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7 Changing springs 7 NOTE! 4 Closing the compression- and the Loosen the screws that hold the fork rebound valves will keep the legs in the upper fork crown. damper rod extended making it With the fork leg still tightened in easier to install the new spring. the lower fork crown unscrew the top cap, use a 24 mm wrench. Pull out the damper rod as far as Loosen the screws that hold the possible. fork legs in the lower fork crown. Close the compression and the Remove the fork legs from the rebound
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Dismantling 10 13 10 Perform steps 4-7 "Changing springs" on page 9. Loosen the bush head, on top of the cartridge tube, with tool 1797-01. Lift up the damper rod assembly and drain the oil. Pull up the scraper with a screw- driver, release and remove the circlip. 1797-01 11 11 14 CAUTION! The fork legs have two fixed and one sliding bushing. Be very care- ful when disassembling the fork legs. Fasten the fork leg horizontally with soft jaws in a vice. Use a hot air gun to warm up the outer leg
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13 Assembling 16 Remove the seals and bushings and 16 check them for wear and damage. Apply a thin layer of Öhlins green Replace if necessary. grease (148-01) on the scraper ring and on the sealing surface of the fork CAUTION! seal. When removing the oil seal and bushings use a small plastic bag to CAUTION! cover the bushing attachment When installing the oil seal and groove and edges of the inner tube, bushings use a small plastic bag to to avoid damage to the seals. cover the bushing attachmen
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19 Notes 19 Fasten the fork leg, at the fork bottom, with soft jaws in a vice. Install the compression valve as- sembly in the fork bottom. Tightening torque 65 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 specification card. First, fill up the cartridge tube, then raise up the outer leg about 250 mm and add the remaining oil. 20 20 Install the damper rod assembly into the
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Service tools Pos. Part No. Description 3 1 1799-02 Bushing/seal mounting tool 2 0786-03 Inner tube tool 2 3 1797-01 Tool-cylinder tube lid 4 0787-03 Cylinder tube tool (cartridge) 5 1702-02 Bushing remover tool 1 4 Technical specifications 5 Fork lengths and diameters Front fork Motorcycle Length (L) ØA ØB FG 012 GasGas 938 mm 53,9 mm 58,4mm Rebound and compression adjustment Refer to mounting instruction for set-up data. Maximum open rebound and compression valve: 20 70 ØA clicks. Free Spring
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Spare parts Pos. Part No. Pcs. DescriptionType/remarks 1 02338-01 2 Nut 1 2 02306-02 2 Top cap 3 00438-17 2 O-ring 2 4 02337-01 2 Spring support 5 02319-01 Preload washersee spec. card 3 6 02328-39 2 Spring front fork 3,9 N/mm 4 02328-41 2 4,1 N/mm 02328-43 2 4,3 N/mm 02328-45 2 4,5 N/mm 02328-47 2 4,7 N/mm 5 7 02324-01 2 Fork leg outer 6 8 00329-02 2 Circlip 9 02021-01 4 Bushing lower 10 02325-01 2 Sleeve 11 02332-03 2 Cover Sticker Öhlins 12 01552-01 2 Washer 13 02336-01 2 Seal 7 14 02015-01 2
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Owners manual
Öhlins motocross front forks FG 012 GasGas
Including:
Setting up
your bike
Fine-tuning
Service
the fork
General
handling set-up
Technical info
Spare parts
& tools
1
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Before installation Contents Safety signals Öhlins Racing AB can not be held Safety signals............................. 2 Important information concerning responsible for any damage what- Introduction................................ 3 safety is distinguished in this soever to shock absorber or vehicle, Design ....................................... 3 manual by the following nota- or injury to persons, if the instruc- Before you start ......................... 3 tions: tions for fitting and main
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Introduction Mounting instructions cated at the bottom of the fork leg, Öhlins Racing congratulates you on fig 1, the rebound adjuster at the top, your choice of front fork for your mo- WARNING fig 2. tocross bike. 1. It is advisable to have an Öhlins Spring preload is adjusted with All Öhlins products are designed dealer or a qualified mechanic to washers, fig 3, and optional springs with just one aim; to win races. To fit your front fork kit. are available to suit different tracks design a win
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Setting up the bike F Compression adjuster We would like to give you some ba- Spring preload is adjusted with spacers, sic guidelines how to set up your bike see “Preload adjustment“ on page 8. with your new Öhlins front fork. Maximum allowed spring preload is However, remember that the front 13 mm. fork is just one part of your motorcy- If you need to preload the springs more cle and to get the fork to work prop- than 13 mm, we recommend you to erly the whole motorcycle has to be change to a “s
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Setting up the bike 4. Checking sag and ride height. Front sag: A - B = 30 ± 10 mm. Front ride height: A - C = 50 ± 10 mm. Rear sag: A - B = 35 ±10 mm. Rear ride height: A - C = 100 ± 10 mm. ground and the rear suspension fully the specialists sometimes need a Checking front ride height extended. specialist! A Measure the distance between the rear With the adjusters you optimize the Put your bike on a stand. wheel axle and a point near the rear end suspension for your riding style and the Arrang
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Oil level Air spring Oil level 100 mm Oil level 110 mm Oil level 120 mm Oil level 130 mm 6. 5. Oil level is A change in oil 500 measured from level will effect 450 the top of the the damping outer leg, with forces, not in 400 the top nut the early stage 350 F off,the fork fully of fork travel o compressed 300 but a great deal r and no preload c in the later 250 e washer nor stage. spring installed. 200 k g 150 f 100 50 0 0 20 40 Stroke 60 80 100 120 Stroke mm When you need more damping Making
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Spare parts Pos. Part No. Pcs. Description Type/remarks 1 02338-01 2 Lock nut 2 01050-01 2 Screw 3 00338-59 2 O-ring 4 02306-02 2 Top cap 2 1 5 01473-02 2 Circlip 24 3 6 00338-53 2 O-ring 4 7 02321-02 1 Adjustment screw 8 01248-01 2 Spring 25 9 00884-04 4 Ball 5 10 02366-12 2 Adjustment rod 6 26 11 00338-76 2 O-ring 9 27 7 12 02301-03 2 Needle housing 28 13 02302-03 2 Guiding sleeve 14 02303-01 2 Sleeve 15 02304-01 2 Hydraulic stop 8 10 16 00131-05 2 Circlip 17 01499-02 2 Circlip 29 18 02305-03
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More info www.ohlins.com The ultimate suspension site. Find out everything about your suspension. Download mounting instructions, manuals and brochures. And a lot more. Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80 Your Öhlins dealer: 16 07295-08 Teknisk Illustration AB, OM Motocross front fork FG 012 GasGas, 02 02. 200 ex.
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General handling set-up C B Suspension bottoming, but can handle Suspension is bottoming, feels soft dur- A smaller bumps. ing the entire wheel travel. Front end falls into the curves (over- Damping force not progressive enough. Spring too soft, compression damping steering) especially in sand. Increase the oil level. too low. Steep front fork angle. Front end too Increase the compression D low in comparison to rear end. damping. Increas the front fork Can handle smaller bumps but is too
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1 Preload adjustment 4 1 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. 2 2 5 Put a box under the front wheel so that the springs are visible. Remove the top cap from the damper rod extender. Use a 16 and 24 mm wrench. Remove the spring support. 3 3 6 Install a new preload spacer to achieve the right static sag. Fit t
