower the rear end by taking off pre loadfrom rear shock spring 2 The front wheel is jumping during the last part of braking e Ifa lot of stroke remains the oil level is too high Lower the oil level e Ifthe fork is bottoming put in harder springs and keep th
17. e oil level 3 The front end feels unpredictable and un safe in the middle of the corner between braking and getting on power e Not enough rebound damping Put on more damping e Too much rebound damping If it at the same time feels harsh take off some rebound damping e 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 e Not enough rebound damping Put on some more rebound damping e Too much pre load Take off some pre load e Rear end is too soft Put on a harder rear spring e 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 Our advice is to change only one thing at a time and do everything step by step The settings on this pressurised Front Fork are based on what currently is being used in Moto GP racing furthermore the delivery spec is something we like to refer to as a balanced setting This means that the pressure drop over the bottom valves base valves and the top pistons 025mm are matched In order to avoid an unnecessary high in ternal pressure or risk of cavitation please use the following guide lines when adjust ing the front fork The FG 570 front fork can be divided into two parts One being
18. ese adjusters more constant For individual adjustments see next page 19 Individual adjustments Individual adjustments Below you can find the recommended ad justment range for the top left compression leg adjuster with different positions on the bottom base valve From soft to hard Base 19 clicks top 17 20 clicks Base 16 clicks top 14 18 clicks Base 12 clicks top 11 14 clicks HARD gt Base 10 clicks top 10 12 clicks Base valve The left bottom base valve can be ad justed from 8 13 clicks if top compression is set at 12 clicks open Compression adjustment Rebound adjustment Left Hand Fork Le Right Hand Fork Le Clockwise turn 109179401 Clockwiseturn Tool 794 01 closes increase closes increase compression rebound damping damping c amp i Counter clockwise gt Ar Counter clockwise turn opens reduce rebound damping turn opens reduce compression damping Counter clockwise turn opens reduce compression damping Clockwise turn closes increase compression damping 20 Other tips and tricks For on track adjustments and satisfying your riders needs we could also look at the adjuster from this angle 1 The compression damping from your left base valve can be adjusted when you need more compression damping but you don t want the damping to react too quick Let s say the rider needs more damping during braking then close the bottom adj
19. front fork function at high freguency 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 Contents Before installation Ohlins front fork FG 5 Adjusters Setting up your forks Changing springs Changing seals Dismantling the forks Assembly of the forks Oil level adjustment Troubleshooting Guidelines Individual adjustments Technical information Spare parts list Service tools 22 23 Front fork 570 is equipped with an external reservoir pressurized with nitrogen A dividing piston separates the oil from the gas Adjusters Your Ohlins super bike fro
20. ing 27 01242 03 2 Adjustment needle 28 00884 02 4 Ball 29 01474 01 2 Spring 30 00338 53 2 O ring 31 01473 02 2 Circlip 24 Spare parts list Compression valve LH Compression valve Pos Part No Pcs Description Type remarks 1 01654 07 1 Piston holder 00530 22 1 Shims 3 01149 01 1 Wave washer 4 00520 20 1 Shims I 5 1 Washer See spec card 6 Shim stack comp See spec card 7 01447 02 1 Piston ring 8 02061 03 1 Piston 9 Shim stack reb 10 1 Washer See spec card Rebound valve 11 01674 01 1 Washer 12 00153 01 1 Washer See spec card Sr 13 01675 01 _1 Nut Spare parts list Rebound valve RH i Pos Part No Pcs Description Type remarks 14 01654 07 1 Piston holder x NE 15 1 Washer See spec card N 16 Shim stack comp See spec card 17 01447 02 1 Piston ring 16 18 02061 03 1 Piston Toss 19 Shim stack reb See spec card 20 1 Washer See spec card 21 01674 01 4 Washer 22 01675 01 1 Nut o N o 0000 0 9 9 0 5 6 N S N N S N v N Service tools Pos Part No Pcs Description 1 E 1 00727 02 _1 Soft jaws one pair 3 2 00786 05 1 Inner tube tool N 3 00786 07 1 Cartridge tube tool gt 4 01781 01 1 Gastool 5 00797 01 1 Top nut socket 5 6 01757 01 1 Attachment bar
21. nt fork is pro vided with the following external adjusters Spring pre load adjuster e Rebound damping adjuster e 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 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 Spring pre load adjustment 17 mm wrench Increase spring pre load Reduce spring pre load 5 Compression adjustment Rebound adjustment 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 coun
22. oad 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 Ta 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 Preload tube Tool 4705 01 Adjustment driver w Releasing high pressure gas from the front fork can be hazardous Do not perform any kind of service until gas pressure is com pletely 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
23. t the bushings from the seal side of the outer leg Install first the upper bushing then the lower one Use installing sleeve 1759 08 guide ring 1758 04 and attachment bar 1757 01 when installing the upper bushing Ap ply Loctite 601 on the seat position of the upper bushing use a long brush Tap the attachment bar until it reaches the correct position stop against a shoulder 4 When the upper bushing is in position the lower bushing is to be installed the same way Apply some red grease 146 01 to the bushing before installation 5 Apply a thin layer of hlins 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 12 CA a an OC Upper bushing J Guide ring 4 1758 04 4 Attachment bar 1757 02 Installing sleeve 1759 08 J Rubber mat NOTE 4 R a Circlip 1 o B Washer CD Seal 6 Install the piston and the shims on the compression valve Tighten the 8 mm nut with a torque of 7 Nm Check the piston ring and the O rings for damages Replace 8 mm Nut if necessary INM Install the compression valve assembly into the valve housing Tighten to 20 Nm 20N Compression valve assembly n TT ZN E d
24. ter 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 Left Hand Fork Le Right Hand Fork Le Clockwise turn Tool 794 01 Clockwise turn Tool 794 01 closes increase closes increase compression rebound X adde Counter clockwise W Counter N Pt turn opens reduce compression ss turn opens reduce rebound damping Counter clockwise turn opens reduce compression damping Clockwise turn closes increase compression damping Setting up your forks F1 R1 R2 A D Bike on a stand Here is some basic guidelines how to set up your hlins 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 nlins 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 lo
25. tool 1797 04 to release the top out spring 21 Push tool 1765 03 to a stop and check the oil level according to page 17 NOTE 22 Refit the Pre load tube Install the spring and refit the adjustment driver 23 Refit the top nut assembly to the piston shaft Tighten the jam nut to 20 Nm 24 Refit the top nut into the fork leg use tool G3 797 01 Adjust the preload compression and rebound CAUTION hand into the fork leg The tightening force of the triple clamp will hold it in locked 1979 10 BY 49940 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 lessened 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 un derstand the difference when the oil level is changed Force N 4000 3500 3000 2500 2000 1500 1000 500 NOTE Adjust the oil level in mm ac
26. uster 1 3 clicks since this adjustment will have time to react during braking but will allow the front fork to go smoothly over bumps at hard cornering 2 If the rider complains about lack of tire feel you can improve this by closing the top left compression adjuster 2 3 clicks since these adjustments will give a quicker response This could also improve the rider s initial dive of the front fork when he is applying the front brake NB By closing this adjuster too much can also remove some comfort and make the fork feel hard and harsh Should the above instructions not be enough or the standard setting somehow not meeting the needs for you riders then please contact hlins racing AB Sweden for setting information rather than attempt ing to modify the setting yourself We have a vast setting bank for this front fork with balanced and matched settings to choose from 21 Technical information Fork length 730 mm Stroke 130 mm Free spring length 260 mm Rebound adjustment Base setting 9 12 clicks Maximum open valve 20 clicks Compression adjustment Base setting 6 16 clicks Maximum open valve 20 clicks Compression adjustment Base valve Base setting 6 16 clicks Maximum open valve 20 clicks Spring pre load adjustment
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