Ohlins 07280-13 Workshop Manual

Brand: Ohlins

Model: 07280-13

Category: Motorcycles

Type: Workshop Manual

OWNER’S MANUAL

Öhlins Front Fork Superbike FGR 700

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.

Any reprinting or unauthorized use

without the written permission of

Öhlins Racing AB is prohibited.

Printed in Sweden.

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

etsu

Setting up your forks 4

itces

Recommended tools 6

Disassemble the Front Fork 7

Change the Spring 9

Change the Seals 10

evl

veR

Replace the Tubes 12

Disassemble the Piston Rod 13

Assemble the Front Fork 14

61 tnemtsujda leve

71 gnit

lbuor

Technical Information 18

Öhlins Front Fork FGR 700

Spare Parts List 19

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.

Top cap

Increase spring preload

Reduce spring preload

14 mm wrench

Adjusters

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.

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.

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

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)

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

Setting Up Your Front Forks

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 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

•

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

Öhlins Front Fork Oil

Öhlins Red Grease

Öhlins White Grease

rag

waste oil container

NOTE!

Check each section for the speciﬁ c tools

needed.

1 Disassemble the Front Fork

Remove the fork legs from the motorcycle.

Put the fork legs in upright position for

about 5 minutes to allow the oil to settle.

Fasten the fork leg in a vice. Use soft jaws.

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.

Loosen the top nut assembly. Use tool

00797-01.

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.

Remove the adjustment driver and the

spring. Use a wire with a hook and care-

fully pull out the preload tube.

Use tool 01797-04 and 01765-03 to

unscrew the seal head from the cartridge

tube. Remove the piston rod unit.

Drain all oil from the fork leg.

14 mm wrench

Tool 00797-01

19 mm wrench

14 mm wrench

Preload tube

Adjustment

driver

Spring

Tool

01797-04

Piston rod unit

Tool 01765-03

NOTE!

WARNING!

Disassemble the Reservoir

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.

Tool

00720-03

Tool

00720-02

2 Change the Spring

14 mm wrench

Release the spring preload completely

by turning the adjustment nut counter

clockwise as far as possible. Use a 14 mm

wrench or socket.

Loosen the screws that hold the fork legs

in the upper triple clamps.

Loosen the Top nut assembly from the fork

leg. Use tool 00797-01.

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.

Remove the adjustment driver and the

spring. Use a wire with a hook and care-

fully pull out the preload tube.

Check the oil level according to page 16.

NOTE!

Use Öhlins Front fork oil 01311-01 only.

Install the Preload tube, the new spring

and the adjustment driver.

Reinstall the top nut assembly to the piston

shaft. Tighten the jam nut to 20 Nm.

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

Preload tube

Adjustment driver

Spring

Check the oil level

01305-01

Tool 00797-01

CAUTION!

20 Nm

Tool 01765-03

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.

Circlip

Washer

Seal

NOTE!

WARNING!

Tire lever or

equivalent

4 Revalve

Release the gas pressure from the

reservoir according to chapter Disas-

semble the Front Fork, steps 9-14. Then,

continue below.

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.

Remove one valve, use a 17 mm wrench.

Make the necessary changes.

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.

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.

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.

Remove the outer tube

Use a heat gun to warm up the fork bot-

tom. Use tool 00786-05 to unscrew the

inner tube.

Remove the inner tube. Clean the threads

thoroughly from Loctite.

Install the new inner tube. Use Loctite 648

on the threads. Tighten the torque to

80 Nm.

Removing the Reservoir Tube

Use a heat gun to warm up the tube bot-

tom. Use tool 00786-07 to remove the

tube.

Remove the tube. Clean the threads thor-

oughly from Loctite.

Install the new tube. Use Loctite 222 on

the threads. Tighten the torque to 45 Nm.

Reinstall the outer tube.

Reinstall the front fork according to chapter

Assemble the Front Fork.

Tool

00786-05

Tool

00786-07

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.

Put the piston rod in a vice with soft jaws.

CAUTION!

Do not tighten the jaws, the piston rod can

be damaged.

Remove the piston, spring and sleeve in

one unit. Use a 16 mm wrench.

Remove the spacer and the o-ring.

Remove the seal head from the shaft.

Check the o-ring and the x-ring. Replace

them if necessary.

Use tool 00715-01 to put the x-ring in right

position. Use plenty of white grease on the

X-ring before installing it.

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.

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.

Tool 00715-01

X-ring

O-ring

7 Assemble the Front Fork

Assemble the Reservoir

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.

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.

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.

Tighten the seal head to 20 Nm. Use Seal

head tool 01797-04 and 01765-03.

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.

Reinstall the circlip. Make sure that it stops

in the intended groove.

Tool

00720-02

Assemble the Front Fork

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!

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.

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.

Tool 01797-04

Tool 02810-01

20 Nm

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

Troubleshooting

Below are a few examples of how to adjust

for the most common road holding prob-

lems in Road Racing driving.

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.

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.

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.

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.

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

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

04720-02 2

Seal

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

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

Brand: Ohlins

Model: 07280-13

Category: Motorcycles

Type: Workshop Manual

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Ohlins 07280-13 Workshop Manual

Ohlins 07280-13 Workshop Manual

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