Ohlins CANNONDALE FG 9910 User's Manual
Contents
1. 13 Spare parts 2299 X D 14 Safety signals Important information concerning safety is distinguished in this manual by the following notations The 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 pre cautions must be taken to avoid damage to the suspension NOTE This indicates information that is of importance with regard to procedures Kit contents Before installing the front fork please check the contents of the kit listed in the mounting instruction If anything is missing contact your Ohlins dealer NOTE During storage and transportation especially at high ambient tempera ture the oil and grease used for as sembling may run out inside the packing and damage the expanded polystyrene packing material This is not unusual and is in no way detri mental to the shock absorber Introduction Ohlins Racing congratulates you on your choice of front fork for your motocross bike All Ohlins products are designed with just one aim to win races To design a winner you need a concept starting with a unique know how You add engineering skill precision and the best material available The re sult is quality endurance and win ning performance Your new Ohlins2. F Can handle the first in a series of bumps but feels hard after a few more bumps Frontal grip insuffi cient in rough and bumpy turns Too much rebound damping V Decrease the rebound damping G Front end rebound too fast after a bump Front wheel grip insufficient in bumpy curves Not enough rebound damping or too much spring preload V Increase the rebound damping V Decrease the spring preload Rear suspension A Rear suspension stroke is not used to its capacity Suspension feels harsh Traction not satisfac tory in bumpy curves Suspension hard in general or too much compression damping too much spring pre load V Decrease the compression damping V Decrease the spring preload V Change to softer spring B Suspension is bottoming feels soft during the entire wheel travel opring too soft compression damp ing too low V Increase the compression damping V Change to harder spring C Suspension is bottoming feels harsh and sags down too much with the rider in the saddle Spring too soft or compression damping too low V Increase the spring preload check ride height 95 5 mm V Change to harder spring if the load is more than 100 mm V Increase compression damping Rear wheel jumps over small bumps during deceleration or when going downhill Traction not satisfactory in washboard curves Too much spring preload as the spring is probably too soft will cause the
3. Owners manual Ohlins motocross front forks FG 9910 Cannondale Including Setting up your bike Fine tuning Service the fork Trouble shooting Technical info Spare parts amp tools Traction handling comfort and safety m ADVANCED SUSPENSION TECHNOLOGY Ohlins motocross front forks FG 9910 Cannondale Ohlins Racing AB All rights reserved Any reprinting or unauthorised use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Contents Salty SIGINGISH aana 2 Leet ct ee 3 Rit 2 JM MEME 3 Before you start 3 Kil 2 6 fi 3 o aa 4 Recommended settings 4 Mounting instructions 4 Setting up the bike 4 Checking front sag 4 Checking rear sag 5 Checking front ride height 5 Checking rear ride height 5 Fine tuning the bike 5 Making adjustments 6 Oil level adjustment 6 Maintenance eeeese 6 Trouble shooting 7 Preload adjustment 8 Changing springs 9 Dismantling the front fork 10 Assembly of the front fork 11 Service tools ssss 13 Technical specifications
4. To make improvements using the adjusters it is important to understand the function of the front fork and the shock absorber and through testing learn how they effect the handling of your bike Make sure that you have the correct springs and the correct spring preload before making any adjustments And always start with the Ohlins recom mended settings NOTE See mounting instruction for recommended settings NOTE Higher click numbers give less damp ing force When making adjustments keep notes make adjustments one at a time and in small steps The adjusters should normally not be adjusted in steps of more than 2 clicks at a time and not outside the usable click range When you think you have made an improvement go back to what you started with and double check to be sure Pay attention to changes in conditions like tires temperatures etc 6 In general compression damping changes should be used to influence the bike s stability and response while rebound damping changes should be used to influence comfort and traction When you need more damping force you should mainly try to in crease compression damping and use as little rebound damping as pos sible This usually means that you gain comfort and performance in handling Oil level adjustment As the air trapped between the oil and the top nut acts as an air spring a change in oil level will effect the damping forces Not in the early
5. bly and drain the oil Pull up the scraper with a screwdriver release and re move the circlip CAUTION The fork legs have three fixed and one sliding bushing Be very careful when disas sembling the fork legs Fasten the fork leg horizon tally with soft jaws in a vice Use a hot air gun to warm up the outer leg where the bush ings are located The first bushing is located at the bottom end of the outer leg the second approximately 150 mm further up the leg Between them is a sleeve to maintain the distance Use the special tool 1702 02 to remove the bushings Install the tool in the top of the inner steel leg Screw the top cap onto the tool and install the cap in the outer leg Rotate the tool to press out the bushings If tool 1702 02 not is avaliable push the inner steel leg to the bottom and then pull it back quickly so that the fork is topping out hard Repeat this procedure until the seal and the bushings can be pulled out from the outer leg Q9 Q o 9 8 O 000600009 00 Remove the seals and bush ings and replace them with new ones Fasten the damper rod assem bly with soft jaws in a vice Remove all parts from the damper rod NOTE If the right order is lost use the specification card as a guide Put them in the right order on the bench Inspect all parts for wear and damage replace if necessary Clean all parts thoroughly Assem
6. compression adjuster is located at the bottom of the fork leg fig 1 the rebound adjuster at the top fig 2 Spring preload is adjusted with washers fig 3 and optional springs are available to suit different tracks and riders In the legs there are also air springs the air trapped above the oil that work together with the real spring You adjust the air spring by raising or lowering the oil level in the legs By using different combinations of springs and air springs you can alter the characteristic of the fork For example a soft spring in combination with a small air spring high oil level makes the fork progressive see Fine tuning the bike Before you start A WARNING Installing a front fork that is not ap proved by the vehicle manufacturer may affect the stability of your vehi cle Ohlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the front fork Contact an Ohlins dealer or other qualified person for advice Ohlins Racing AB can not be held responsible for any damage whatso ever to front fork 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 A WARNING Please study and make certain that you fully understand all the mounting instructions and the owner s manu als before handli
7. front fork is devel oped from experience gained during years of successful cooperation with the World Championship winning works motocross teams Spring rates and damping forces are developed just for your bike The design and the settings are conse quently the results of extensive test ing and no guesswork Ohlins shock absorbers and front forks have dominated the motorcycle scene for several years and have captured more World Championship titles than any other brand over 60 titles A well equipped network of author ised Ohlins service centres around the world with specially trained me chanics can help you with personally tuned settings service repairs and spare parts Design Ohlins new up side down USD front fork is designed to combine the advantages of comfortable safe conventional forks and rigid light USD forks The result is a unique combination of being rigid precise in corners and during hard braking yet comfortable forgiving when over landing and in big bumps Your new Ohlins USD front fork has aluminium outer legs and 46 mm steel inner legs with a polished tita nium nitride surface for lowest possi ble friction The legs also feature a completely new bushing design with two fixed and one sliding bushing The new USD fork features the Ohlins championship winning car tridge damping system The fork is fully adjustable with ex ternal adjuster for compression and rebound damping The
8. ride height A Put your bike on a stand Arrange the stand so that the rear wheel is off the ground and the rear suspension fully extended Measure the distance between the rear wheel axle and a point near the rear end of the seat for example a seat bolt fig 4 distance A Make a note of the measurement Race dressed sit on the bike straight above the foot pegs with the feet barely touching the ground Have somebody to measure between the same point as before fig 4 distance C C The difference of the two measure ments should be 100 10 mm CAUTION Do not try to alter ride height by alter ing the spring preload A new spring is needed D A stiffer spring is needed if the difference is more than 110 mm A softer spring if the difference is less than 90 mm Consult your Ohlins dealer for a spring of the right rate 2 E 3 9 o f ES D X RB lt 3 O WwW ao lt Should you still experience exces sive bottoming or that the bike feels much to stiff and suspension travel is not fully used harder softer than nor mal springs may be needed for the track you are testing on Consult your Ohlins dealer for ad vice Fine tuning the bike Learning how to use the adjusters will take time but you quickly appreciate them once you know the tricks Even the specialists sometimes need a specialist With the adjusters you optimize the suspension for your riding style and the track you a
9. spring to extend too fast V Change to a harder spring in order to achieve a balanced position using less spring pre load V Check the static sag and ride height Rear end kicks up over bumps with sharp edges but can handle bumps with round edges Compression damping too hard V Decrease the compression damping F Rear end becomes too low in series of bumps Traction not satisfactory in washboard type curves or when decelerating on washboard ground Rebound damping too slow V Decrease the rebound damping G Rear end very unstable Shock does not respond to adjustments Shock damping is gone caused of low gas pressure bad oil is used or components are broken in the shock absorber Service is needed V Gas filling required V Change shock oil V Repair or change the shock absorber Ur Ty Preload adjustment Put the bike on a stand and loosen the screws in the fork top crown that hold the fork legs NOTE On most MX bikes you have to take of the handle bar before you can unscrew the top cap Unscrew the top cap use a 24 mm wrench Put a box under the front wheel so that the springs are visible Loosen the top cap from damper rod extender and re move it Remove the spring support Install a new preload spacer to achieve the right static sag Fit the spring support top cap and the handle bar Tighten all screws For tightening torques please see your bike s wor
10. stage of fork travel but a great deal in the later stage A general description of how the oil level air spring effects the damping forces are shown in fig 5 The air spring gives the Ohlins USD fork a progressive spring rate preventing it from bottoming out hard By using different combinations of springs and oil levels air springs you can alter the characteristic of the fork and tailor it to suit different tracks and conditions CAUTION The oil level must be the same in both front fork legs Riding a bike with different oil levels will cause instability When the oil level is raised The air spring in the later half of travel is strong and thus the front fork hard When the oil level is lowered The air spring in the later half stage of travel is soft and thus the front fork soft Oil level 6 Oil level is measured from the top of the outer leg with the top nut of the fork fully compressed and no preload washer nor spring installed Oil level CAUTION Adjust the oil level with the fork leg fully compressed and no preload washer nor spring installed NOTE See mounting instruction for recommended oil level The oil level is measured from the top of the outer leg with the top nut off see fig 6 A change in oil level should be made in small steps We recommend a change of 5 mm at a time and not outside the range of 80 130 mm Maintenance Telescopi
11. 3 9 N mm 2328 41 4 1 N mm 2328 43 4 3 N mm 2328 45 4 5 N mm 2328 47 4 7 N mm Oil level See mounting instruction for recommended oil level Adjustment range 90 130 mm CAUTION Use only hlins high performance front fork fluid No 5 1305 01 Loctite glue 542 for fork bottom thread and cartridge top lid Tighten torque Triple clamp bolt See your bike s work shop manual Compression valve 45 Nm Base valve Cylinder tube lid cartridgetube 40 Nm Compression valve 8 mm nut 8 Nm Rebound valve 8 mm nut 8 Nm Grease Ohlins Front Fork grease 148 01 Green grease Service Intervals Every 20 hours 13 14 Spare parts Pos Ni O B Go PO 10 11 12 13 14 15 16 al 18 19 20 21 22 23 24 25 26 2 28 Part No 02338 01 01050 01 00338 59 02306 02 00438 17 02337 01 02319 01 02328 39 02324 02 02332 03 00329 02 02021 01 02325 01 02021 01 01552 01 02336 01 02015 01 02014 01 02339 01 02022 01 02315 83 02314 01 00438 30 02333 01 02333 02 02314 02 Pcs NO DO POT DO DO PO NO RB HJ SH PP DM PLDT DTP DP DPTDO DOD PO PO DO PO Description Type remarks Nut Screw O ring End cap O ring Spring support Spring washer see spec card Spring preload Spring see spec card Spring Outer tube Sticker Circlip Bush Sleeve Bush Washer Seal Circlip Scraper Cylinder tube Bush Fork leg in
12. ble the damper rod 1799 02 Remove the compression valve assembly from the fork bottom use a 17 mm socket Fasten the valve assembly with soft jaws in a vice Remove all parts from the valve body Put them in the right order on the bench Inspect all parts for wear and damage replace if necessary Clean all parts thoroughly Assemble the compression valve 1799 02 Assembling Apply a thin layer of Ohlins green grease 148 01 on the scraper ring and on the sealing surface of the fork seal Mount the scraper circlip fork seal Support ring and the bushings separated by the sleeve on the inner steel leg Fasten the outer leg with soft jaws in a vice Install the inner leg and mount the upper bushing with tool 1799 02 and the sleeve Mount the lower bushings Apply some Ohlins green grease on the seals Again use tool 1799 02 turn it around to install the seal in the outer leg Install the circlip and the scraper CAUTION Make sure the circlip is fitted correctly into the groove in the outer leg 11 Fasten the fork leg at the fork Notes bottom with soft jaws ina vice Install the compression valve assembly in the fork bottom Tightening torque 45 Nm Apply some front fork oil on the outer surface of the inner leg and push the outer leg up and down a few times Measure the correct amount of oil according to the specifi cation card First fill u
13. c front forks depend on a smooth friction free action Make sure your forks are regularly serviced Do not use strong solvents such as brake cleaner to clean the front forks This will dry out the seals and the steel tubes and cause friction or leakage After every race Clean externally and spray with an all purpose oil after washing with detergent Check externally for damage Put a little Ohlins green grease 148 01 on the steel tubes and work it in by pushing the fork up and down Every 20 hours Dismantle the fork and check all parts for wear and damage replace if necessary see page 10 General handling set up A Front end falls into the curves over steering especially in sand Steep front fork angle Front end too low in comparison to rear end V Increase the front fork compression damping V Change to harder springs V Lower fork leg approximately 5 mm in the triple clamp Front end ploughs understeers Shallow front fork angle Front end too high in comparison to rear end V Decrease the front fork compression damping V Raise the fork legs approximately 5 mm in the triple clamp V Change to softer fork springs C Front end unstable at high speed unstable when accelerating out of curves Front fork angle too steep Front end too low in comparison to rear end V Lower the fork legs approxi mately 5 mm in triple clamp V Change the front fork springs to harder ones Front en
14. d unstable during decel eration Front fork angle too steep during braking Front end too low or rear end too high V Increase the oil level in the front fork V Change to harder fork springs V Increase the front fork compression damping Front suspension A Front fork travel is not used to its full capacity Harsh feeling front wheel grip is not satisfactory in bumpy turns Suspension too hard V Decrease the front fork compression damping V Change to softer springs Suspension bottoming too soft during entire travel Spring too weak or compression damping too soft V Increase oil level 5 mm V Increase compression damping V Change to stiffer springs C Suspension bottoming but can handle smaller bumps Damping force not progressive enough V Increase the oil level Can handle smaller bumps but is too hard during the last part of the travel Damping force is too progressive V Decrease the oil level Front end feels low initially feels soft but is not bottoming The initial spring rate is too soft or spring preload is too low V Increase the spring preload Feels harsh over small bumps but using full wheel travel Too much spring preload or too much compression damping V Increase the oil level or change to softer springs V Decrease the compression damping V Decrease the spring preload v Clean the oil seals and scrapers Use Ohlins grease 148 01 for regreasing
15. ety OHLINS 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 Cannondale Teknisk Illustration AB OM motocross front fork 99 12 400 ex
16. gs from the bike according to the work shop manual CAUTION 1 The outer legs both left and right should be adjusted evenly in the fork crown 2 The Ohlins fork legs feature grooves on top of the outer fork legs to make adjustment of the fork height easier The distance between the grooves is 4 mm B Fit the Ohlins front fork legs For recommended front fork mounting height see mounting instruction C Fit the brake components and the front wheel according to the work shop manual Tighten all screws For maximum torque please see your bike s work shop manual Setting up the bike We would like to give you some basic guidelines how to set up your bike with your new Ohlins front fork However remember that the front fork is just one part of your motorcy cle and to get the fork to work prop erly the whole motorcycle has to be set up according to standards Please follow the instructions be low see also your bike s work shop manual Your new front fork is dialled in to the Ohlins recommended settings for your bike The same goes for the rear shock absorber if you are using an Ohlins unit All settings are based on a bike and a rider of normal weight Depending on your own and your bike s actual weight minor differ ences between the Ohlins recom mended settings and the settings you achieve may occur Therefore it is always wise to start the setting up by checking The sag effects not just on
17. k shop manual Changing springs Loosen the screws that hold the fork legs in the upper fork crown With the fork leg still tightened in the lower fork crown unscrew the top cap use a 24 mm wrench Loosen the screws that hold the fork legs in the lower fork crown Remove the fork legs from the motorcycle Fasten the fork leg with soft jaws in a vice and loosen the lock nut on the top of the fork cap Remove the top cap from the damper rod extender use a 16 and 24 mm wrench Hemove the spring support the preload washer and the spring For free spring length see tech nical information on page 13 NOTE Closing the compression and the rebound valves will keep the damper rod extended making it easier to install the new spring Pull out the damper rod as far as possible Close the compression and the rebound valve clockwise Install the spring and the preload washer Install the spring support fork top cap and the lock nut Tighten the top cap and the lock nut against each other use a 16 and 24 mm wrench Adjust the compression and the rebound valves according to specification card Fit the fork legs on the motorcy cle For tightening torques please see your bike s work shop manual 1797 01 Dismantling Perform steps a d Changing springs on page 9 Loosen the bush head on top of the cartridge tube with tool 1797 01 Lift up the damper rod assem
18. ly the suspension but also the rake of the front fork and therefore the overall behaviour of the bike Checking front static sag A Put your bike on a stand Arrange the stand so that the front wheel is off the ground and the front fork fully extended Measure the distance between the upper fork crown and the front wheel axle fig 4 distance A Make a note of the measurement C Remove the stand With the wheels on the ground measure the distance again fig 4 distance B The difference of the two measure ments is the static sag D The static sag should be 30 10 mm E If the static sag is Jess than 20 mm you need to reduce spring preload If the static sag is more than 40 mm you need to increase spring preload F opring preload is adjusted with spacers see Preload adjustment on page 8 Maximum allowed spring preload is 13 mm If you need to preload the springs more than 13 mm we recommend you to change to a stiffer spring Checking rear static sag A Put your bike on a stand Arrange the stand so that the rear wheel is off the ground and the rear suspension fully extended Measure the distance between the rear wheel axle and a point near the rear end of the seat for example a seat bolt fig 4 distance A Make a note of the measurement C Hemove the stand With the wheels on the ground measure the distance again fig 4 distance B The difference of the two measure ments is the s
19. ner Screw O ring Bottom piece CN left Bottom piece CN right Screw See next page Fig A See next page sep drawing Fig A Spare parts Pos Part No 01473 02 00338 53 02321 02 01248 01 00884 04 02366 12 00338 76 02301 03 02302 03 02303 01 02304 01 00131 05 01499 01 02305 03 02059 01 00338 19 00110 01 02340 01 02307 01 02063 02 00438 31 02356 03 02322 01 02320 03 01149 01 00530 22 02335 01 01447 02 00153 01 00430 05 01473 02 00338 53 01242 05 01248 01 00884 04 02054 02 00438 02 02334 01 00438 03 00530 21 01149 01 00153 01 00430 05 Pcs MINIMNININININININININI NINI NINININININ BDO DO DO PO DOT PO POT RY POTD DO DO PO DO DO NO PO POT PO NO PO POT POL DO PO Description Type remarks Circlip O ring Adjustment screw Spring Ball Adjustment rod O ring Needle housing Guide sleeve Sleeve Hydraulic stop Circlip Circlip Cylinder tube cap Bushing holder O ring Bush Washer Shaft Spring O ring Rebound needle Spring Piston holder Shims see spec card Wave washer see spec card Shims Rebound piston Piston ring Shims see spec card rebound Clamp washersee spec card rebound Washer Nut Circlip O ring Adjustment needle Spring Ball End piece O ring Clamp washer see spec card Shims see spec card Compression piston O ring Shims Wave washer Washer Nut 15 Traction handling comfort and saf
20. ng this front fork kit If you have any questions regarding proper installation procedures con tact an Ohlins dealer or other quali fied person A WARNING The vehicle service manual must be referred to when installing the Ohlins front fork Marking All Ohlins front forks are marked You will find the part number on the inside of the fork bottom Your Ohlins front fork has the fol lowing marking FG 9910 Cannondale Recommended settings The front fork in your kit is adjusted to the Ohlins recommended setting for your bike see Making adjust ments We advise you to use this as your start setting Compression adjuster 1 The compression adjuster is located at the bottom of the fork leg Rebound adjuster 2 The rebound adjuster at the top of the fork leg Preload adjustment Za v 3 Spring preload is adjusted with washers and optional springs are available 4 Mounting instructions A WARNING 1 It is advisable to have an Ohlins dealer or a qualified mechanic to fit your front fork kit 2 To install the kit you need your motorcycle s work shop manual 3 When working on your motorcycle support it securely so it does not fall Over The hlins front fork is designed to fit your bike s standard triple clamps and to use the standard brake com ponents and wheel A Put your bike on a stand and remove the front wheel the front brake components and the fork le
21. p the cartridge tube then raise up the outer leg about 250 mm and add the remaining oil Install the damper rod assem bly into the cartridge tube Use Lotite 542 on the car tridge top lid Tighten with tool 1797 01 Tightening torque 40 Nm Pump the damper rod up and down a few times to check that there is no air left Pull out the damper rod as far as possible and close the compression and the rebound valves Install the spring and the preload spacer Install the fork top cap and the lock nut Tighten the top cap and the lock nut against each other use a 16 and 24 mm wrench Fit the fork legs on the motor cycle For tightening torques please see your bike s work shop manual Adjust the compression and the rebound valves according to the specification card MSs Service tools Pos Part No Description 1 1799 02 Bushing seal mounting tool 2 0786 03 Inner tube tool 3 1797 01 Tool cylinder tube lid 4 0787 03 Cylinder tube tool cartridge 5 1702 02 Bushing remover tool Technical specifications Rebound and compression adjustment Refer to mounting instruction for set up data Maximum open rebound and compression valve 20 clicks Free Spring Length All forks 467 mm service limit 460 mm Spring preload Maximum allowed adjustment range 3 13 mm with washers Spring rate All forks 2328 45 4 5 N mm Optional spring rate 2328 39
22. re competing on The same basic guide lines go for both the front fork and the rear shock absorber Too much compression damping will give you a harsh ride as your bike jumps along the track With too much rebound damping your bike will have difficulties with several bumps in a row The suspen sion will not extend fast enough be tween bumps your bike will ride lower and lower and eventually the suspension will bottom External adjusters On the Ohlins front fork the adjusters are bleed valves totally separated from each other The compression bleed valve con trols the flow in the cartridge tube during the compression stroke the rebound bleed valve the flow during the rebound stroke CAUTION Using too much force when closing the adjusters will destroy important sealing surfaces Air spring el oii level 100 mm eloii level 110 mm ml oi level 120 mm Al oil level 130 mm 5 A change in oil level will effect the damping forces not in the early stage of fork travel but a great deal in the later stage Both the adjusters have a normal right hand thread Click position zero 0 is when the adjusters are turned clockwise to fully closed The adjustment range from fully closed until maximum open valve anticlockwise is 20 clicks In order not to click in the wrong direction always first close the ad juster then dial in the new setting Making adjustments
23. tatic sag Setting up the bike 4 Checking sag and ride height Front sag A B 30 10mm Front ride height A C 5024 10mm Rear sag A B 30210mm Rear ride height A C 1004 10mm NOTE Refer to mounting instruction for more specific set up data D The static sag should be 30 10 mm E If the static sag is Jess than 20 mm you need to reduce spring preload If the static sag is more than 40 mm you need to increase spring preload F Adjust the spring preload according to your rear shock mounting instruc tion Checking front ride height A Put your bike on a stand Arrange the stand so that the front wheel is off the ground and the front fork fully extended Measure the distance between the upper fork crown and the front wheel axle fig 4 distance A Make a note of the measurement Race dressed sit on the bike straight above the foot pegs with the feet barely touching the ground Have somebody to measure between the same point as before fig 4 dis tance C C The difference of the two measure ments should be 50 10 mm CAUTION Do not try to alter ride height by alter ing the spring preload New springs are needed If you need to change the springs see Changing springs on page 9 Stiffer springs are needed if the difference is more than 60 mm Softer springs if the difference is less than 40 mm Consult your Ohlins dealer for the right rate Checking rear
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