Ohlins FG 470 User's Manual
Contents
1. Front fork 470 is equipped with an external reservoir pressurized with nitrogen A dividing piston separates the oil from the gas Adjusters Your hlins super bike front fork is pro vided with the following external adjusters e 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 from2. Dismantling sleeve 1759 07 11 v Tool 786 07 to refit the reservoir tube Tighten to 45 Nm ja Y 2 lt Tool 786 05 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 Fit 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 Lower bushing upper bushing use a long brush Tap the Mm uds uM attachment bar until it reaches the correct Long brush Y m position stop against a shoulder we 4 Gh 4 Attachment bar When the upper bushing is in position the A 1757 02 lower bushing is to be installed the same cm way Apply some red grease 146 01 to 4 Se the bushing before installation Outer tube 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 4 a A 8 CD ovin Tis mporant ose Te corec grease 1 A e Rubber mat Norg It is important to use the correct grease in SI Seal D 12 6 Install the piston and the shims on the compression valve Tighten the 8 mm nut
3. 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 according 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 Ohlins front fork fluid 1305 01 EH Push to a stop use tool 1765 03 1979 10 34 49940 Oil Level Stroke mm 17 18 Troubleshooting Below are a few examples of how to adjust 4 for the most common road holding prob The front end loses grip coming out of a lems in Road Racing driving corner 1 e Not enough rebound damping Put on some more The front wheel chatters entering a repounddamping corner the problem goes away as soon aS e Too much pre load Take off some pre load you le
4. 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 deg LL Notes Tool 720 03 has 720 02 Bs L Tool 1765 03 A e Tool 1797 04 Piston rod unit Seal head O 13 mm socket a Y Rebound Valve RH Leg N Compression Valve LH Leg 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 thoro
5. with a torgue of 7 Nm Check the piston ring and the O rings for damages Replace if necessary Install the compression valve assembly into the valve housing Tighten to 20 Nm 20N Compression valve assembly ue c 884 02 x 2 Ball 1473 02 Circlip gt 1672 01 Collar 438 02 O ring amp 3 3 1242 08 Needle 1474 01 Spring 338 53 O ring gt 153 01 Washer _ Lt 641 02 Washer ep Shim stack Comp gt 1669 01 Sleeve o E a 7 F co o 1675 01 Nut 1670 01 Piston 338 11 O ring 530 22 Shims T Apply some front fork oil 1305 01 to the inner tube surface and carefully mount the outer tube slide it completely down Be careful not to damage the fork seal 8 K Fill up with hlins front fork oil 1305 01 all ord 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 9 and O ring fitted to the reservoir bottom Tool 720 02 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 Fit the O ring on the adjustment needle Apply plenty of red grease on the O ring so that the needle
6. 22 30 01656 02 2 Oylinder tube 31 01699 02 2 Forkleg inner 32 01565 04 2 Stroke indicator 33 00338 63 2 O ring 34 0019410 2 Sticker Ohlins 35 04759 02 2 Circlip 36 01682 28 2 Fender bracket ring 37 _ 01678 14 2 Fender bracket 38 00382 08 2 Screw 39 01902 09 1 Fork bottom Left 01902 10 1 Fork bottom Right 40 01050 01 2 Screw 41 00338 59 2 O ring 42 01240 08 4 Bolt Titan 43 00438 33 2 O ring 44 00382 07 2 Screw 45 05426 02 2 Plug Koenig 46 2 Base valve See page 21 47 00338 722 2 O ring 48 02804 01 2 Reservoir tube 49 00338 25 2 O ring 50 01447 02 2 Piston ring 51 02806 01 2 Gas piston 52 00604 01 2 Rubber valve 599 00338 25 MaM O ring 54 02805 01 2 Reservoir end 55 00338 59 27 O ring 56 01050 01 2 Screw 57 01152 01 2 Circlip Spare parts list Top nut assey Top nut assey Pos Part No Pcs Description Type remarks 1 1 04747 02 2 Cap 2 04756 01 2 Adjuster gt 3 00884 04 4 Ball 4 04727 01 2 Spring a S P 5 04722 07 2 O ring 6 04748 01 2 Bolt spring adjuster 7 04722 04 2 O ring 8 04749 02 2 Plate center 9 02801 01 2 Adjustment housing 10 00338 61 2 O ring 11 04751 02 2 Washer S 12 04752 01 2 Washer 13 04753 01 2 Washer 14 04762 03 2 Spring seat e Spare parts list Base valve 8 C Base valve Pos Part No Pcs Description Type remarks ds 15 01675
7. Refit the front fork O 3rd Washer Dismantling the Forks 1 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 Unload 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 7 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 Adjustment driver oad tube 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 9 Remove the circlip 10 Use tool 720 08 to lift up the reservoir end cap Install the tool 720 02 into the gas
8. isBuu o Jayjo je uo oseo1D pay 022 91020 WN 02 peeu leas WN SI Heys UOISIA POI UOISIJ WN MaS ecc 911907 UIN Z INN esealb pay UN Sp eqm 1on asay 222 100 WN Z INN uj UIT 6seeJb eiuM eqni 110119581 JO episu Base valve 45 Nm 19 Spare parts list FG 470 Pos Part No Pcs Description Type remarks J 2 Top nut assembly See page 21 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 Guide ring 5 01460 37 2 Preload tube 6 01900 05 2 Fork leg outer W 01683 02 2 Bushing upper 8 01684 02 2 Bushing lower g 04758 01 2 Washer 10 04720 02 2 Seal 11 04759 01 2 Circlip 12 02807 01 2 Adjustment rod 13 01901 03 2 Rod extensioner 14 02302 08 2 Guide sleeve 15 01499 01 2 Circlip 16 01440 01 2 Bump rubber 17 01651 04 2 Sealhead 18 01027 04 2 X ring 19 00438 02 2 O ring 20 01056 04 2 Bushing 21 00438 41 2 O ring 22 02803 01 2 Spacer ES 01653 05 MEME Sleeve 24 01585 11 2 Topout spring 25 01698 30 2 Rebound needle 26 00338 14 2 O ring 27 02367 00 2 Shaft 28 1 Compression valve LH See page 22 29 1 Rebound valve RH See page
9. slides easily into the piston shaft 11 Check the X ring and O ring on the seal head Replace if necessary Smear plenty 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 Wrap some teflon tape arond the thread of the shaft to protect the seal and O ring from damages Apply some red grease 146 01 to the tape and the shaft end Mount the seal head and the O ring 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 d5 E B Qs gt ag lt wu o 5 j tt 2 x S 55 z z as EMH ae EH o 2 us lt 15 co o 2 amp 5 5 aw 598 5 4252 Sa ay Q S55 a 5 8 gE O 6949 go x K o 585 5 es 9 i rr DE N ro gt d 641 02 Washer e Shim Stack N S N anos Tool 0715 01 je holder opout spring amp Sleeve amp Spacer Shim stack rebound 2061 03 Piston 1447 02 Pison ring Shim stack compression 641 02 Washer 1654 06 Piston holder T 1 E es od I 9 9 o 9 o o ec R gt 50 6 Es E S E 5 SS T sz z o x 3 2 07 05 o G n om N oc as f ST SN 9 2 Ge ET o
10. 01 2 Nut 16 00153 01 2 Washer 17 00641 02 2 Washer 18 Shim stack See spec card 19 01670 01 2 Piston compression 20 00338 11 2 O ring 21 0053022 2 Shims 22 0169 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 ring 27 01242 08 2 Adjustment needle 28 00884 02 4 Ball 29 01474 01 2 Spring 30 00338 53 2 O ring 31 01473 02 2 Circlip 21 22 Compression valve Rebound valve v Spare parts list Compression valve LH Pos Part No Pcs Description Type remarks o gt a o m T e 1 01654 06 1 Piston holder 2 00338 19 1 O ring 3 01618 02 1 One way valve cup 4 00530 22 1 Shims 5 01149 01 1 Wave washer 6 00520 20 1 Shims W 01618 01 1 Cup holder 8 00641 02 1 Washer 9 N Shim stack comp See spec card 10 01447 02 1 Piston ring 11 02061 03 1 Piston rebound 12 Shim stack reb See spec card 19 00641 02 1 Washer 14 01674 01 1 Washer 15 00153 01 1 Washer 16 01675 01 1 Nut Spare parts list Rebound valve RH Pos Part No Pcs Description Type remarks N o reooo OCCeO 2 o 00OGOOG O00000 4 m a n N N 5 N N s ER N A v AR m a N ER ar o n a 17 01654 06 1 Piston hol
11. Owner s Manual hlins Superbike Front Fork FG 470 ADVANCED SUSPENSION TECHNOLOGY Safety signals Important information concerning safety is distinguished in this manual by the 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 sus pension or to bystanders 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 EEE Introduction All of hlins 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 hlins suspension Before installation hlins 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 hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden 1 Installing a suspension th
12. Use of inflammable gas for pressurising the soch absorber can be hazardous Use nitrogen gas N2 only 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 Ensure that there is no leakage of gas or fluid 20 Screw the gas filler screw with O ring Remove tool 2810 01 and tool 1797 04 to release the top out spring 21 Push tool 1765 08 to a stop and check the oil level according to page 17 NOTE Use hlins Front fork oil 1305 01 only 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 797 01 Adjust the preload compression and rebound CAUTION The top nut should only be tightened by hand into the fork leg The tightening force of the triple clamp will hold it in locked position 16 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
13. Ya Y amp T 19 Erre otro PA co 2 St Oo ar o e o 2 Lo r OT 0 e ro 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 la 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 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 No TE Tr Tool 1765 03 Tool 720 03 15
14. at is not ap proved by the vehicle manufacturer may affect the stability of your vehicle hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an hlins dealer or other qualified person for advice 2 Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this suspension kit If you have any questions regarding proper installation procedures contact an hlins dealer or other gualified person 3 The vehicle service manual must be referred to when installing the hlins sus pension 55 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 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 _ hlins Front Fork FG 470 This Super Bike front fork is an improved version of FG 370 with pressurised damp ing
15. 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 Spring pre load adjustment 17 mm wrench Increase spring pre load c Reduce spring pre load gt Compression adjustment Rebound adjustment Left Hand Fork Leg Right Hand Fork Le Tool 794 01 Tool 794 01 Clockwise turn closes increase rebound damping Counter clockwise turn opens reduced rebound damping Clockwise turn closes increase compression damping u Counter clockwise J gt turn opens reduced compression damping Counter clockwise turn opens reduced compression damping Clockwise turn closes increase compression damping Setting up your forks coe v 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 acco
16. der 18 00641 02 1 Washer 19 Shim stack comp See spec card 20 01447 02 1 Piston ring 21 02061 03 1 Piston rebound 22 Shim stack reb See spec card NA 23 00641 02 1 Washer 24 01674 01 4 Washer 25 01675 01 1 Nut Service tools Pos Part No Pcs Description 1 00727 02 1 Soft jaws one pair 2 00786 05 1 Inner tube tool 3 00786 07 1 Cartridge tube tool 4 01781 01 1 Gastool 5 00797 01 1 Top nut socket 6 01757 01 1 Attachment bar 7 01759 07 1 Dismantling bar 8 01759 08 1 Installing sleeve g 01758 04 1 Guide ring 10 00720 02 1 Measure pin 11 00720 03 1 Pin tool 12 04705 01 1 Spanner 13 01765 03 1 Pull up spring tool 14 01797 04 1 Seal head tool 15 02810 01 1 Pull up spring tool holder 16 00715 01 1 Screwdriver 23 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 10 Issued 06 07 26 hlins Racing AB Mattias Johansson majo Update Tiina Harakka
17. he 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 4 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 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 tripple 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 ian FFEGE EL ETT 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 reb
18. on 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 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 1305 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 Tighten torgue Loctite and Grease sjuiod dn 114 410g WN M S eseaih on Hun 109 9111907 Buiusnq 19ddn Ajuo puey Ag Buisnoy juawysnipy Buu x esealb eiuM 81190 ON Buiusnq 18901 pou 01 Japjoy uoisid uoenv iS re1ep uoisid ejquiesse 910499 SPS 9901 WN Ort Be x04 879 811007 WN 08 eqni 1apulj4o 072 9111907 WN SI 1euoisueixe poJ Jeus uoisid WN Oz JaIsnipe Buds 1joq 1euoisueixe poy
19. ound according to above instructions CAUTION The top nut should only be tightened by hand into the fork leg 6 Adjustment driver am Spring Preload tube UTion N SE a I T 2 1879 10 y YOOYD i Tool 797 01 Changing seals 1 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 It is important to use the correct grease in order to achieve optimum fork function No TE 7 CO Circlip C Washer 8 Apply some front fork oil 1305 01 to the inner tube surface and carefully mount the outer tube slide it completely down N A Be careful not to damage the fork seal 9 Repeat instructions 6 to 9 in Changing springs on page 6
20. rding to your bikes manual 1 Put your bike on a front stand and fit the hlins 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 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 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 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 Makea 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 t
21. system FG 470 is based on 4 years experience from factory road racing The pressurised damping system improves the 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 Hg 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 nennen 2 hlins front fork FG 470 Adjusters Setting up your forks Changing springs Changing seals Dismantling the forks Assembly of thie Torks retener p TAKA 12 Oil level adjustment Troubleshooting Technical information Spare parts lisb een ee 20 Service tools nennen 23
22. t the brakes off or when you get on the power e Rear end is too soft Put on a harder rear spring e Front end is too high Lower the front end by e This is caused by the fact that the fork is working pulling the fork legs through the triple clamps too low in the travel and reaches the progressive hard part at the end of the travel p As mentioned in the beginning the whole e Put on more pre load bike setup affects the front forks Try to s Cliange to aharder sping understand the feelings and work step by step e Ifa lot of stroke remains after riding drop the oil level See oil level chart NOTE e Make sure the front forks have no friction Our advice is to change only one thing ata 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 the 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 Technical informati
23. ughly change O rings if necessary and dry all parts with compressed air Notes 10 13 FI Ed Piston holder e Topout spring A S Sleeve Spacer O ring 1 N e l exons a i R i N Seal head N S o O ring O m Wii gt lt K Te neendle ei o 09400 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 J KA 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 Upper bushing O Lower bushing NON b O C 2nd Seal Attachment bar 1757 01 ue
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