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
Safety signals Important information concerning safety is distinguished in this manual by the following notations: The Safety alert symbol means: Caution! Your safety is involved. WARNING! Failure to follow warning instructions could result in severe or fatal injury to anyone working with, inspecting or using the suspension, or to bystanders. CAUTION! Caution indicates that special precautions must be taken to avoid damage to the suspension.
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 1. The compression adjuster is located at the bottom of the fork leg. Rebound adjuster Setting up the bike F We would like to give you some basic guidelines how to set up your bike with your new Öhlins front fork. However, remember that the front fork is just one part of your motorcycle and to get the fork to work properly the whole motorcycle has to be set up according to standards. Please follow the instructions below, see also your bike’s work shop manual.
Setting up the bike A: Fully extended. Rear sag: A - B = 35 ±10 mm. B: On the ground. Front ride height: A - C = 50 ± 10 mm. C: Rider on. Front sag: A - B = 30 ± 10 mm. A: F u B: O lly ext end n th ed. eg C: R r oun ide d. r on . 4. Checking sag and ride height. Rear ride height: A - C = 100 ± 10 mm. Checking front ride height A Put your bike on a stand. Arrange the stand so that the front wheel is off the ground and the front fork fully extended.
Oil level 110 mm Oil level 120 mm Oil level 130 mm 500 450 400 F 350 o r 300 c e 250 k 200 g f 150 Oil level 6. Oil level is measured from the top of the outer leg, with the top nut off,the fork fully compressed and no preload washer nor spring installed. Oil level 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 Front end falls into the curves (oversteering) especially in sand. Steep front fork angle. Front end too low in comparison to rear end. Increas 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 end too high in comparison to rear end. Decrease the front fork compression damping. Raise the fork legs approximately 5 mm in the triple clamp.
1 Preload adjustment 1 4 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. 8 2 2 3 3 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. Install a new preload spacer to achieve the right static sag.
Changing springs 4 7 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. Loosen the screws that hold the fork legs in the lower fork crown. Remove the fork legs from the motorcycle.
Dismantling 10 13 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 screwdriver, release and remove the circlip. 1797-01 11 11 14 CAUTION! The fork legs have two fixed and one sliding bushing. Be very careful when disassembling the fork legs. Fasten the fork leg horizontally with soft jaws in a vice.
13 16 Remove the seals and bushings and check them for wear and damage. Replace if necessary. Assembling 16 Apply a thin layer of Öhlins green grease (148-01) on the scraper ring and on the sealing surface of the fork seal. CAUTION! When removing the oil seal and bushings use a small plastic bag to cover the bushing attachment groove and edges of the inner tube, to avoid damage to the seals.
19 19 20 20 21 21 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 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.
Service tools 3 2 1 Pos. Part No. Description 1 2 3 4 5 1799-02 0786-03 1797-01 0787-03 1702-02 Bushing/seal mounting tool Inner tube tool Tool-cylinder tube lid Cylinder tube tool (cartridge) Bushing remover tool 4 5 Technical specifications Fork lengths and diameters Front fork Motorcycle Length (L) ØA ØB FG 012 GasGas 938 mm 53,9 mm 58,4mm 70 ØA 200 300 ØB L Rebound and compression adjustment Refer to mounting instruction for set-up data.
Spare parts 1 2 3 4 5 6 11 17 9 10 18 20 19 9 12 13 14 15 22 22 21 24 23 25 14 22 25 26 Part No. Pcs. DescriptionType/remarks 1 2 3 4 5 6 02338-01 02306-02 00438-17 02337-01 02319-01 02328-39 02328-41 02328-43 02328-45 02328-47 02324-01 00329-02 02021-01 02325-01 02332-03 01552-01 02336-01 02015-01 02014-01 02339-01 02022-01 02315-83 02309-80 00438-30 02314-01 02372-01 02372-02 02314-02 00195-01 2 2 2 2 Nut Top cap O-ring Spring support Preload washersee spec.
Spare parts 1 2 3 24 4 25 5 6 7 10 11 9 26 27 28 8 29 30 31 32 33 34 12 36 37 38 13 39 40 41 43 42 14 15 16 17 18 44 45 46 47 48 19 20 21 22 23 49 50 51 52 53 Pos. Part No. Pcs.
More info 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. www.ohlins.
