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Owner’s Manual
Öhlins Superbike Front Fork FG 470
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Safety signals ! WARNING! 1. Installing a suspension, that is not ap- Important information concerning safety is proved by the vehicle man u fac turer , may distinguished in this manual by the affect the stability of your ve hi cle. Öhlins following notations: 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. This Safety alert symbol means: Caution! Contact an Öhlins deal er or oth er qual i fi
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Öhlins Front Fork FG 470 This Super Bike front fork is an improved version of FG 370 with pressurised damp- ing 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 move- ments. 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 char
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Adjusters Compression adjustment reservoir valve Your Öhlins super bike front fork is pro- (Base valve) vided with the following external adjusters: Adjust the compression damping (shaft displacement) on the lower part of the fork � Spring pre-load adjuster legs. Use a normal screwdriver. Adjustment � Rebound damping adjuster. range from closed valve (clockwise) to � Two type of compression maximum open valve (counter clockwise) damping adjuster: is 20 “clicks”. Recommen
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Setting up your forks F1 F2 F3 R1 R2 R3 E. Bike on the ground F. Bike with rider on A-D. Bike on a stand Here is some basic guidelines, how to set Setting the spring pre-load generally on up your Öhlins front forks. However you the bike must remember that the front forks are just one part of your motorcycle and to get it to 3 work properly, the whole motorcycle has to Pre-load on the spring/springs is very be set up according to your bikes manual. important, since it affects the height of th
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Check the oil level CAUTION! Changing springs 1. Unload the spring pre-load completely 12 by turning the adjustment nut counter clockwise as far as possible. Use a 17 mm wrench or socket. 17 mm socket 2. Loosen the screws that hold the fork legs in the upper tripple clamps. 34 3. Remove the Top nut assembly. Use tool Tool 797-01 797-01. 17 mm socket 4. Remove the top nut assembly from the piston shaft. Use a 17 mm wrench to the Tool 4705-01 top and tool 4705-01 to hold the nut on the low
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! WARNING! NOTE! Changing seals 1. Remove the fork legs from the motorcycle. 2 4 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 5 6 check the condition. If the seal is in good condition apply some red grease (146-01) 0 180 to it. A damaged seal must be replaced
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NOTE! ! WARNING! 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. 23 2. Fasten the fork leg in a vice. Use soft jaws. 3. Unload the spring pre-load completely by turning the adjustment nut counter 17 mm socket clockwise as far as possible. Use a 17 mm wrench or socket. 4 5 4. Tool 797-04 Loosen the top nut assembly. Use tool 797-04. 17 mm socket 5. Remove the top nut assembly from the T
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NOTE! ! WARNING! 910 Tool 720-03 Releasing high pressure gas from the Tool 720-02 shock absorber can be hazardous. Do not perform any kind of service until gas pres- sure is completely released. 9. Remove the circlip. 10. Use tool 720-03 to lift up the reservoir end cap. Install the tool 720-02 into the gas piston. 11. Tool 1765-03 Use tool 1797-04 and 1765-03 to unscrew the seal head from the cartridge tube. Remove the piston rod unit. 11 12. Tool 1797-04 Piston rod unit Fasten the piston
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14 mm Wrench 13. 14 13 Remove the Piston holder. Use a 14 mm wrench. Piston holder Topout spring 14. Sleeve Remove the Topout spring, the Sleeve, the Spacer Spacer and the O-ring. O-ring 15. Remove the Seal head. Check the O-ring and the X-ring. Change them if necessary. 16. Remove the needle and change the O-ring 15 16 if necessary. X-ring 17. Seal head Drain the cylinder tube from oil. O-ring O-ring Rebound neendle 18. Remove the gas piston in the reservoir, use tool 720-02. 19. Drain th
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22 23 22. 0 180 Remove the outer tube, clean the seal and check the condition. If the seal is in good 1st, Circlip condition apply some red grease (146-01) to it. A damaged seal must be replaced! 2nd, Seal 23. First remove the circlip, then the seal and finally the washer. 3rd, Washer 24. Heat the tube where the bushings are posi- tioned. Use a heat air gun. 24 25 25. Put the outer tube standing up on a soft Attachment bar suface, seal side facing down. Remove the (1757-01) bushings by pus
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NOTE! Assembly of the forks 1. Use Tool 786-07 to refit the reservoir tube. Tighten to 45 Nm. 12 Tool 786-07 2. Tool 786-05 Use Tool 786-05 to refit the inner tube of the fork leg. Tighten to 80 Nm. 3. Put the outer tube standing up on a soft surface, seal side up. Fit the bushings from the seal side of the outer leg. Install first the upper bushing then the lower one. Use installing sleeve (1759-08), guide ring (1758-04) and attachment bar (1757-01) when installing the upper bushing. A
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! WARNING! 6 6. Install the piston and the shims on the compression valve. Tighten the 8 mm nut with a torque of 7 Nm. Check the piston ring and the O-rings for damages. Replace 8 mm Nut, 7Nm if necessary. Install the compression valve assembly into the valve housing. Tighten to 20 Nm. Comp. valve assembly, 20 Nm Compression valve assembly: 7 8 7. Apply some front fork oil (1305-01) to the inner tube surface and carefully mount the outer tube (slide it completely down). ! WARNING! Be car
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NOTE! 10. 10 11 Grip the piston shaft with soft jaws 727-02. X-ring Fit the O-ring on the adjustment needle. Apply plenty of red grease on the O-ring so that the needle slides easily into the piston shaft. O-ring 11. Check the X-ring and O-ring on the seal head. Replace if necessary. Smear plenty Tool 0715-01 of white grease on the X-ring before you fit 10 11 it. Use tool 0715-01 to get the X-ring into the right position. Piston holder 10. Topout spring Wrap some teflon tape arond the th
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NOTE! CAUTION! 14 Tool 1765-03 The Washers must be positioned correctly (Notice that there is a difference between Tool 2810-01 the compression and the rebound valve). Also make sure to fi t the Wave washer (1149-01) in the correct position (convex side facing piston). Tool 1797-04 NOTE! The right hand fork leg is the rebound leg. The left hand fork leg is the compression leg. 14. Fit the Seal head tool and the Top-out spring tool on the piston rod. Pull the Top- out spring tool and, at
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Check the oil level ! WARNING! NOTE! CAUTION! ! WARNING! Use of infl ammable gas for pressurising the soch absorber can be hazardous. Use nitrogen gas (N2) only! 19 20 19. 3 Nm Check the gas pressure stipulated in the spec. card. Dip the needle of the gas tool (1781-01) in red grease and insert the nee- dle 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. 20. Screw the gas filler screw
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Check the oil level Oil level adjustment Compared with conventional type of front NOTE! forks, the upside down front forks are very Adjust the oil level in mm according to the sensitive to variations in oil level. Therefore, fi gure with the fork leg fully compressed. adjust the oil level with special care. For the right oil-level, please see the speci- fi cation card. A change in the fork oil level will not affect the spring force at the beginning of the fork Air spring characteristics trave
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Troubleshooting Below are a few examples of how to adjust 4. for the most common road holding prob- The front end loses grip coming out of a lems in Road Racing driving. corner. � Not enough rebound damping. Put on some more 1. rebound damping. The front wheel “chatters” entering a corner, the problem goes away, as soon as � Too much pre-load. Take off some pre-load. you let the brakes off, or when you get on � Rear end is too soft. Put on a harder rear spring. the power.
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Inside of reservoir tube White grease, thin film Reservoir tube, 45 Nm Nut, 7 Nm Loctite 222 Red grease on all other o-rings! Red grease Nut, 7 Nm Piston rod/piston shaft, 15 Nm Loctite 222 Loctite 270 Rod extensioner/bolt spring adjuster, 20 Nm Screw, 3 Nm Piston shaft/rod extensioner, 15 Nm Seal head, 20 Nm Loctite 270 Adjustment housing, By hand only Lower bushing No loctite Upper bushing X-ring Cylinder tube, 80 Nm Loctite 601 White grease Loctite 648 Fork leg, 140 Nm Attach piston holder to
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Spare parts list, FG 470 Pos. Part No. Pcs. Description Type/remarks 1 1 - 2 Top nut assembly See page 21 12 2 01408-04 2 Adjustment driver 3 04744-95 2 Spring 25.5/260/9.5 2 04744-10 2 Option spring 25.5/260/10.0 04744-90 2 Option spring 25.5/260/9.0 13 4 01438-04 4 Guide ring 5 01460-37 2 Preload tube 3 6 01900-05 2 Fork leg outer 14 7 01683-02 2 Bushing, upper 8 01684-02 2 Bushing, lower 9 04758-01 2 Washer 10 04720-02 2 Seal 15 11 04759-01 2 Circlip 4 16 12 02807-01 2 Adjust
