Ohlins FG 012 manual

1 Owners manual Öhlins motocr oss fr ont forks FG 012 GasGas Including: Setting up your bike Fine-tuning Service the fork General handling set-up T echnical info Spare par ts & tools[...]

2 Contents Safety signals ............................. 2 Introduction ................................ 3 Design ....................................... 3 Before you start ......................... 3 Marking ...................................... 3 Recommended settings ............. 3 Mounting instructions ................. 4 Setting up the bike ..[...]

3 cated at the bottom of the fork leg, fig 1, the rebound adjuster at the top, fig 2. Spring preload is adjusted with washers, fig 3, and optional springs ar e available to suit differ ent tracks and riders. In the legs ther e are also “air - springs“ (the air trapped above the oil) that work together with the “real“ spring. Y ou adjust the[...]

4 F Spring pr eload is adjusted with spacers, see “Preload adjustment“ on page 8. Maximum allowed spring pr eload is 13 mm. If you need to pr eload the springs more than 13 mm, we r ecommend you to change to a “stiffer“ spring. Checking r ear static sag A Put your bike on a stand. Arrange the stand so that the rear wheel is of f the ground [...]

5 Checking front ride height A Put your bike on a stand. Arrange the stand so that the fr ont wheel is off the gr ound and the fr ont fork fully extended. Measure the distance between the up- per fork crown and the fr ont wheel axle, fig 4 distance A. Make a note of the measurement. B Race dressed sit on the bike, straight above the foot pegs, with[...]

6 CAUTION! Adjust the oil level with the fork leg fully compressed and no preload washer nor spring installed. NOTE! See mounting instruction for rec- ommended oil level. The oil level is measured fr om the top of the outer leg, with the top nut off, see fig 6. A change in oil level should be made in small steps. W e recommend a change of 5 mm at a[...]

7 General handling set-up A Front end falls into the curves (over - steering) especially in sand. Steep front fork angle. Fr ont end too low in comparison to rear end.  Increas the fr ont fork compression damping.  Change to harder springs.  Lower fork leg approximately 5 mm in the triple clamp. B Front end ”ploughs”, understeers. Shal[...]

8 Preload adjustment 1 Put the bike on a stand and loosen the screws in the fork top cr own 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. 2 Put a box under the front wheel so that the springs are visible. Remove the top cap from the dam[...]

9 Changing springs 4 Loosen the screws that hold the fork legs in the upper fork crown. With the fork leg still tightened in the lower fork crown unscr ew the top cap, use a 24 mm wrench. Loosen the scr ews that hold the fork legs in the lower fork cr own. Remove the fork legs from the motorcycle. 5 Fasten the fork leg with soft jaws in a vice and [...]

10 Dismantling 10 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 scr ew- driver , release and remove the cir clip. 11 CAUTION! The fork legs have two fixed and one sliding bushing. Be very c[...]

11 13 Remove the seals and bushings and check them for wear and damage. Replace if necessary . 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. 14 Fasten the damper rod assembly with soft jaws in a vice. Remove all parts fr om t[...]

12 Notes 19 Fasten the fork leg, at the fork bottom, with soft jaws in a vice. Install the compression valve as- sembly 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 corr ect amount of oil accor ding to the specification card.[...]

13 T echnical specifications Fork lengths and diameters Front fork Motorcycle Length (L) ØA ØB FG 012 GasGas 938 mm 53,9 mm 58,4mm Rebound and compression adjustment Refer to mounting instruction for set-up data. Maximum open rebound and compr ession valve: 20 clicks. Free Spring Length: All forks: 467 mm (service limit 460 mm). Spring preload: M[...]

14 Spare parts Pos. Part No. Pcs. DescriptionT ype/remarks 1 02338-01 2 Nut 2 02306-02 2 T op cap 3 00438-17 2 O-ring 4 02337-01 2 Spring support 5 02319-01 Pr eload washer see spec. car d 6 02328-39 2 Spring front fork 3,9 N/mm 02328-41 2 4,1 N/mm 02328-43 2 4,3 N/mm 02328-45 2 4,5 N/mm 02328-47 2 4,7 N/mm 7 02324-01 2 Fork leg outer 8 00329-02 2 [...]

15 Spar e parts Pos. Part No. Pcs. Description T ype/remarks 1 02338-01 2 Lock nut 2 01050-01 2 Screw 3 00338-59 2 O-ring 4 02306-02 2 T op cap 5 01473-02 2 Circlip 6 00338-53 2 O-ring 7 02321-02 1 Adjustment screw 8 01248-01 2 Spring 9 00884-04 4 Ball 10 02366-12 2 Adjustment rod 11 00338-76 2 O-ring 12 02301-03 2 Needle housing 13 02302-03 2 Guid[...]

16 07295-08 T eknisk Illustration AB, OM Motocr oss front fork FG 012 GasGas, 02 02. 200 ex. Mor e info www .ohlins.com The ultimate suspension site. Find out everything about your suspension. Download mounting instructions, manuals and br ochur es. And a lot mor e. Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby , Sweden Phone +46 8 590 025 0[...]