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© Öhlins Racing AB.All rights reserved.

Any reprinting or unauthorised usewithout the written permission ofÖhlins Racing AB is prohibited.

Printed in Sweden.

Contents

Safety signals................................. 2Introduction .................................... 3Design ............................................ 3Before you start ............................. 3Marking .......................................... 3Recommended settings ................. 3Mounting instructions ..................... 4Setting up the bike ......................... 4Checking front sag ......................... 4Checking rear sag .......................... 4Checking front ride height .............. 5Checking rear ride height............... 5Fine-tuning the bike ....................... 5Making adjustments ....................... 6Oil level adjustment ....................... 6Maintenance .................................. 6General handling set-up ................ 7Preload adjustment ........................ 8Changing springs ........................... 9Dismantling the front fork............. 10Assembly of the front fork .............11Service tools ................................ 13

Technical specifications ............... 13Spare parts .................................. 14

Öhlinsmotocross front forksFG 012 GasGas

Safety signals

Important information concerningsafety is distinguished in this manualby the following notations.

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injury toanyone working with, inspecting orusing the suspension, or to bystanders.

CAUTION!Caution indicates that special pre-cautions must be taken to avoiddamage to the suspension.

NOTE!This indicates information that is of

importance with regard to procedures.

Kit contents

Before installing the front fork, pleasecheck the contents of the kit, listed inthe mounting instruction. If anything ismissing, contact your Öhlins dealer.

NOTE!During storage and transportation,especially at high ambient tempera-ture, the oil and grease used for as-

sembling may run out inside thepacking and damage the expandedpolystyrene packing material. This isnot unusual and is in no way detri-mental to the shock absorber.


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springs and air-springs you can alterthe characteristic of the fork. Forexample, a soft spring in combinationwith a small air-spring (high oil level)makes the fork progressive, see“Fine-tuning the bike“.

Before you start

WARNING!Installing a front fork, that is not ap-proved by the vehicle manufacturer,may affect the stability of your vehi-cle. Öhlins Racing AB cannot be heldresponsible for any personal injury ordamage whatsoever that may occurafter fitting the front fork. Contact anÖhlins dealer or other qualifiedperson for advice.

Öhlins Racing AB can not be held

responsible for any damage whatso-ever to front fork or vehicle, or injuryto persons, if the instructions forfitting and maintenance are notfollowed exactly. Similarly, thewarranty will become null and void ifthe instructions are not adhered to.

WARNING!Please study and make certain thatyou fully understand all the mountinginstructions and the owner´s manu-

als before handling this front fork kit.If you have any questions regardingproper installation procedures, con-tact an Öhlins dealer or other quali-fied person.

WARNING!The vehicle service manual must bereferred to when installing the Öhlinsfront fork.

NOTE!Öhlins products are subject to con-tinual improvement and develop-ment. Consequently, although theseinstructions include the most up-to-date information available at the timeof printing, there may be minor differ-ences between your suspension andthis manual. Please consult yourÖhlins dealer if you have any ques-tions with regard to the contents ofthe manual.

Introduction

Öhlins Racing congratulates you onyour choice of front fork for yourmotocross bike.

All Öhlins products are designedwith just one aim; to win races. Todesign a winner you need a conceptstarting with a unique know-how. Youadd engineering skill, precision and

the best material available. The re-sult is quality, endurance and win-ning performance.

Your new Öhlins front fork is devel-oped from experience gained duringyears of successful cooperation withthe World Championship winningworks motocross teams.

Spring rates and damping forcesare developed just for your bike. Thedesign and the settings are conse-quently the results of extensive test-ing and no guesswork!

Öhlins shock absorbers and frontforks have dominated the motorcyclescene for several years and have cap-tured more World Championship titlesthan any other brand, over 80 titles!

A well equipped network of author-ised Öhlins service centres aroundthe world, with specially trained me-chanics, can help you with personallytuned settings, service, repairs andspare parts.

DesignÖhlins new up-side-down (USD) front

fork is designed to combine theadvantages of comfortable, safeconventional forks and rigid, lightUSD forks. The result is a uniquecombination of being rigid, precise incorners and during hard braking yetcomfortable, forgiving when “over-landing“ and in big bumps.

Your new Öhlins USD front forkhas aluminium outer legs and 46 mmsteel inner legs, with a polished sur-face for lowest possible friction.

The legs also feature a completely

new bushing design with fixed andone sliding bushing.The new USD fork features the

Öhlins championship winning car-tridge damping system.

The fork is fully adjustable withexternal adjuster for compression-and rebound damping.

The compression adjuster is locatedat the bottom of the fork leg, fig 1, therebound adjuster at the top, fig 2.

Spring preload is adjusted withwashers, fig 3, and optional springsare available to suit different tracks

and riders.In the legs there are also “air-springs“

(the air trapped above the oil) that worktogether with the “real“ spring. You adjust the air-spring by raising or loweringthe oil level in the legs.

By using different combinations of

Marking All Öhlins front forks are marked.

You will find the part number on theinside of the fork bottom.

Your Öhlins front fork has the fol-lowing marking:

FG 012 GasGas

Recommended settingsThe front fork in your kit is adjustedto the Öhlins recommended settingfor your bike, see “Making adjust-ments“. We advise you to use this asyour start setting.


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ences, between the Öhlins recom-mended settings and the settings youachieve, may occur. Therefore, it isalways wise to start the setting up bychecking!

The sag effects not just only thesuspension but also the rake of thefront fork and therefore the overallbehaviour of the bike.

Checking front static sag

A

Put your bike on a stand.Arrange the stand so that the frontwheel is off the ground and the frontfork fully extended.

B

Measure the distance between theupper fork crown and the front wheelaxle, fig 4 distance A. Make a note ofthe measurement.

C

Remove the stand. With the wheelson the ground measure the distanceagain, fig 4 distance B.The difference of the two measure-ments is the static sag.

D

The static sag should be 30 ± 10 mm.

E

If the static sag is less than 20 mm,you need to reduce spring preload.If the static sag is more than 40 mm,you need to increase spring preload.

F

Spring preload is adjusted with spacers,see “Preload adjustment“ on page 8.Maximum allowed spring preload is13 mm.If you need to preload the springs morethan 13 mm, we recommend you tochange to a “stiffer“ spring.

Checking rear static sag

A

Put your bike on a stand. Arrange thestand so that the rear wheel is off theground and the rear suspension fullyextended.

B

Measure the distance between therear wheel axle and a point near therear end of the seat, for example aseat bolt, fig 4 distance A.Make a note of the measurement.

C

Remove the stand. With the wheelson the ground measure the distanceagain, fig 4 distance B.The difference of the two measure-ments is the static sag.

1.The compression adjuster is located atthe bottom of the fork leg.

Compressionadjuster

3.Spring preload is adjusted with washersand optional springs are available.

Preloadadjustment

2.The rebound adjuster at the top of thefork leg.

Reboundadjuster

Mounting instructions

WARNING1. It is advisable to have an Öhlinsdealer or a qualified mechanic to fityour front fork kit.2. To install the kit you need yourmotorcycle’s work shop manual.3. When working on your motorcycle,

support it securely so it does not fallover.

The Öhlins front fork is designed to fityour bike’s standard triple clampsand to use the standard brake com-ponents and wheel.

A

Put your bike on a stand and removethe front wheel, the front brakecomponents and the fork legs fromthe bike according to the work shopmanual.

CAUTION!1. The outer legs, both left and right,should be adjusted evenly in the forkcrown.2. The Öhlins fork legs featuregrooves on top of the outer fork legsto make adjustment of the fork heighteasier. The distance between thegrooves is 4 mm.

B

Fit the Öhlins front fork legs. For

recommended front fork mountingheight see mounting instruction.

C

Fit the brake components and thefront wheel according to the workshop manual.

D

Tighten all screws. For maximumtorque, please see your bike’s workshop manual.

Setting up the bike

We would like to give you some basicguidelines how to set up your bikewith your new Öhlins front fork.

However, remember that the frontfork is just one part of your motorcy-cle and to get the fork to work prop-erly the whole motorcycle has to beset up according to standards.

Please follow the instructions be-low, see also your bike’s work shopmanual.

Your new front fork is dialled-in tothe Öhlins recommended settings for

your bike. The same goes for the rearshock absorber if you are using anÖhlins unit.

All settings are based on a bike anda rider of normal weight.

Depending on your own and yourbike’s actual weight minor differ-


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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 = 45 ± 10 mm.

Rear ride height:A - C = 115 ± 10 mm.

A

: F u l l y

e x t e

n d e d

.

B : O n

t h

e g r o u n d

.

C : R i d

e r o n

.

A:Fullyextended.

B:Onthe

ground.

C:Ridero

n.

NOTE!

Refer to mounting instruction formore specific set-up data.

D

The static sag should be 45 ±10 mm.

E

If the static sag is less than 35 mm,you need to reduce spring preload.If the static sag is more than 55 mm,you need to increase spring preload.

F

Adjust the spring preload accordingto your rear shock mounting instruc-tion.

Checking front ride height

A

Put your bike on a stand.Arrange the stand so that the frontwheel is off the ground and the frontfork fully extended.Measure the distance between theupper fork crown and the front wheelaxle, fig 4 distance A. Make a note of

the measurement.B

Race dressed sit on the bike, straightabove the foot pegs, with the feetbarely touching the ground.Have somebody to measure betweenthe same point as before, fig 4 dis-tance C.

C

The difference of the two measure-ments should be 50 ± 10 mm.

CAUTION!Do not try to alter ride height by alter-ing the spring preload.New springs are needed.

D

If you need to change the springs,see “Changing springs“ on page 9.

E

Stiffer springs are needed if thedifference is more than 60 mm.Softer springs if the difference is lessthan 40 mm.Consult your Öhlins dealer for theright rate.

Checking rear ride height

A

Put your bike on a stand. Arrange thestand so that the rear wheel is off theground and the rear suspension fullyextended.Measure the distance between therear wheel axle and a point near therear end of the seat, for example aseat bolt, fig 4 distance A.Make a note of the measurement.

B

Race dressed sit on the bike, straightabove the foot pegs, with the feet

barely touching the ground. Havesomebody to measure between thesame point as before, fig 4 distance C.

C

The difference of the two measure-ments should be 115 ± 10 mm.

CAUTION!Do not try to alter ride height by alter-ing the spring preload.A new spring is needed.

D

A stiffer spring is needed if thedifference is more than 110 mm.A softer spring if the difference is lessthan 90 mm.Consult your Öhlins dealer for a springof the right rate.

Should you still experience exces-

sive bottoming or that the bike feelsmuch to stiff and suspension travel isnot fully used, harder/softer than nor-mal springs may be needed for thetrack you are testing on.

Consult your Öhlins dealer for ad-vice!

Fine-tuning the bike

Learning how to use the adjusters willtake time but you quickly appreciatethem once you know the tricks. Eventhe specialists sometimes need aspecialist!

With the adjusters you optimize thesuspension for your riding style andthe track you are competing on.

The same basic guide lines goesfor both the front fork and the rearshock absorber.

Too much compression dampingwill give you a harsh ride as your bike“jumps“ along the track.

With too much rebound dampingyour bike will have difficulties withseveral bumps in a row. The suspen-sion will not extend fast enough be-

tween bumps, your bike will ridelower and lower and eventually thesuspension will bottom!

External adjustersOn the Öhlins front fork the adjustersare bleed valves, totally separatedfrom each other.

The compression bleed valve con-trols the flow in the cartridge tubeduring the compression stroke, therebound bleed valve the flow duringthe rebound stroke.

CAUTION!Using too much force when closingthe adjusters will destroy importantsealing surfaces.


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CAUTION!Adjust the oil level with the fork legfully compressed and no preloadwasher nor spring installed.

NOTE!See mounting instruction forrecommended oil level.

The oil level is measured from the

top of the outer leg, with the top nutoff, see fig 6.A change in oil level should be

made in small steps. We recommenda change of 5 mm at a time and notoutside the range of 90-130 mm.

Maintenance

Telescopic front forks depend on asmooth, friction free action.

Make sure your forks are regularlyserviced.

Do not use strong solvents, suchas brake cleaner, to clean the front

forks. This will dry out the seals andthe steel tubes and cause friction orleakage.

After every race:Clean externally and spray with anall-purpose oil after washing withdetergent.Check externally for damage.Put a little Öhlins green grease(148-01) on the steel tubes andwork it in by pushing the fork upand down.

Every 20 hours:

Dismantle the fork and check allparts for wear and damage, replaceif necessary, see page 10.

Both the adjusters have a normalright-hand thread.

Click position zero (0) is when theadjusters are turned clockwise to fullyclosed.

The adjustment range, from fullyclosed until maximum open valve(anticlockwise), is 20 clicks.

In order not to click in the wrongdirection; always first close the adjuster, then dial-in the new setting.

Making adjustments

To make improvements using theadjusters, it is important to understandthe function of the front fork and theshock absorber and through testinglearn how they effect the handling ofyour bike.

Make sure that you have the correctsprings and the correct spring preloadbefore making any adjustments. Andalways start with the Öhlins recom-mended settings:

NOTE!

See mounting instruction forrecommended settings.

NOTE!Higher click numbers give less damp-ing force.

When making adjustments; keepnotes, make adjustments one at atime... and in small steps.

The adjusters should normally notbe adjusted in steps of more than 2clicks at a time and not outside the

usable click range.When you think you have made animprovement, go back to what youstarted with and double check to besure. Pay attention to changes inconditions like tires, temperaturesetc.

In general, compression dampingchanges should be used to influencethe bike’s stability and response,while rebound damping changesshould be used to influence comfortand traction.

When you need more dampingforce, you should mainly try to in-crease compression damping anduse as little rebound damping as pos-sible.

This usually means that you gain

comfort and performance in handling.Oil level adjustmentAs the air trapped between the oiland the top nut acts as an air-spring,a change in oil level will effect thedamping forces. Not in the earlystage of fork travel, but a great dealin the later stage.

A general description of how the oillevel/air-spring effects the dampingforces are shown in fig 5.

The air-spring gives the ÖhlinsUSD fork a progressive spring rate,preventing it from bottoming out hard.

By using different combinations ofsprings and oil levels/air-springs youcan alter the characteristic of the forkand tailor it to suit different tracks andconditions.

CAUTION!The oil level must be the same inboth front fork legs.Riding a bike with different oil levelswill cause instability.

When the oil level is raised:The air-spring in the later half of travel

is strong, and thus the front fork hard.When the oil level is lowered:The air-spring in the later half of travel

is soft, and thus the front fork soft.

Oil level

6.Oil level ismeasured fromthe top of theouter leg, withthe top nut off,the fork fullycompressedand no preload

washer norspring installed.

Air spring

5.A change in oillevel will effectthe dampingforces, not in theearly stage offork travel but agreat deal in thelater stage.

Oillevel

50 0

45 0

40 0

35 0

30 0

25 0

20 0

15 0

10 0

5 0

0

F

o

r

c

e

k

g

f

Stroke mm

0 2 0 4 0 6 0 8 0 100 120

Oil level 100 mm Oil level 110 mm Oil level 120 mm Oil level 130 mm

Force

Stroke


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General handling set-up

A

Front end falls into the curves(over-steering) especially in sand.Steep front fork angle. Front end toolow in comparison to rear end. Increase the front fork

compression damping.

Change to harder springs. Lower fork leg approximately

5 mm in the triple clamp.

B

Front end ”ploughs”, understeers.Shallow front fork angle. Front endtoo high in comparison to rear end. Decrease the front fork

compression damping. Raise the fork legs approximately

5 mm in the triple clamp. Change to softer fork springs.

CFront end unstable at high speed,unstable when accelerating out ofcurves.Front fork angle too steep. Front endtoo low in comparison to rear end. Lower the fork legs approxi-

mately 5 mm in triple clamp. Change the front fork springs to

harder ones.

D

Front end unstable during decel-

eration.Front fork angle too steep duringbraking. Front end too low or rearend too high. Increase the oil level in the

front fork. Change to harder fork springs. Increase the front fork

compression damping.

Front suspension.

A

Front fork travel is not used to itsfull capacity. Harsh feeling, frontwheel grip is not satisfactory inbumpy turns.Suspension too hard. Decrease the front fork

compression damping. Change to softer springs.

B

Suspension bottoming, too softduring entire travel.Spring too weak or compressiondamping too soft.

Increase oil level 5 mm. Increase compression damping. Change to stiffer springs.

C

Suspension bottoming, but can

handle smaller bumps.Damping force not progressiveenough. Increase the oil level.

D

Can handle smaller bumps but istoo hard during the last part of thetravel.Damping force is too progressive. Decrease the oil level.

E

Front end feels low, initially feelssoft, but is not bottoming.The initial spring rate is too soft orspring preload is too low. Increase the spring preload.

E

Feels harsh over small bumps, but

using full wheel travel.Too much spring preload or too muchcompression damping. Increase the oil level or change

to softer springs. Decrease the compression

damping. Decrease the spring preload. Clean the oil seals and scrapers.

Use Öhlins grease 148-01 forregreasing.

F

Can handle the first in a series of

bumps but feels hard after a fewmore bumps. Frontal grip insuffi-cient in rough and bumpy turns.Too much rebound damping. Decrease the rebound damping.

G

Front end rebound too fast after abump. Front wheel grip insufficientin bumpy curves.Not enough rebound damping, or toomuch spring preload Increase the rebound damping.

Decrease the spring preload.Rear suspension.

A

Rear suspension stroke is notused to its capacity. Suspensionfeels harsh. Traction not satisfac-tory in bumpy curves.Suspension hard in general or toomuch compression damping, toomuch spring pre-load. Decrease the compression

damping. Decrease the spring preload. Change to softer spring.

B

Suspension is bottoming, feels

soft during the entire wheel travel.Spring too soft, compression damp-ing too low. Increase the compression

damping. Change to harder spring.

C

Suspension is bottoming, feelsharsh and sags down too muchwith the rider in the saddle.Spring too soft or compressiondamping too low. Increase the spring preload,

check ride height. 95 +- 5 mm. Change to harder spring if the

load is more than 100 mm. Increase compression damping.

D

Rear wheel jumps over small

bumps during deceleration orwhen going downhill. Traction notsatisfactory in washboard curves.Too much spring preload, as thespring is probably too soft, will causethe spring to extend too fast. Change to a harder spring in

order to achieve a balancedposition using less spring pre-load.

Check the static sag andride height.

E

Rear end kicks up over bumpswith sharp edges, but can handlebumps with round edges.Compression damping too hard. Decrease the compression

damping.

F

Rear end becomes too low inseries of bumps. Traction notsatisfactory in washboard typecurves or when decelerating onwashboard ground.

Rebound damping too slow. Decrease the rebound damping.

G

Rear end very unstable. Shockdoes not respond to adjustments.Shock damping is gone, caused oflow gas pressure, bad oil is used, orcomponents are broken in the shockabsorber. Service is needed. Gas filling required. Change shock oil. Repair or change the shock

absorber.


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Preload adjustment

Put the bike on a stand andloosen the screws in the forktop crown that hold the forklegs.

NOTE

On most MX-bikes you have totake of the handle bar beforeyou can unscrew the top cap.

Unscrew the top cap, use a24 mm wrench.

a

bPut a box under the front wheelso that the springs are visible.

Remove the top cap from thedamper rod extender.Use a 16 and 24 mm wrench.

Remove the spring support.

Install a new preload spacer toachieve the right static sag.

Fit the spring support, top capand the handle bar.

Tighten all screws.

For tightening torques,please see your bike'swork shop manual.

c

a

b

c


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e

f

dChanging springs

Loosen the screws that holdthe fork legs in the upper forkcrown.

With the fork leg still tightenedin the lower fork crown unscrewthe top cap, use a 24 mm

wrench.

Loosen the screws that holdthe fork legs in the lower forkcrown.

Remove the fork legs from themotorcycle.

Fasten the fork leg with soft jaws in a vice and loosen thelock nut on the top of the forkcap.

Remove the top cap from thedamper rod extender, use a 16and 24 mm wrench.

Remove the spring support, thepreload washer and the spring.

For free spring length see tech-nical information on page 13.

NOTEClosing the compression- andthe rebound valves will keep thedamper rod extended making iteasier to install the new spring.

Pull out the damper rod as faras possible.

Close the compression and therebound valve (clockwise).

Install the spring and thepreloadwasher.

Install the spring support forktop cap and the lock nut.

Tighten the top cap and thelock nut against each other, usea 16 and 24 mm wrench.

Adjust the compression- andthe rebound valves accordingto specification card.

Fit the fork legs on the motorcy-cle.

For tightening torques, pleasesee your bike's work shop

manual.


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b

c

a d

e

f

Dismantling

Perform steps a-d "Changingsprings" on page 9.

Loosen the bush head, on topof the cartridge tube, with tool1797-01.

Lift up the damper rod assem-bly and drain the oil.

Pull up the scraper with ascrewdriver, release and re-move the circlip.

CAUTION!The fork legs have two fixedand 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 upthe outer leg where the bush-ings are located.

The first bushings is locatedat the bottom end of the outerleg, the second approximately150 mm further up the leg.

Between them is a sleeve tomaintain the distance.

Use the special tool 1702-02 toremove the bushings.

Install the tool in the top of theinner steel leg.

Screw the top cap onto thetool and install the cap in theouter leg.

Rotate the tool to press outthe bushings.

If tool 1702-02 not is avaliablepush the inner steel leg to thebottom and then pull it back

quickly, so that the fork istopping out hard.

Repeat this procedure until theseal and the bushings can bepulled out from the outer leg.

1 7 0 2

- 0 2

15o mm

1797-01


11/1611

a

b

c

Remove the seals and bush-ings and check them for wearand damage.Replace if necessary.

CAUTION!When removing the oil seal andbushings use a small plasticbag to cover the bushingattachment groove and edgesof the inner tube, to avoiddamage to the seals.

Fasten the damper rod assem-bly with soft jaws in a vice.

Remove all parts from thedamper rod.

NOTEIf the right order is lost, use thespecification card as a guide.

Put them in the right order onthe bench.

Inspect all parts for wear anddamage, replace if necessary.

Clean all parts thoroughly.

Assemble the damper rod.

Remove the compression valveassembly from the fork bottom,use a 17 mm socket.

Fasten the valve assembly withsoft jaws in a vice.

Remove all parts from thevalve body.

Put them in the right order onthe bench.

Inspect all parts for wear anddamage, replace if necessary.

Clean all parts thoroughly.

Assemble thecompression valve.

Assembling

Apply a thin layer of Öhlinsgreen grease (148-01) onthe scraper ring and on thesealing surface of the forkseal.

CAUTION!

When installing the oil sealand bushings use a smallplastic bag to cover thebushing attachment grooveand edges of the inner tube,to avoid damage to theseals.

Mount the scraper, circlip, forkseal, support ring and thebushings separated by thesleeve on the inner steel leg.

Fasten the outer leg withsoft jaws in a vice.

Install the inner leg andmount the upper bushingwith tool 1799-02, and thesleeve.

Mount the lower bushings.

Apply some Öhlins greengrease on the seals.

Again, use tool 1799-02 turnit around to install the sealin the outer leg.

Install the circlip and thescraper.

CAUTION!Make sure the circlip isfitted correctly into thegroove in the outer leg.

1799-02

1799-02


12/1612

e

f

d NotesFasten the fork leg, at the fork

bottom, with soft jaws in a vice.

Install the compression valveassembly in the fork bottom.

Tightening torque 65 Nm.

Apply some front fork oil onthe outer surface of the inner

leg, and push the outer leg upand down a few times.

Measure the correct amountof oil according to the specifi-cation card.

First, fill up the cartridge tube,then raise up the outer legabout 250 mm and add theremaining oil.

Install the fork top cap and thelock nut.

Tighten the top cap and thelock nut against each other,use a 16 and 24 mm wrench.

Fit the fork legs on the motor-cycle.

For tightening torques, pleasesee your bike's work shopmanual.

Adjust the compression- andthe rebound valves according

to the specification card.

Install the damper rod assem-bly into the cartridge tube.Use Lotite 542 on the car-tridge top lid.

Tighten with tool 1797-01.Tightening torque 65 Nm.

Pump the damper rod up anddown a few times to checkthat there is no air left.

Pull out the damper rod as far

as possible and close thecompression- and the reboundvalves.

Install the spring and thepreload spacer.


13/1613

Technical specificationsFork lengths and diameters

Front fork Motorcycle Length (L) ØA ØBFG 012 GasGas 938 mm 53,9 mm 58,4 mm

Rebound and compression adjustmentRefer 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 adjustmentrange 3-13 mm (with washers).Spring rate:All forks: 2328-41 4,1 N/mm.

2328-43 4,3 N/mm suppliedOptional spring rate:2328-39: 3,9 N/mm.2328-45: 4,5 N/mm.2328-47: 4,7 N/mmOil level:See mounting instruction for recommended oil level.Adjustment range 90-130 mm.

CAUTION!Use only Öhlins high performance frontfork fluid No. 5 (1305-01).

Loctite glue:

542 for fork bottom thread and cartridge top lid.Tighten torque:Triple clamp bolt: See your bike's work shop manual.Compression valve: 65 Nm (Base valve).Cylinder tube lid (cartridgetube): 65 NmCompression valve, 8 mm nut 8 Nm.Rebound valve, 8 mm nut 8 Nm.Grease:Öhlins Front Fork grease 148-01(Green grease).Service Intervals:Every 20 hours.

Service tools

Pos. Part No. Description

1 1799-02 Bushing/seal mounting tool2 0786-03 Inner tube tool3 1797-01 Tool-cylinder tube lid4 0787-03 Cylinder tube tool (cartridge)5 1702-02 Bushing remover tool

1

2

3

4

5

ØA

ØB

L

70

300

200


14/1614

Spare parts

Pos. Part No. Pcs. Description Type/remarks

1 02338-01 2 Nut2 02306-02 2 Top cap3 00438-17 2 O-ring4 02337-01 2 Spring support5 02319-01 Preload washer see spec. card6 02328-39 2 Spring front fork 3,9 N/mm

02328-41 2 4,1 N/mm

02328-43 2 4,3 N/mm02328-45 2 4,5 N/mm02328-47 2 4,7 N/mm

7 02324-01 2 Fork leg outer8 00329-02 2 Circlip9 02021-01 4 Bushing lower

10 02325-01 2 Sleeve11 02332-03 2 Cover Sticker Öhlins12 01552-01 2 Washer13 02336-01 2 Seal14 02015-01 2 Circlip15 02014-01 2 Scraper17 02339-01 2 Cylinder tube cartridge18 02022-01 2 Bushing upper

19 02315-83 2 Fork leg inner20 02309-80 1 Cover fork leg pair21 00438-30 2 O-ring22 02314-01 6 Bolt23 02372-01 1 Fork bottom left24 02372-02 1 Fork bottom right25 02314-02 4 Bolt fork bottom- 00195-01 2 Sticker Öhlins white / transparent

1

2

3

4

5

6

7

8

9

10

12

13

14

2425

21

23

25

18

1920

22

22

22

26

17

9

11

15


15/1615

Spare parts

Pos. Part No. Pcs. Description Type/remarks

1 02338-01 2 Lock nut2 01050-01 2 Screw3 00338-59 2 O-ring4 02306-01 2 Top cap5 01473-02 2 Circlip6 00338-53 2 O-ring7 02321-02 1 Adjustment screw

8 01248-01 2 Spring9 00884-04 4 Ball10 02366-12 2 Adjustment rod11 00338-76 2 O-ring12 02301-03 2 Needle housing13 02302-03 2 Guiding sleeve14 02303-01 2 Sleeve15 02304-01 2 Hydraulic stop16 00131-05 2 Circlip17 01499-02 2 Circlip18 02305-03 2 Cylinder tube cap19 02059-01 2 Bushing holder20 00338-19 2 O-ring21 00110-01 2 Bushing

22 02340-01 2 Washer23 02307-01 2 Shaft24 02063-02 2 Spring25 00438-31 2 O-ring26 02356-03 2 Rebound needle27 02322-01 2 Spring28 02320-03 2 Piston holder29 00530-18 8 Shim washer see spec. card,

notes30 01149-01 6 Wave washer see spec. card,

notes31 - Shims see spec. card,

notes32 02335-01 2 Rebound piston

33 01447-02 2 Piston ring34 - - Shim see spec. card,rebound

36 - 2 Clamp washer see spec. card,rebound

37 00153-01 2 Washer38 00430-05 2 Lock nut39 01473-02 2 Circlip40 00338-53 2 O-ring41 01242-05 2 Adjustment needle42 01248-01 2 Spring43 00884-04 4 Ball44 02054-02 2 End piece45 00438-02 2 O-ring46 - 2 Clamp washer see spec. card

compression47 - - Shims see spec. card

compression48 02334-01 2 Compression piston49 00438-03 2 O-ring50 00530-22 2 Shims51 01149-01 2 Wave washer52 00153-01 2 Washer53 00430-05 2 Nut

1

4

5

7

6

10

11

12

13

14

151617

18

19

2021

22

23

23

9

8

24

25

2627

28

293031

32

3334

363738

394041

43

42

44

45

46

47

4849

505152

53


16/16

0 7 2

9 5

- 0 8

TekniskIllustrationAB,OM

Motocrossfro

ntfork,0012,250ex.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.E-mail: [email protected]: www.ohlins.com

Motorcycles

AUSTRALIASteve Cramer Proucts, BRAESIDE, Tel. +61 3 9587 1466, Fax. +61 3 9587 2018AUSTRIAMotopart Handelsges. m.b.H., WIEN, Tel. +43 1 667 6628, Fax. +43 1 667 0696CANADAS. Hansen Racing Products, EDMONTON, Tel. +1 403 466 8653, Fax. +1 403 465-9483CROATIA

Moto ZIP trgovina d.o.o, KRANJ, Tel: +386 64 268 515, Fax: +386 64 268 514DENMARKF.I. Motorcykler ApS, SORÖ, Tel. +45 57 833 348, Fax. +45 57 834 855ESTONIARamo Ltd, VORU, Tel. +372 78 219 59, Fax. +372 78 219 59FINLANDMauri Penttilä Racing, HYVINKÄÄ, Tel. +358 19 437 100, Fax. +358 19 489 872FRANCEP.F.P - Öhlins France, Arpajon-Sur-Cere, Tel. +33 471 481 534, Fax. +33 471 642 593GERMANYZupin Moto-Sport GmbH, TRAUNREUT, Tel. +49 8669 8480, Fax. +49 8669 848590GREECEVassilis Dulaveris, ATHENS, Tel. +30 1-923 6051, Fax. +30 1-924 9957HONG KONGPower Motorcycle Specialist, KOWLOON, Tel. +852 3903 949, Fax. +852 3919 434ICELAND

Baldurssons Trading, AKUREYRI, Tel: +354 8545 3136, Fax: +354 462 2777ITALYMotorquality S.p.A., SESTO S GIOVANNI (MI), Tel. +39 02 249 511, Fax. +39 02 2495 1232JAPANCarrozzeria Japan Co., Ltd., SAITAMA-PREF; 336, Tel. +81 48 863 1801, Fax. +81 48 863 1802The NETHERLANDS, BELGIUM, LUXEMBURGWim Kroon Import V.O.F., HV MILL, Tel. +31 485 453 911, Fax. +31 485 454 848NORWAYMC-Spesialisten, SKÅRER, Tel. +47 67 920 380, Fax. +47 67 972 855NEW ZEALANDHawera Motorcycles LMVD, HAWERA TARNAKI, Tel.+64 627 84160, Fax. +64 627 86552POLANDP.T.M. SP. zo.o., NIEPORET, Tel. +48 22 774 8978, Fax. +48 22 774 8978PORTUGALMotoni, AMADORA, Tel. +351 1 472 8160, Fax. +351 1 471 4809

RUSSIAAlpine Ltd, MOSCOW 121 552, Tel. +7 95 149 5069, Fax. +7 95 141 2310

Öhlins distributors

SINGAPORESporting Motorcycles, SINGAPORE 1232, Tel. +65 250 5508, Fax. +65 253 6312SLOVENIAMoto ZIP trgovina d.o.o, KRANJ, Tel: +386 64 26 85 15, Fax: +386 64 26 85 14SPAINZacatin S.A., TORREJON DE ARDOZ, Tel. +34 91 677 7897, Fax. +34 91 677 6123SWITZERLAND

3W Motorsport, WINTERTHUR, Tel. +41 52 315 3188, Fax. +41 52 315 3754TAIWANHenly Company Ltd, TAIPEI 10422, Tel. +886 2 5375 600, Fax. +886 2 5631 357TURKEYDemaks Motor-Servis Hizmetleri A.S., ISTANBUL,Tel. +90 216 442 1580,Fax. +90 216 442 2380U.K.Harris Performance Prod. Ltd., HERTFORD, Tel. +44 1992 551 026, Fax. +44 1992 587 052USA and CANADAParts Unlimited, JANESVILLE, WI 53547, Tel. +1 608 758 1111, Fax. +1 608 758 1144service

Pettersson Pro Suspension, ANAHEIM, CA 92807, Tel. +1 714 630 4777, Fax. +1 714 630 4788service

TUF Racing Products, DEKALB, IL 60115, Tel. +1 815 756 3588, Fax. +1 815 756 3528(MX & Enduro steeringdampers)Scotts Performance MC Products, MONTROSE, Tel. +1 818 248 6747, Fax. +1 818 248 4529

Öhlins Authorized Dealers in SWEDEN

Claessons Motor AB, Bromölla, Tel. 0456-230 30, Fax. 0456-232 31R G Motor AB, Helsingborg, Tel. 042-16 96 60, Fax. 042-16 18 15Nilssons Motor AB, Skåne-Fagerhult, Tel. 0433-300 70, Fax. 0433-300 80DML Pro Bike, Värnamo, Tel. 0370-271 00, Fax 0370-271 61LEJ Motor AB, Skövde, Tel. 0500-48 11 95, Fax. 0500-46 17 14Carlbarks Motor AB, Kumla, Tel. 019-57 07 01, Fax. 019-58 12 74Beviks Motor AB, Linköping, Tel. 013-36 25 00, Fax. 013-36 25 10BIKE Trollhättan AB, Trollhättan, Tel. 0520-700 75, Fax. 0520-762 84Stötdämparexperten AB, Stockholm, Tel. 08-650 10 07, Fax. 08-650 10 09Schneiders MC AB, Upplands Väsby, Tel. 08-590 310 80, Fax. 08-590 725 53MB Racing AB, Västerås, Tel. 021-81 17 77, Fax. 021-81 17 78

Revelj Racing, Hede, Tel. 0684-120 59, Fax. 0684-122 75Two Wheels I Umeå AB, Umeå, Tel. 090-187 595, Fax 090-18 77 61Heds Motor AB, Boden, Tel. 0921-175 10, Fax.0921-162 20

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