Ohlins FG 470 User Manual
Owner’s Manual
Öhlins Superbike Front Fork FG 470
Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:
!
This 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 suspension, or to bystanders.
CAUTION!
Caution indicates that special precautions
must be taken to avoid damage to the
suspension.
NOTE!
This indicates information that is of importance with regard to 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 individually just for the motorcycle that you have
decided to fit with Öhlins suspension.
! 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 fi t ting the sus pen sion.
Contact an Öhlins deal er or oth er qual i fi ed
person for advice.
2. Please study and make certain that you
ful ly un der stand all the mount ing in struc tions
and the owner´s man u als 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 or other qual i fi ed
per son.
3. The vehicle service manual must be
re ferred to when installing the Öhlins suspension.
NOTE!
Öhlins products are subject to con tin u al
improve ment and de vel op ment. Con se quent ly, 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 with regard to the con tents of the manual.
Before installation
Öhlins Racing AB can not 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 fitting and main tenance
are not fol lowed exactly. Similarly, the
warranty will be come null and void if the
instructions are not ad hered to.
© 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
NOTE!
During storage and transportation, es pe cial ly at high ambient tem per a ture, the oil
and grease used for as sem bling may run
out inside the pack ing and dam age the expanded pol y sty rene pack ing ma te ri al. This
is not unusual and is in no way det ri men tal
to the suspension.
Öhlins Front Fork FG 470
This Super Bike front fork is an improved
version of FG 370 with pressurised damping system. FG 470 is based on 4 years
experience from factory road racing. The
pressurised damping system improves the
front fork function at high frequency movements. The immediate damping responses
improve the tyre feeling and also give more
possibilities for adjustments. Of course
the combination of spring and air-gap (oil
level*) still gives a possibility to adjust the
characteristic of the fork to suit different
tracks and riders.
For example a soft spring in combination
with a small air-gap (high oil level) gives a
more progressive action of the front forks.
NOTE!
Gas pressure should not be changed or
used as an alternative to adjust the damping.
For better understanding, please refer to
our oil level chart see page 17.
A telescopic front fork is depending on a
smooth friction-free action. Make sure your
front forks are serviced regularly and don’t
use strong solvents such as brake cleaner
to clean the front forks. This will dry out the
seals and cause friction.
For tighten torque, loctite and grease see
page 19.
Contents
Before installation
Öhlins front fork FG 470
...........................................................................4
Adjusters
Setting up your forks
Changing springs
Changing seals
Dismantling the forks
Assembly of the forks
Oil level adjustment
Troubleshooting
Technical information
Spare parts list
Service tools
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*
Front fork 470 is equipped with an external reservoir, pressurized
with nitrogen. A dividing piston separates the oil from the gas.
3
Adjusters
Your Öhlins super bike front fork is provided with the following external adjusters:
• Spring pre-load adjuster
• Rebound damping adjuster.
• Two type of compression
damping adjuster:
- Reservoir valve adjuster in the
lower part of the fork leg.
- Main valve bleed circuit.
NOTE!
The rebound damping adjuster is located at
the top of the right hand fork leg. The Main
valve bleed circuit (compression adjuster) is
located at the top of the left hand fork leg.
Spring pre-load adjustment
Use a 17-mm wrench to turn the upper
adjustment screw. The adjustment range
is 0-18mm. On the adjustment screw one
turn will change 1mm in spring pre-load.
Recommended static sag is 25-30 mm.
Compression adjustment main valve.
Adjust the compression damping on the
adjustment screw positioned at the top of
the left hand fork leg. Use a hex key with
spherical head (use tool 794-01).
Compression adjustment reservoir valve
(Base valve)
Adjust the compression damping (shaft
displacement) on the lower part of the fork
legs. Use a normal screwdriver. Adjustment
range from closed valve (clockwise) to
maximum open valve (counter clockwise)
is 20 “clicks”. Recommended adjustment
“clicks”, from closed position:
See specification card.
Spring pre-load adjustment
17 mm wrench
Increase spring pre-load
Top cap
Reduce spring pre-load
Compression adjustment
Left Hand Fork Leg
Clockwise turn
closes = increase
compression
damping
Tool 794-01
Rebound adjustment
Right Hand Fork Leg
Clockwise turn
closes = increase
rebound damping
Tool 794-01
Adjustment range from closed valve
(clockwise) to maximum open valve
(counter clockwise) is 20 “clicks”. Recommended adjustment “click”, from closed
position: See specification card.
Rebound adjustment
Adjust the rebound damping on the adjustment screw positioned at the top centre of
the right hand fork leg. Use a hex key with
a spherical head (use tool 794-01).
Adjustment range from closed valve (clockwise) until maximum open valve (counter
clockwise) is 20 “clicks”. Recommended
adjustment “click”, from closed position:
See specification card.
4
Counter clockwise
turn opens = reduced
compression damping
Compression adjusment reservoir valve (Base valve))
Counter clockwise turn opens =
reduced compression damping
Screwdriver
Counter clockwise
turn opens = reduced
rebound damping
Clockwise turn closes =
increase compression damping
Setting up your forks
F1
R1
A-D. Bike on a stand
R2
E. Bike on the ground F. Bike with rider on
Here is some basic guidelines, how to set
up your Öhlins front forks. However you
must remember that the front forks are just
one part of your motorcycle and to get it to
work properly, the whole motorcycle has to
be set up according to your bikes manual.
1
Put your bike on a front stand and fit the
Öhlins front fork.
NOTE!
The lower triple clamp must not be tightened to more than 12-15 Nm. This is also
important for the steering damper bracket,
when located around the upper front leg.
To high torque might deform the front fork
leg.
2
Set your initial pre-load of the spring, by
using a 17mm socket or wrench, until you
get a static sag of 25-30 mm. Each turn
gives 1mm in pre-load, maximum pre-load
is 18mm.
Spring pre-load adjustment
F2
R3
F3
Setting the spring pre-load generally on
the bike
3
Pre-load on the spring/springs is very
important, since it affects the height of
the motorcycle and the fork angle. Consequently, handling characteristics can be
changed, even negatively.
Proceed as follows (it will be much easier if
done by two persons):
1 Place the motorcycle on a stand.
2 Lift up the rear end to a fully extended upper
position.
3 Measure the distance, e.g. from the ower edge of
the rear mud guard or from a point marked by a
piece of tape, immediately above the rear whee
axle, to the wheel axle. (R1)
4 Make a similar measurement on the front axle, e.g.
from the bottom of the upper fork crown to the
front wheel axle. The fork must be fully
extended. (F1)
5 Allow the motorcycle (without rider) to apply load
on the springs and repeat the measuring proce dure. (R2, F2)
6 Then take the same measurements with the rider
and equipment on the motorcycle. It is important
that the rider has a correct riding posture, so that
the weight is balanced on the front and rear wheel
in the same way as when riding. (R3, F3)
Increase spring pre-load
Reduce spring pre-load
17 mm wrench
4
The measurements may not differ from the
following sizes:
Without rider:
Rear: 5-15 mm (R1-R2)
Front: 25-30 mm (F1-F2)
With rider:
Rear: 30-40 mm (R1-R3)
Front: 35-50 mm (F1-F3)
5
Changing springs
1.
Unload the spring pre-load completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 17 mm
wrench or socket.
12
2.
Loosen the screws that hold the fork legs
in the upper tripple clamps.
3.
Remove the Top nut assembly. Use tool
797-01.
4.
Remove the top nut assembly from the
piston shaft. Use a 17 mm wrench to the
top and tool 4705-01 to hold the nut on the
lower side of the top nut.
5.
Remove the adjustment driver and the
spring. Use a wire with a hook and carefully pull out the preload tube.
6.
Check the oil level according to page 17.
NOTE!
Use Öhlins Front fork oil 1305-01 only.
7.
Refit the Pre-load tube. Install the new
spring and refit the adjustment driver.
17 mm socket
34
Tool 797-01
17 mm socket
Tool 4705-01
5 6
Adjustment driver
Spring
Tool 1765-03
1305-01
Check the oil level
8.
Refit the top nut assembly to the piston
shaft. Tighten the jam nut to 20 Nm.
9.
Refit the top nut into the fork leg, with
the front wheel off the ground (use tool
797-01). Tighten the upper triple clamps
and adjust the preload, compression and
rebound according to above instructions.
CAUTION!
The top nut should only be tightened by
hand into the fork leg.
6
Preload tube
8 9
20 Nm
CAUTION!
Tool 797-01
Changing seals
!
1.
Remove the fork legs from the motorcycle.
Put the fork legs in upright position for
about 5 minutes to allow the oil to settle.
2.
Fasten the fork leg in a vice. Use soft jaws.
3.
Carry out instructions 1 to 5 in “Changing
springs”, page 6.
4.
Drain the cylinder tube from oil.
5.
Remove the outer tube, clean the seal and
check the condition. If the seal is in good
condition apply some red grease (146-01)
to it. A damaged seal must be replaced!
6.
First remove the circlip, then the seal and
finally the washer.
2 4
5 6
180
1st, Circlip
2nd, Seal
0
7.
Apply a thin layer of Öhlins red grease
(146-01) to the washer and to the sealing
surfaces of the fork seal. Install the seal
and the washer in the outer tube. Fit the
circlip into the groove.
NOTE!
It is important to use the correct grease in
order to achieve optimum fork function.
8.
Apply some front fork oil (1305-01) to the
inner tube surface and carefully mount the
outer tube (slide it completely down).
! WARNING!
Be careful not to damage the fork seal!
9.
Repeat instructions 6 to 9 in “Changing
springs” on page 6. Refit the front fork.
NOTE!
7
Circlip
Seal
Washer
3rd, Washer
WARNING!
8
7
Dismantling the Forks
!
1.
Remove the fork legs from the motorcycle.
Put the fork legs in upright position for
about 5 minutes to allow the oil to settle.
2.
Fasten the fork leg in a vice. Use soft jaws.
3.
Unload the spring pre-load completely
by turning the adjustment nut counter
clockwise as far as possible. Use a 17 mm
wrench or socket.
4.
Loosen the top nut assembly. Use tool
797-04.
5.
Remove the top nut assembly from the
piston shaft. Use a 17 mm wrench to the
top and tool 4705-01 to hold the nut on the
lower side of the top nut.
6.
Remove the adjustment driver and the
spring. Use a wire with a hook and carefully pull out the preload tube.
23
17 mm socket
4 5
Tool 797-04
17 mm socket
Tool 4705-01
6 7
NOTE!
7.
Remove the screw and o-ring from the
reservoir end cap.
NOTE!
Before the gas pressure is relieved the
adjuster settings must be counted and
noted. Even check that the gas pressure is
correct. Follow that, the adjusters should
be set in a fully open position.
8.
Relieve the nitrogen gas by inserting an
injection needle into the reservoir end cap
through the rubber valve.
8
Adjustment driver
Spring
WARNING!
8
Preload tube
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