Ohlins Exercise Bike FG 9700 User's Manual
Contents
1. Optional springs supplied 1596 10 10 0 N mm marking 10 1596 90 9 0 N mm marking 90 Optional springs 1596 85 8 5 N mm marking 85 1596 80 8 0 N mm marking 80 Oil Capacity Please see specification card CAUTION Use only hlins high performance ront fork fluid No 5 1305 01 Loctite glue 542 on Fork Bottom thread Tighten torque Triple Clamp bolt 15 18 Nm Grease hlins front fork grease 148 01 green grease Service interval Every 10 hours Notes p EFN 3 GIN aa 585 NG 23 Le Spare parts Fig Part No 1 01 00338 65 1202 01460 33 1 03 01438 02 1 04 01596 90 1 04 01596 10 1 04 01596 95 1 05 01689 02 1 06 01627 01 1 07 01626 01 1 08 01552 01 1 09 01524 01 1 10 01553 01 Tai 01565 01 00338 63 ES 01656 01 1 14 01525 02 01046 19 116 01240 01 01591 01 1 18 00430 04 leg 01564 01 1 20 00194 10 1221 01593 01 01593 02 22 01239 03 1 23 01666 01 01666 02 Service tools Part No 0787 04 0797 01 0786 03 1797 01 0794 01 1765 02 1766 01 Description O ring Preload tube Guide ring Spring 230 0 90 Spring 230 1 0 Spring 230 0 95 Fork leg outer Bushing Bushing Washer Seal Circlip Stroke indicator O ring Cylinder tube Fork leg inner Bolt Bolt Fender bracket Nut Fender bracket Sticker Caliper bracket LH Caliper bracket RH Bolt Fork bottom2. LH Fork bottom RH Description Cylinder tube tool cartridge Pin sleeve tool Inner tube tool T handle Hex key with spherical head Pull up top out spring tool Preload tube pusher Pieces Al AI Bl Al ININ AINA I INININININININININININI N Dia 46 mm 786 03 COMPR VALVE Spare parts Fig 2 01 2 02 2 03 2 04 2 05 2 06 2 07 2 08 2 09 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 18 2 19 2 20 2 21 2 22 2 23 2 23a 2 24 2 25 2 26 ay 2 28 2 29 2 30 2 31 2 32 2 33 2 34 2 35 2 36 2 37 2 38 2 39 2 40 2 41 2 42 2 43 2 44 2 45 2 46 2 48 2 49 2 50 2 51 2 52 2 53 2 54 2 55 2 56 2 57 2 58 2 59 2 60 2 61 01059 04 01059 05 01437 01 01403 01 01437 01 00338 22 01468 02 01437 01 01403 01 01404 01 01408 01 01473 01 00577 01 01467 01 01474 01 00884 04 01673 01 01469 05 01407 02 01648 01 01499 02 01649 01 01582 11 01580 01 01651 01 00110 01 01582 10 00438 28 01653 01 01585 01 01644 01 01508 01 00338 14 01508 01 01654 02 00530 16 01669 01 01672 01 01671 02 00530 22 02061 01 01447 02 00641 01 01674 01 01657 01 01473 02 00338 53 01242 05 01474 01 00884 02 00438 02 01658 02 01652 02 01670 01 00338 11 01669 01 00530 22 01671 01 01672 01 00120 01 01657 01 07280 05 Description Nut Nut Thrust washer Thrust needle bearing Thrust washer O ring Adjustment housing Thrust washer Thrust needle
3. bearing Thrust washer Adjustment driver Circlip O ring Adjustment screw Spring Ball Adjustment needle Adjustment screw Flat key Lock nut Circlip Stop screw Spacer Bump rubber Seal head Bushing Spacer O ring Sleeve Topout spring Shaft Back up ring O ring Back up ring Piston holder Shims Sleeve Spring collar Spring Shim Piston Piston ring Shim see spec card Washer Washer Nut Circlip O ring Adjustment needle Spring Ball O ring End piece Washer Shim see spec card Piston O ring Sleeve Shim Spring Spring collar Washer Nut Owner s manual Pieces MININININININININIAININININININIAINID NININI AINININ MININININININININIOJNI Ohlins distributors Motorcycles AUSTRALIA Steve Cramer Proucts BRAESIDE Tel 61 3 9587 1466 Fax 61 3 9587 2018 AUSTRIA Motopart Handelsges m b H WIEN Tel 43 1 667 6628 Fax 43 1 667 0696 CANADA S Hansen Racing Products EDMONTON Tel 1 403 466 8653 Fax 1 403 465 9483 CROATIA Moto ZIP trgovina d o o KRANJ Tel 386 64 268 515 Fax 386 64 268 514 DENMARK F I Motorcykler ApS SORO Tel 45 57 833 348 Fax 45 57 834 855 FINLAND Mauri Penttil Racing HYVINK Tel 358 19 437 100 Fax 358 19 489 872 FRANCE Ohlins France Arpajon Sur Cere Tel 33 471 481 534 Fax 33 471 642 593 GERMANY Zupin Mo
4. between braking and getting on power 1 Not enough rebound damping Put on more damping 2 Too much rebound damping If it at the same time feels harsh take off some rebound damping 3 Too much compression damping Also gives a harsh feeling Take off some compression damping The front end loses grip coming out of a corner 1 Not enough rebound damping Put on some more rebound damping 2 Too much preload Take off some preload 3 Rear end is too soft Put on a harder rear spring 4 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 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 damping force at the early Se EH yp A WAVES 2 22 iz 22227 22 zz msm aa an aa aa 2 TC k Oil level LLLLLML LLL LALLA ALAM EE LLL LLLL 0 LZ 7 SS d C
5. the vice and drain the oil 3 Pull up the outer tube and remove the seals 4 Fasten the inner tube on the fork bot tom in a vice Use soft jaws 5 Unscrew the seal head pos 24 page 7 from the cartridge tube and remove the piston rod unit use tool 1797 01 Drain the remaining oil 6 Hemove the complete compression valve use a 17 mm wrench 7 Remove the piston and the shims from the piston rod and compression valve Place the shims in their correct posi tion on the work bench 8 Clean all parts thoroughly and dry with 4 compressed air Assembly of the forks 1 Apply a thin layer of Ohlins green grease 148 01 on the scraper ring and on the sealing surfaces of the fork seal Install the seals in the outer tube Please note that it is important to use the correct grease in order to achieve optimum fork function 2 Install the piston and the shims on the piston rod and the compression valve Tighten the 6 mm lock nuts with a torque of 0 6 Nm Check the piston ring for damages Re place if necessary 3 Install the compression valve assem bly into the valve housing 4 Apply some front fork oil 1305 01 on the inner steel tube surface and install the outer aluminium tube Measure the correct amount of 1305 01 oil according to the specification card CAUTION Be careful not to damage the fork leg seals 5 Raise the outer tube approximately 120 mm and fill the oil Insta
6. 0 18 77 61 Heds Motor AB Boden Tel 0921 175 10 Fax 0921 162 20 Traction handling comfort and safety ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 E mail info ohlins se 07280 05 99 ed1 Teknisk Illustration AB OHL763 rm super bike front fork 99 01 500 ex
7. LERK ALLEL LKAL hihkthibittitibithbtiLiiLihtiitttd an a CLL LLLP d LAL LLL a PTL ee 2 EELER 72 7277122222732 Air spring characteristics Oil level 100 mm Oil level 110 mm A Oil level 120 mm Oil level 130 mm _ O ho LL e Stroke mm stage of the fork travel but will have a great effect at 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 forks harder When the oil level is lowered The air spring in the later half stage of travel is lessened and thus the front forks are softer The oil level works most effectively 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 in mm according to the figure with the fork fully compressed and with the spring mounted For the right STD level please see the specification card Technical information Fork length 730 mm Stroke 120 mm Free spring length 230 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 Spring preload adjustment 0 18 mm 0 18 turns Spring rate 1596 95 9 5 N mm marking 95
8. Racing manual Ohlins super bike front fork FG 9700 A itl 4 i 1 j jn 3 Including Setting up your fork Changing springs and seals Service the fork Trouble shooting Technical info Spare parts amp tools Traction handling comfort and safety Ohlins super bike front fork FG 9700 Hex 24 Hex 12 Contents Introduction 2 Setting up your forks Spring preload adjustment 3 Rebound adjustment Compression adjustment Changing springs Changing seals Dismantling the forks 4 Assembly of the forks Troubleshooting Oil level adjustment 5 Technical information Spare parts 6 Tools Safety signals Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED dt WARNING Failure to follow WARNING instruc tions could result in severe injury or death to the shock absorber operator a bystander or a person inspecting or repairing the shock absorber CAUTION A CAUTION indicates special precau tions that must be taken to avoid damage to the shock absorber NOTE A NOTE provides key information to make procedures easier or clear Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Intr
9. any Ltd TAIPEI 10422 Tel 886 2 5375 600 Fax 886 2 5631 357 TURKEY Demaks Motor Servis Hizmetleri A S ISTANBUL Tel 90 216 442 1580 Fax 90 216 442 2380 U K Harris Performance Prod Ltd HERTFORD Tel 44 1992 551 026 Fax 44 1992 587 052 USA and CANADA LeMans Corporation JANESVILLE WI 53547 Tel 1 608 758 1111 Fax 1 608 758 1144 service Pettersson Pro Suspension ANAHEIM CA 92807 Tel 1 714 630 4777 Fax 1 714 630 4788 service TUF Racing Products DEKALB IL 60115 Tel 1 815 756 3588 Fax 1 815 756 3528 MX amp Enduro steeringdampers Scotts Performance MC Products MONTROSE Tel 1 818 248 6747 Fax 1 818 248 4529 Ohlins Authorized Dealers in SWEDEN Claessons Motor AB Bromolla Tel 0456 230 30 Fax 0456 232 31 R G Motor AB Helsingborg Tel 042 16 96 60 Fax 042 16 18 15 DML Pro Bike Varnamo Tel 0370 271 00 Fax 0370 271 61 LEJ Motor AB Skovde Tel 0500 48 11 95 Fax 0500 46 17 14 Carlbarks Motor AB Kumla Tel 019 57 07 01 Fax 019 58 12 74 Beviks Motor AB Linkoping Tel 013 36 25 00 Fax 013 36 25 10 BIKE Trollhattan AB Trollhattan Tel 0520 700 75 Fax 0520 762 84 Stotdamparexperten AB Stockholm Tel 08 650 10 07 Fax 08 650 10 09 Schneiders MC AB Upplands Vasby Tel 08 590 310 80 Fax 08 590 725 53 MB Racing AB Vasteras Tel 021 81 17 77 Fax 021 81 17 78 Revelj Racing Hede Tel 0684 120 59 Fax 0684 122 75 Two Wheels Umea AB Umea Tel 090 187 595 Fax 09
10. ll the complete piston rod into the cartridge tube 6 Lightly tighten the seal head using tool 1797 01 7 Pump the piston rod up and down and the oil will be sucked into the cartridge tube Close the clickers and check the function 8 Pull the piston rod out as far as possi ble and close the compression valve screw completely clockwise 9 Go on with 8 to 13 according to page 3 Changing springs Trouble shooting We like to give a few examples which are common in Road Racing and how to solve them A 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 1 Put on more preload 2 Change to a harder spring 3 If a lot of stroke remains after riding drop the oil level See oil level chart 4 Make sure the front forks have no fric tion 5 Hear ride height is to high too much rear spring preload Lower the rear end by taking off preload from rear shock spring The front wheel is jumping during the last part of braking 1 If a lot of stroke remains the oil level is too high Lower the oil level 2 If the fork is bottoming put in harder springs and keep the oil level C The front end feels unpredictable and unsafe in the middle of the cor ner
11. oduction The Ohlins front forks use a Cartridge system for damping This gives a damp ing 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 ad just the characteristic of the fork to suit different tracks and riders For example a soft spring in combi nation with a small air gap high oil level gives a progressive action of the front forks For better understanding please re fer to our oil level chart A telescopic front fork is depending on a smooth friction free action Make sure your front forks are serv iced regularly and don t use strong sol vents such as brake cleaner to clean the front forks This will dry out the seals and steel tubes and cause friction Regularly put a little Ohlins grease 148 01 on the steel tube and work it in by pushing the forks up and down hlins Racing AB can not be held responsible for any damage to spare parts or person if the mounting main taining and servicing instructions are not followed exactly Also no guarantee can be given for the performance and reliability if these instructions are not followed Setting up your forks We would like to give you some basic guidelines how to set up your Ohlins front forks However you must remem ber 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
12. spring preload completely by turning the adjustment screw completely anticlockwise Use a 12 mm wrench Make a note of the number of turns Remove the two blue lock nuts 3 Carefully remove the adjustment hous ing CAUTION Do not damage the o ring and do not drop the flat key into the fork leg 4 Remove the preload tube 5 Slide the outer fork leg up until the top bushing is just above the inner leg Approx 140 mm from complete bot tom position This is to make sure there is no oil above the top bushing 6 Slide the outer tube completely down Fork seal touching fork bottom 7 Push the piston rod down so that it is in level with the top of the outer tube When measuring the oil level always have the spring installed Measure the oil level using the top of the outer tube as the zero mark Note the measurement 8 Remove the spring and tip the oil in a clean container 9 Remove the outer tube clean the seals and check for damaged if the seals are damaged remove and replace lf the seals are OK then apply with Ohlins grease green grease 148 01 10 Apply Ohlins fork oil on the seals and on the inner tube 12 Carefully mount outer tube slide com pletely down install spring and set the oil level 13 Go on with 9 to 13 according to page 3 Changing springs Dismantling the forks 1 Carry out 1 to 7 of page 3 Changing springs 2 Free the fork leg from
13. tment hous ing 7 Remove the preload tube and spring The free spring length see page 5 8 Install the new spring and check the oil level Install the tool 1765 01 on top of the preload adjustment screw Pull out the piston rod as far as possi ble and turn the compression adjust ment screw fully clockwise This will keep the piston rod in top po sition which will make the continued assembly easier 9 Install the preload tube Install the tool 1766 01 on top of the preload tube and fasten it below the edge of the preload adjustment screw pos 18 page 7 Remove the tool and continue the as sembling 10 Install the adjustment housing CAUTION The flat key must be guided in the slot of the adjustment housing The o ring must be greased or it might be damaged 11 Install the two blue nuts 12 Loosen the preload tube and bring it to its correct position in the adjustment housing Tighten the lower lock nut gently and then unscrew it 1 4 of a turn Tighten the upper gently against the lower nut Fasten the adjustment housing in the fork leg Make sure that the fork leg is fully ex tended when tighten the adjustment housing 13 Install the fork legs on the motorcycle and adjust the preload compression and rebound according to the above instructions Changing seals Put the fork legs upright for 15 minutes 1 Fasten the fork leg in a vice Use soft jaws 2 Unload the
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15. um adjustment range is 18 mm One turn on the adjustment screw will cause 1 mm change in spring preload Adjust so the front forks lowers 25 30 mm from the top unloaded position Rebound adjustment Adjust the rebound rate on the adjust ment screws positioned at the top cen tre of the front forks Use a hex key with a spherical head use tool 794 01 Adjustment range from closed valve clockwise until maximum open valve anticlockwise is 20 clicks Hecommended adjustment click from closed position see specification card Compression adjustment Adjust the compression rate on the lower part of the front forks compres sion valve Use a hex key with spheri cal head use tool 794 01 Adjustment range from closed valve clockwise to maximum open valve anticlockwise is 20 clicks Recommended adjustment clicks from closed position see specification card Changing springs 1 Loosen the screws that hold the fork legs in the upper triple clamps 2 Loosen the adjustment housings pos 7 page 7 about two turns use tool 797 01 3 Remove the fork legs from the motor cycle 4 Fasten a fork leg in a vice Use soft jaws 5 Unload the spring completely by turn ing the adjustment screw completely anticlockwise Use a 12 mm wrench Remove the blue locking nuts 6 CAUTION Do not damage the o ring and do not drop the flat key into the fork leg Carefully remove the adjus
16. your bikes manual 1 Put your bike on a front stand so you can fit the front forks Maximum torque on the bottom triple clamp and steering damper bracket if itis located on the diameter on the outer tube is 15 18 Nm Fit the front wheel and brakes 2 Unscrew the adjustment housing on top of the fork use tool 797 01 on both upper tubes and slide the fork up and down gentle to make sure everything works correctly 3 Assemble the adjustment housing again and set your initial preload of the spring by using a 12 mm socket until you get a static sag of 25 30 mm Each turn gives 1 mm in preload maxi mum preload is 18 mm 4 The best way to check the static sag is to put the bike on the ground in run ning condition Measure the distance between the bot tom of the outer tube to the fork bot tom Then lift the front end of the bike so the fork is fully extended Take the measurement again The dif ference between those two figures is static sag 5 The clickers are a bleed function separate for rebound and compression damping Rebound is on the top centre of the fork and compression at the bottom part of the fork You start to count from fully closed clockwise and set it to the recom mended click use tool 794 01 For recommended start setting please refer to the specification card Spring preload adjustment Using a 12 mm wrench turn the upper adjustment screw Maxim
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