Ohlins FG 470 Owner's Manual
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Ohlins FG 470 Owner's Manual

Superbike front fork
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Öhlins Superbike Front Fork FG 470

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Summary of Contents for Ohlins FG 470

  • Page 1 Owner’s Manual Öhlins Superbike Front Fork FG 470...

  • Page 2: Before Installation

    Safety signals Important information concerning safety is distinguished in this manual by the following notations: This 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 sus- pension, or to bystanders.

  • Page 3: Table Of Contents

    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.

  • Page 4: Adjusters

    Adjusters Your Öhlins super bike front fork is pro- vided with the following external adjusters: • Spring pre-load adjuster • Rebound damping adjuster. • Two type of compression damping adjuster: - Reservoir valve adjuster in the lower part of the fork leg. - Main valve bleed circuit.

  • Page 5: Setting Up Your Forks

    Setting up your forks A-D. Bike on a stand Here is some basic guidelines, how to set up your Öhlins front forks. However you must remember that the front forks are just one part of your motorcycle and to get it to work properly, the whole motorcycle has to be set up according to your bikes manual.

  • Page 6: Changing Springs

    Changing springs Unload the spring pre-load completely by turning the adjustment nut counter clockwise as far as possible. Use a 17 mm wrench or socket. Loosen the screws that hold the fork legs in the upper tripple clamps. Remove the Top nut assembly. Use tool 797-01.

  • Page 7: Changing Seals

    Changing seals Remove the fork legs from the motorcycle. Put the fork legs in upright position for about 5 minutes to allow the oil to settle. Fasten the fork leg in a vice. Use soft jaws. Carry out instructions 1 to 5 in “Changing springs”, page 6.

  • Page 8: Dismantling The Forks

    Dismantling the Forks Remove the fork legs from the motorcycle. Put the fork legs in upright position for about 5 minutes to allow the oil to settle. Fasten the fork leg in a vice. Use soft jaws. Unload the spring pre-load completely by turning the adjustment nut counter clockwise as far as possible.
  • Page 9 WARNING! Releasing high pressure gas from the shock absorber can be hazardous. Do not perform any kind of service until gas pres- sure is completely released. Remove the circlip. Use tool 720-03 to lift up the reservoir end cap. Install the tool 720-02 into the gas piston.
  • Page 10 Remove the Piston holder. Use a 14 mm wrench. Remove the Topout spring, the Sleeve, the Spacer and the O-ring. Remove the Seal head. Check the O-ring and the X-ring. Change them if necessary. Remove the needle and change the O-ring if necessary.
  • Page 11 Remove the outer tube, clean the seal and check the condition. If the seal is in good condition apply some red grease (146-01) to it. A damaged seal must be replaced! First remove the circlip, then the seal and finally the washer. Heat the tube where the bushings are posi- tioned.

  • Page 12: Assembly Of The Forks

    Assembly of the forks Use Tool 786-07 to refit the reservoir tube. Tighten to 45 Nm. Use Tool 786-05 to refit the inner tube of the fork leg. Tighten to 80 Nm. Put the outer tube standing up on a soft surface, seal side up.
  • Page 13 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 if necessary. Install the compression valve assembly into the valve housing. Tighten to 20 Nm. Compression valve assembly: Apply some front fork oil (1305-01) to the inner tube surface and carefully mount the...
  • Page 14 Grip the piston shaft with soft jaws 727-02. 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. Check the X-ring and O-ring on the seal head.
  • Page 15 CAUTION! The Washers must be positioned correctly (Notice that there is a difference between 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). NOTE! The right hand fork leg is the rebound leg. The left hand fork leg is the compression leg.
  • Page 16 WARNING! Use of infl ammable gas for pressurising the soch absorber can be hazardous. Use nitrogen gas (N2) only! 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.

  • Page 17: Oil Level Adjustment

    Oil level adjustment Compared with conventional type of front forks, the upside down front forks are very sensitive to variations in oil level. Therefore, adjust the oil level with special care. A change in the fork oil level will not affect the spring force at the beginning of the fork travel, but will have a great effect at the end of the travel.

  • Page 18: Troubleshooting

    Troubleshooting Below are a few examples of how to adjust for the most common road holding prob- lems in Road Racing driving. The front wheel “chatters” entering a corner, the problem goes away, as soon as you let the brakes off, or when you get on the power.

  • Page 19: Technical Information

    Technical information Fork length: 730 mm. Stroke: 130 mm. Free spring length: 260 mm. Rebound adjustment: Base setting 9-12 “clicks”. Maximum open valve 20 “clicks”. Compression adjustment: Base setting 6-16 “clicks”. Maximum open valve 20 “clicks”. Compression adjustment (Base valve): Base setting 6-16 “clicks”.

  • Page 20: Spare Parts List

    Spare parts list, FG 470 40 41 Pos. Part No. Pcs. Description 01408-04 04744-95 04744-10 04744-90 01438-04 01460-37 01900-05 01683-02 01684-02 04758-01 04720-02 04759-01 02807-01 01901-03 02302-08 01499-01 01440-01 01651-04 01027-04 00438-02 01056-04 00438-41 02803-01 01653-05 01585-11 01698-30 00338-14 02367-06...
  • Page 21 Top nut assey Base valve Spare parts list, Top nut assey Pos. Part No. Pcs. Description 04747-02 04756-01 00884-04 04727-01 04722-07 04748-01 04722-04 04749-02 02801-01 00338-61 04751-02 04752-01 04753-01 04762-03 Spare parts list, Base valve Pos. Part No. Pcs. Description 01675-01 00153-01 00641-02...
  • Page 22 Compression valve Rebound valve Spare parts list, Compression valve (LH) Pos. Part No. Pcs. Description 01654-06 Piston holder 00338-19 O-ring 01618-02 One way valve cup 00530-22 Shims 01149-01 Wave washer 00520-20 Shims 01618-01 Cup holder 00641-02 Washer Shim stack (comp.) 01447-02 Piston ring 02061-03...

  • Page 23: Service Tools

    Service tools Pos. Part No. Pcs. Description 00727-02 00786-05 00786-07 01781-01 00797-01 01757-01 01759-07 01759-08 01758-04 00720-02 00720-03 04705-01 01765-03 01797-04 02810-01 00715-01 Soft jaws (one pair) Inner tube tool Cartridge tube tool Gas tool Top nut socket Attachment bar Dismantling bar Installing sleeve Guide ring...
  • Page 24 More info www.ohlins.com Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80...

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