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
Öhlins motocross front forks FG 9910 Cannondale Contents Safety signals Safety signals ................................. 2 Introduction .................................... 3 Design ............................................ 3 Before you start ............................. 3 Kit content ...................................... 3 Marking .......................................... 4 Recommended settings ................. 4 Mounting instructions ..................... 4 Setting up the bike ..................
Introduction Öhlins Racing congratulates you on your choice of front fork for your motocross bike. All Öhlins products are designed with just one aim; to win races. To design a winner you need a concept starting with a unique know-how. You add engineering skill, precision and the best material available. The result is quality, endurance and winning performance.
Compression adjuster Mounting instructions WARNING 1. It is advisable to have an Öhlins dealer or a qualified mechanic to fit your front fork kit. 2. To install the kit you need your motorcycle’s work shop manual. 3. When working on your motorcycle, support it securely so it does not fall over. 1. The compression adjuster is located at the bottom of the fork leg.
Setting up the bike NOTE! D Refer to mounting instruction for more specific set-up data If you need to change the springs, see “Changing springs“ on page 9. D E The static sag should be 30 ±10 mm. Stiffer springs are needed if the difference is more than 60 mm. Softer springs if the difference is less than 40 mm. Consult your Öhlins dealer for the right rate. E If the static sag is less than 20 mm, you need to reduce spring preload.
Oil level 110 mm Oil level 120 mm Oil level 130 mm Oil level 6. Oil level is measured from the top of the outer leg, with the top nut of, the fork fully compressed and no preload washer nor spring installed. 500 450 400 F 350 o r 300 c e 250 Force 5. A change in oil level will effect the damping forces, not in the early stage of fork travel but a great deal in the later stage.
General handling set-up A handle smaller bumps. Damping force not progressive enough. ✓ Increase the oil level. soft during the entire wheel travel. Spring too soft, compression damping too low. ✓ Increase the compression damping. ✓ Change to harder spring. Front end falls into the curves (over-steering) especially in sand. Steep front fork angle. Front end too low in comparison to rear end. ✓ Increase the front fork compression damping. ✓ Change to harder springs.
a Preload adjustment 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. b Put a box under the front wheel so that the springs are visible. b Loosen the top cap from damper rod extender and remove it. Remove the spring support. c Install a new preload spacer to achieve the right static sag.
Changing springs d NOTE Closing the compression- and the rebound valves will keep the damper rod extended making it easier to install the new spring. Loosen the screws that hold the fork legs in the upper fork crown. With the fork leg still tightened in the lower fork crown unscrew the top cap, use a 24 mm wrench. Pull out the damper rod as far as possible. Close the compression and the rebound valve (clockwise). Loosen the screws that hold the fork legs in the lower fork crown.
a Dismantling 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 assembly and drain the oil. Pull up the scraper with a screwdriver, release and remove the circlip. 1797-01 b CAUTION! e The fork legs have three fixed and one sliding bushing. Be very careful when disassembling the fork legs. Fasten the fork leg horizontally with soft jaws in a vice.
Remove the seals and bushings and replace them with new ones. a Assembling 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 assembly with soft jaws in a vice. b Fasten the outer leg with soft jaws in a vice. Install the inner leg and mount the upper bushing with tool 1799-02, and the sleeve.
d Fasten the fork leg, at the fork bottom, with soft jaws in a 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 specification card. First, fill up the cartridge tube, then raise up the outer leg about 250 mm and add the remaining oil. e Install the damper rod assembly into the cartridge tube.
Service tools 3 2 1 Pos. Part No. 1 2 3 4 5 1799-02 0786-03 1797-01 0787-03 1702-02 Description Bushing/seal mounting tool Inner tube tool Tool-cylinder tube lid Cylinder tube tool (cartridge) 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).
Spare parts 2 3 1 4 5 28 Pos. Part No. Pcs.
Spare parts 1 2 3 24 4 5 6 25 26 27 28 9 7 10 8 } 29 30 31 11 32 33 34 12 36 37 38 13 39 40 41 43 42 14 15 16 17 44 45 46 18 47 } Pos. Part No. Pcs.
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.
