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Owners manual
Öhlins motocross front forks FG 9910 Cannondale
Including:
Setting up
your bike
Fine-tuning
Service
the fork
Trouble
shooting
Technical
info
Spare parts
& tools
Traction, handling,
comfort and safety
1
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Öhlins Contents Safety signals Safety signals................................. 2 Important information concerning motocross Introduction .................................... 3 safety is distinguished in this manual front forks Design ............................................ 3 by the following notations Before you start ............................. 3 FG 9910 Kit content ...................................... 3 The Safety alert symbol means: Cannondale Marking ................................
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oil) that work together with the “real“ Introduction Marking spring. You adjust the air-spring by raising or lowering the oil level in the All Öhlins front forks are marked. Öhlins Racing congratulates you on legs. You will find the part number on the your choice of front fork for your By using different combinations of inside of the fork bottom. motocross bike. springs and air-springs you can alter Your Öhlins front fork has the fol- All Öhlins products are designed the characteristic of the fo
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ences, between the Öhlins recom- Mounting instructions mended settings and the settings you Compression achieve, may occur. Therefore, it is adjuster WARNING always wise to start the setting up by checking! 1. It is advisable to have an Öhlins The sag effects not just only the dealer or a qualified mechanic to fit suspension but also the rake of the your front fork kit. front fork and therefore the overall 2. To install the kit you need your behaviour of the bike motorcycle’s work shop manual. 3
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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 = 30 ±10 mm. Rear ride height: A - C = 100 ± 10 mm. D NOTE! Should you still experience exces- If you need to change the springs, sive bottoming or that the bike feels Refer to mounting instruction for see “Changing springs“ on page 9. much to stiff and suspension travel is more specific set-up data not fully used, harder/softer than nor- E D mal springs may
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Air spring Oil level Oil level 100 mm Oil level 110 mm Oil level 120 mm Oil level 130 mm 5. 6. A change in oil Oil level is 500 level will effect measured from the damping the top of the 450 forces, not in the outer leg, with early stage of the top nut of, 400 fork travel but a the fork fully great deal in the 350 compressed F later stage. and no preload o 300 washer nor r spring installed. c 250 e 200 k g 150 f 100 50 0 0 20 40 Stroke 60 80 100 120 Stroke mm Both the adjusters have a normal I
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General handling set-up handle smaller bumps. soft during the entire wheel travel. A Damping force not progressive Spring too soft, compression damp- Front end falls into the curves enough. ing too low. (over-steering) especially in sand. Increase the oil level. Increase the compression Steep front fork angle. Front end too damping. D low in comparison to rear end. Change to harder spring. Increase the front fork Can handle smaller bumps but is C compression damping. too hard during the
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Preload adjustment a a 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. Put a box under the front wheel so that the springs are visible. b b Loosen the top cap from damper rod extender and re- move it. Remove the spring support. Install a new preload spacer to achieve the right static sag. c c Fit the spring support, top
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Changing springs NOTE d Closing the compression- and Loosen the screws that hold the rebound valves will keep the the fork legs in the upper fork damper rod extended making it crown. easier to install the new spring. With the fork leg still tightened Pull out the damper rod as far in the lower fork crown unscrew as possible. the top cap, use a 24 mm wrench. Close the compression and the rebound valve (clockwise). Loosen the screws that hold the fork legs in the lower fork crown. Remove the fork
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Dismantling a d Perform steps a-d "Changing springs" on page 9. Loosen the bush head, on top of the cartridge tube, with tool 1797-01. Lift up the damper rod assem- bly and drain the oil. Pull up the scraper with a screwdriver, release and re- move the circlip. 1797-01 CAUTION! b e The fork legs have three fixed and one sliding bushing. Be very careful when disas- sembling the fork legs. Fasten the fork leg horizon- tally with soft jaws in a vice. Use a hot air gun to warm up the outer leg where
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Remove the seals and bush- Assembling ings and replace them with new a ones. Apply a thin layer of Öhlins green grease (148-01) on the scraper ring and on the sealing surface of the fork seal. Mount the scraper, circlip, fork seal, support ring and the bushings separated by the sleeve on the inner steel leg. Fasten the damper rod assem- Fasten the outer leg with bly with soft jaws in a vice. soft jaws in a vice. b Remove all parts from the Install the inner leg and damper rod. mount the upper bu
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Fasten the fork leg, at the fork Notes bottom, with soft jaws in a d vice. Install the compression valve assembly in the fork bottom. Tightening torque 45 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 specifi- cation card. First, fill up the cartridge tube, then raise up the outer leg about 250 mm and add the remaining oil. Install the damper rod assem- bly into the cartridge
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Service tools Pos. Part No. Description 3 1 1799-02 Bushing/seal mounting tool 2 2 0786-03 Inner tube tool 3 1797-01 Tool-cylinder tube lid 4 0787-03 Cylinder tube tool (cartridge) 1 5 1702-02 Bushing remover tool 4 5 Technical specifications Rebound and compression adjustment Refer to mounting instruction for set-up data. Maximum open rebound and compression valve: 20 clicks. Free Spring Length: All forks: 467 mm (service limit 460 mm). Spring preload: Maximum allowed adjustment range 3-13 mm (
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Spare parts Pos. Part No. Pcs. Description Type/remarks 1 2 1 02338-01 2 Nut 3 2 01050-01 2 Screw 3 00338-59 2 O-ring 4 4 02306-02 2 End cap 5 00438-17 2 O-ring 5 6 02337-01 2 Spring support 28 7 02319-01 Spring washer see spec. card 6 Spring preload 8 02328-39 2 Spring see spec. card Spring 7 9 02324-02 2 Outer tube 10 02332-03 2 Sticker 8 11 00329-02 2 Circlip 10 12 02021-01 2 Bush 13 02325-01 2 Sleeve 14 02021-01 2 Bush 15 01552-01 2 Washer 16 02336-01 2 Seal 17 02015-01 2 Circlip 9 18 02014-
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Spare parts Pos. Part No. Pcs. Description Type/remarks 5 01473-02 2 Circlip 6 00338-53 2 O-ring 7 02321-02 2 Adjustment screw 2 1 8 01248-01 2 Spring 3 24 9 00884-04 4 Ball 10 02366-12 2 Adjustment rod 4 11 00338-76 2 O-ring 12 02301-03 2 Needle housing 25 5 13 02302-03 2 Guide sleeve 6 14 02303-01 2 Sleeve 26 9 15 02304-01 2 Hydraulic stop 7 27 16 00131-05 2 Circlip 28 17 01499-01 2 Circlip 18 02305-03 2 Cylinder tube cap 10 19 02059-01 2 Bushing holder 8 20 00338-19 2 O-ring 21 00110-01 2 Bus
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Traction, handling, comfort and safety Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden. Phone +46 8 590 025 00, fax +46 8 590 025 80. E-mail: info@ohlins.se 16 Cannondale Teknisk Illustration AB, OM motocross front fork, 99 12, 400 ex.
