Ohlins 07280-13 Workshop Manual

Ohlins
Brand
Ohlins
Model
07280-13
Category
Motorcycles
Type
Workshop Manual
OWNER’S MANUAL
Öhlins Front Fork Superbike FGR 700
1
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.
!
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.
NOTE!
Note indicates information that is of impor-
tance regarding procedures.
Introduction
All of Öhlins advanced suspension products
are adapted to the brand and model. This
means that length, travel spring action and
damping charac teristics, are tested individ-
ually just for the motorcycle that you have
decided to fit with Öhlins suspension.
Before installing
Öhlins Racing AB cannot be held re-
spon si ble for any damage whatsoever to
sus pen sion or vehicle, or injury to persons,
if the instruc tions for installing and main-
tenance are not fol lowed exactly. Similarly,
the warranty will be come null and void if
the instructions are not followed.
!
WARNING!
1. Installing a suspension, that is not ap-
proved by the vehicle man u fac tur er, may
affect the stability of your ve hi cle. Öhlins
Rac ing AB cannot be held responsible
for any per son al in ju ry or dam age what-
so ev er that may oc cur after installing the
sus pen sion.
2. Please study and make certain that you
ful ly un der stand the mount ing in struc tions
and the owner´s man u al before han dling this
suspension kit. If you have any questions
regarding proper in stal la tion pro ce dures,
contact an Öhlins deal er.
3. The vehicle service manual must be
re ferred to when installing the Öhlins sus-
pension.
NOTE!
Öhlins products are subject to continuous
improve ment and de vel op ment. Therefore,
although these in struc tions in clude the
most up-to-date in for ma tion available at
the time of print ing, there may be minor dif-
fer enc es between your sus pen sion and this
manual. Please con sult your Öhlins dealer
if you have any ques tions regarding the
con tents of the manual.
NOTE!
During storage and transportation, espe-
cially at high ambient temperature, some of
the oil and grease used for assembling may
run out and stain the packaging. This is in
no way detrimental to the product, wipe off
the excessive oil/grease with a cloth.
© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
!
2
The FGR700 Front Fork is the very es-
sence of front fork technology and is the
evolutionary result from the FG470, FG570
and FG670. The new, improved front fork
comes fully packed with technical solutions
from Öhlins MotoGP technicians.
The new FGR700 is a giant leap in the
evolution of high tech front fork systems. It
is pressurised as its predecessors but now
it is equipped with the latest TTX-technol-
ogy.
Features:
Consistent behaviour, immediate
response
Wide adjustment range with external
adjusters
Separated compression and rebound
function
NOTE!
Gas pressure should not be changed or
used as an alternative to adjust the damp-
ing.
•
•
•
In this manual
Öhlins Front Fork FGR 700 2
3 s
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Setting up your forks 4
5
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o
itces
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W
Recommended tools 6
Disassemble the Front Fork 7
Change the Spring 9
Change the Seals 10
1
1
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a
veR
Replace the Tubes 12
Disassemble the Piston Rod 13
Assemble the Front Fork 14
61 tnemtsujda leve
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Technical Information 18
Öhlins Front Fork FGR 700
Spare Parts List 19
3
This Öhlins superbike front fork is
equipped with the following external ad-
justers:
• Spring preload adjuster
• Rebound damping adjuster
• Compression damping adjuster
Spring preload adjustment
Adjust the spring preload by turning
the nut on top of the fork leg. Use a
14 mm wrench.
The adjustment range is 0-18 mm.
On the adjustment nut one turn will
change 1 mm in spring preload. Rec-
ommended static sag is 25-30 mm.
Rebound adjustment
Adjust the rebound damping by turn-
ing the screw at the fork bottom. Use
tool 00794-01.
The adjustment range from closed
valve (clockwise) until maximum
open valve (counter clockwise) is
20 “clicks”. Recommended adjust-
ment “click”, from closed position:
See specification card.
Compression adjustment
Adjust the compression damping by
turning the screw at the fork bottom.
Use tool 00794-01.
The adjustment range from closed
valve (clockwise) to maximum
open valve (counter clockwise) is
20 “clicks”. Recommended adjust-
ment “click”, from closed position:
See specification card.
1
2
3
R
C
2
3
Top cap
Increase spring preload
Reduce spring preload
14 mm wrench
1
Adjusters
4
Basic Guidelines
- how to set up your Öhlins front forks
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 ac-
cording to your vehicle service manual.
1
Put the motorcycle on a work stand and
install the Öhlins front fork. Consult your
vehicle service manual.
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.
Too high torque may deform the front fork
leg.
2
Set your initial spring preload, use a 14 mm
socket or wrench, until you get a static
sag of 25-30 mm. Each turn gives 1 mm in
preload, maximum preload is 18 mm.
Guidelines -
Setting the Spring Preload
3
The spring preload is very important since
it affects the height of the motorcycle and
the fork angle. Consequently, handling
characteristics can be changed, even
negatively.
Procedure
We recommend you to have an assistant
for this procedure.
1 Put the motorcycle on a stand.
2 Make sure that the shock absorber is fully ex-
tended.
3 Measure the distance from the lower edge of
the rear mud guard or from a point marked by a
piece of tape, immediately above the rear wheel
axle, to the wheel axle. (R1)
4 Make a similar measurement on the front axle, for
example, from the bottom of the upper fork crown
to the front wheel axle. Make sure that the front
fork is fully extended. (F1)
5 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. (R2, F2)
4
The measurements should not differ from
the following:
With rider:
Rear: 15-30 mm (R1-R2)
Front: 35-50 mm (F1-F2)
Increase spring preload
Reduce spring preload
14 mm wrench
Bike on a stand
Bike with rider on
3
2
Setting Up Your Front Forks
R1
R2
F1
F2
5
Work Section
Section Plan
Page
Recommended Tools 6
1 Disassemble the Front Fork 7
2 Change the Spring 9
3 Change the Seals 10
4 Revalve 11
5 Replace the Tubes 12
6 Disassemble the Piston Rod 13
7 Assemble the Front Fork 14
page 13
page 12
page 12
page 10
page 11
page 9
NOTE!
Read through the whole section and make
sure you understand all the steps in the
procedure before you begin
Make sure you have all the proper tools
needed for the section you are about to
work on before you begin
Clean all parts thoroughly after disassembly
Contact an Öhlins dealer if you have any
questions regarding the front fork
•
•
•
•
6
Tools
1 Vice with soft jaws
2 Wrench 14 mm
17 mm
19 mm
3 Allen key
4 Wire with hook
5 Heat gun
6 Teflon tape
7 Brass wire brush
8 Sleeve pin 00797-01
9 Seal head tool 01797-04
10 Pull-up tool 01765-03
11 Measure pin 00720-02
12 Pin tool 00720-03
13 Soft jaws clamp 00786-05
14 Soft jaws clamp 00786-07
15 Sharp screw driver 00715-01
16 Pull up holder tool 02810-01
17 Gas filling device 01781-01
Öhlins Front Fork oil 01311-01
Öhlins Red Grease 00146-01
Öhlins White Grease 00147-01
Loctite 648
Loctite 222
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Öhlins Front Fork Oil
Öhlins Red Grease
Öhlins White Grease
rag
waste oil container
NOTE!
Check each section for the specifi c tools
needed.
7
1 Disassemble the Front Fork
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.
Release the spring preload completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 14 mm
wrench or socket.
NOTE!
Do not use the preload adjuster to tighten
or loosen the top nut assembly.
4.
Loosen the top nut assembly. Use tool
00797-01.
5.
Remove the top nut assembly from the
piston shaft. Use a 14 mm wrench to the
top and a 19 mm wrench 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.
Use tool 01797-04 and 01765-03 to
unscrew the seal head from the cartridge
tube. Remove the piston rod unit.
8.
Drain all oil from the fork leg.
14 mm wrench
Tool 00797-01
19 mm wrench
14 mm wrench
2
3
4
5
6
7
Preload tube
Adjustment
driver
Spring
Tool
01797-04
Piston rod unit
Tool 01765-03
8
8
NOTE!
!
WARNING!
Disassemble the Reservoir
9.
Remove the screw and the o-ring from the
reservoir end cap.
NOTE!
Before releasing the gas pressure, count
and note the adjuster settings. Also check
that the gas pressure is correct. Then,
the adjusters should be set in a fully open
position.
!
WARNING!
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.
10.
Release the nitrogen gas by inserting an
injection needle into the reservoir end cap
through the rubber valve.
11.
Remove the circlip.
12.
Remove the reservoir end cap. Use tool
00720-03.
13.
Remove the gas piston, use tool 00720-02.
14.
Drain the oil from the reservoir by remov-
ing the compression valve. Use a 17 mm
wrench.
10
11
9
Tool
00720-03
Tool
00720-02
12
14
13
9
2 Change the Spring
12
14 mm wrench
1.
Release the spring preload completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 14 mm
wrench or socket.
2.
Loosen the screws that hold the fork legs
in the upper triple clamps.
3.
Loosen the Top nut assembly from the fork
leg. Use tool 00797-01.
4.
Remove the Top nut assembly from the
piston shaft. Use a 14 mm wrench to the
top and a 19 mm wrench 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 16.
NOTE!
Use Öhlins Front fork oil 01311-01 only.
7.
Install the Preload tube, the new spring
and the adjustment driver.
8.
Reinstall the top nut assembly to the piston
shaft. Tighten the jam nut to 20 Nm.
9.
Reinstall the top nut into the fork leg,
with the front wheel off the ground (use
tool 00797-01). Tighten the upper triple
clamps and adjust the preload according
to the instructions on page 3.
CAUTION!
The top nut should only be tightened by
hand into the fork leg.
Tool 00797-01
19 mm wrench
14 mm wrench
8
9
Preload tube
Adjustment driver
Spring
5
6
Check the oil level
01305-01
Tool 00797-01
CAUTION!
20 Nm
3
4
Tool 01765-03
10
1st, Circlip
2nd, Seal
3rd, Washer
3 Change the Seals
Remove the fork leg from the motorcy-
cle. Remove the top nut and piston rod
unit according to steps 1-14 in chapter
Disassemble the Front Fork. Then, con-
tinue below.
15.
Remove the outer tube, clean the seal
and check the condition. If the seal is in
good condition apply some red grease
(00146-01) to it. A damaged seal must be
replaced!
16.
First remove the circlip, then the seal and
finally the washer.
17.
Apply a thin layer of Öhlins red grease
(00146-01) to the washer and to the seal-
ing surfaces of the fork seal. Install the seal
and the washer into the outer tube. Install
the circlip into the groove.
NOTE!
It is important to use the correct grease in
order to achieve optimum fork function.
18.
Apply some front fork oil (01311-01) to the
inner tube surface and carefully reinstall
the outer tube on the fork leg (slide it com-
pletely down).
!
WARNING!
Be careful not to damage the fork seal!
19.
Reinstall the front fork leg to the motor-
cycle according to chapter Assemble the
Front Fork, step 1-13.
15
18
16
17
Circlip
Washer
Seal
NOTE!
!
WARNING!
Tire lever or
equivalent
11
4 Revalve
Release the gas pressure from the
reservoir according to chapter Disas-
semble the Front Fork, steps 9-14. Then,
continue below.
1.
Put the fork leg, in horizontal position, in a
vice with soft jaws.
NOTE!
Do not mix up the two valves, they must
be installed in their intended valve housing.
We recommend you to remove one valve at
a time to keep them apart.
2.
Remove one valve, use a 17 mm wrench.
3.
Make the necessary changes.
4.
Add some front fork oil into the valve hous-
ing. Reinstall the valve. Make the neces-
sary service on the other valve according
to the same procedure.
5.
Add gas pressure to the reservoir accord-
ing to chapter Assemble the Front Fork.
NOTE!
Do not mix up the valves, they must be
installed in their intended valve housing.
Also, keep in mind how the parts in the
valves were installed.
1
2
12
5 Replace the Tubes
Remove the fork leg from the motorcy-
cle. Remove the top nut and piston rod
unit according to steps 1-14 in chapter
Disassemble the Front Fork. Then, con-
tinue below.
1.
Remove the outer tube
2.
Use a heat gun to warm up the fork bot-
tom. Use tool 00786-05 to unscrew the
inner tube.
3.
Remove the inner tube. Clean the threads
thoroughly from Loctite.
4.
Install the new inner tube. Use Loctite 648
on the threads. Tighten the torque to
80 Nm.
Removing the Reservoir Tube
5.
Use a heat gun to warm up the tube bot-
tom. Use tool 00786-07 to remove the
tube.
6.
Remove the tube. Clean the threads thor-
oughly from Loctite.
7.
Install the new tube. Use Loctite 222 on
the threads. Tighten the torque to 45 Nm.
8.
Reinstall the outer tube.
9.
Reinstall the front fork according to chapter
Assemble the Front Fork.
1
2
Tool
00786-05
5
Tool
00786-07
8
13
16 mm Wrench
Piston
Topout spring
Sleeve
Spacer
O-ring
6 Disassemble the Piston Rod
Remove the fork leg from the motorcy-
cle. Remove the top nut and piston rod
unit according to steps 1-7 in chapter
Disassemble the Front Fork. Then, con-
tinue below.
1.
Put the piston rod in a vice with soft jaws.
CAUTION!
Do not tighten the jaws, the piston rod can
be damaged.
2.
Remove the piston, spring and sleeve in
one unit. Use a 16 mm wrench.
3.
Remove the spacer and the o-ring.
4.
Remove the seal head from the shaft.
5.
Check the o-ring and the x-ring. Replace
them if necessary.
6.
Use tool 00715-01 to put the x-ring in right
position. Use plenty of white grease on the
X-ring before installing it.
7.
Wrap some teflon tape around the shaft
thread to protect the seal and O-ring
from damages. Apply some red grease
00146-01 to the tape and the shaft end.
Install the seal head and the O-ring back
on the shaft.
8.
Use a brass wire brush to clean the piston
rod from tape. Install the o-ring, spacer,
sleeve, topout spring and piston. Tighten
the piston to a torque: 8 Nm. Use a 16 mm
wrench.
1
3
2
Tool 00715-01
X-ring
O-ring
6
7
8
14
7 Assemble the Front Fork
Assemble the Reservoir
1.
Pour Öhlins Oil Front Fork Oil 01311-01
to the top edge of the reservoir. Carefully
continue to fill until the oil level is the same
in the reservoir and the cylinder tube.
2.
Push the gas piston, with the teflon band
and O-ring installed, to the reservoir bot-
tom without allowing it to be pushed back
over the circlip groove. Make sure that
there is no air between the piston and the
oil. Use tool 00720-02.
3.
Install 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 02810-01 on
tool 01765-03 to keep the contraction.
Assemble the complete piston rod into
the cartridge tube and tighten it by hand
(3-4 turns).
NOTE!
Make sure that the gas piston is in the bot-
tom of the reservoir.
4.
Tighten the seal head to 20 Nm. Use Seal
head tool 01797-04 and 01765-03.
5.
Check the O-ring on the reservoir end
cap. Replace if necessary. Apply some red
grease on the O-ring and push the reser-
voir end cap into the chamber. Use tool
00720-03.
6.
Reinstall the circlip. Make sure that it stops
in the intended groove.
1
2
Tool
00720-02
3
4
5
6
15
Assemble the Front Fork
7.
Once again contract the top out spring us-
ing tool 02810-01, tool 01765-03 and tool
01797-04
NOTE!
Nitrogen (N2) gas. Use pressure gauge
(01781-01)
!
WARNING!
Use of infl ammable gas for pressurising
the shock absorber can be hazardous. Use
nitrogen gas (N2) only!
8.
Check the gas pressure stipulated in the
spec. card. Dip the needle of the gas tool
(01781-01) in red grease and insert the
needle 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
fl uid.
9.
Screw the gas filler screw with O-ring.
Remove tool 02810-01 and tool 01797-04
to release the top-out spring.
10.
Push tool 01765-03 to a stop and check
the oil level according to page 16.
NOTE!
Use Öhlins Front fork oil 01311-01 only.
11.
Reinstall the Preload tube. Install the spring
and the adjustment driver.
12.
Reinstall the top nut assembly to the piston
shaft. Tighten the jam nut to 20 Nm.
13.
Reinstall the top nut into the fork leg. Use
tool 00797-01. Adjust the preload, com-
pression and rebound.
CAUTION!
The top nut should only
be tightened by hand
into the fork leg.
7
8
9
Tool 01797-04
Tool 02810-01
10
11
12
20 Nm
13
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.
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 reduced, 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.
NOTE!
Adjust the oil level in mm according to the
fi gure with the fork leg fully compressed.
For the right oil-level, please see the speci-
fi cation 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.
Check the oil level
Öhlins front fork fl uid 1311-01
Push to a stop,
use tool 1765-03
17
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.
• Put on more preload.
• Change to a harder spring.
• If a lot of stroke remains after riding, drop the oil
level. See oil level chart.
• Make sure the front forks have no friction.
• Rear ride height is to high, too much rear spring
preload.
• Lower the rear end by taking off preload from rear
shock spring.
2.
The front wheel is jumping during the last
part of braking.
• If a lot of stroke remains, the oil level is too high.
Lower the oil level.
• If the 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).
• Not enough rebound damping. Put on more
damping.
• Too much rebound damping. If it at the same time
feels harsh, take off some rebound damping.
• 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.
• Not enough rebound damping. Put on some more
rebound damping.
• Too much preload. Take off some preload.
• Rear end is too soft. Put on a harder rear spring.
• 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!
We advise to change only one thing at a
time and do everything step by step.
1
4
18
Technical Information
Service Intervals
This product is designed for racing use
only.
Recommended service every 10 hours.
Disposal
Discarded products should be handed over
to an authorized Öhlins Service Centre for
proper disposal.
Front Fork length 740 mm
Stroke 130 mm
Free spring length 260 mm
Recommended setting
Compression 15 clicks
Rebound 12 clicks
Spring preload 4 turns
from closed position
Range 0-18 mm (0-18 turns)
Spring rate
04744-95 9.5 N/mm (mark -95)
Optional springs supplied
04744-10 10.0 N/mm (mark -10)
04744-90 9.0 N/mm (mark -90)
Optional springs available
04744-85 8.5 N/mm (mark -85)
04744-80 8.0 N/mm (mark -80)
Oil capacity
Please see specification card
Use Öhlins high performance front fork
fluid no. 5 only 01311-01
Torque
Lower triple clamp bolt 12-15 Nm
Upper triple clamp bolt 18-22 Nm
Grease
Öhlins Front Fork
Red Grease 00146-01
White Grease 00147-01
1 - - Top nut assembly See page 21
2 03316-01 2 Spring support
3 04744-95
04744-10
04744-90
2
2
2
Spring
Option spring
Option spring
25.5/260/9.5
25.5/260/10.0
25.5/260/9.0
4 01438-04 4 Guide ring
5 01460-06 2 Preload tube
6 01900-06 2 Fork leg outer
7 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 01901-04 2 Rod extensioner
13 02302-08 2 Guide sleeve
14 01499-08 2 Circlip
15 01440-01 2 Bump rubber
16 01651-04 2 Seal head
17 01027-04 2 X-ring
18 00438-02 2 O-ring
19 01056-04 2 Bushing
20 00438-41 2 O-ring
21 - - Spacer See spec. card
22 01653-07 2 Sleeve
23 01585-01 2 Topout spring
24 02368-02 2 Shaft
25 00338-60 2 O-ring
26 02061-04 2 TTX-piston
27 00338-05 2 O-ring
28 01447-01 2 Piston ring
Spare parts list, FGR 700
Pos. Part No. Pcs. Description Type/remarks
19
1 -
2 -
3 -
4 -
5 -
4 -
7 -
8 -
9 -
10 -
11 -
- 12
- 13
- 14
- 15
- 16
- 17
- 18
- 19
- 20
- 21
- 22
- 23
- 24
6 -
- 25
- 26
- 27
- 28
Note! The number of pieces is
valid for 1 pair of Front fork legs
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Ohlins 07280-13 Workshop Manual

Ohlins
Brand
Ohlins
Model
07280-13
Category
Motorcycles
Type
Workshop Manual
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