Ohlins SUPERBIKE FG 570 manual

Owners Manual Öhlins Superbike Fr ont Fork FG 570[...]

Safety signals Important information concerning safety is distinguished in this manual by the following notations: This Safety alert symbol means: Caution! Y our safety is involved. ! W ARNING! Failure to follow warning instructions could result in severe or fatal injur y to anyone working with, inspecting or using the sus- pension, or to bystander[...]

Öhlins Fr ont Fork FG 570 This Super Bike front fork is an impr oved version of FG 470 with pressurised damp- ing system. FG 570 is based on 5 years experience from factory r oad racing. The pressurised damping system impr oves the front fork function at high fr equency move- ments. The immediate damping responses improve the tyr e feeling and als[...]

Adjusters Y our Öhlins super bike fr ont fork is pro- vided with the following external adjusters: • Spring pre-load adjuster • Rebound damping adjuster . • T wo type of compr ession damping adjuster: - Reservoir valve adjuster in the lower part of the fork leg. - Main valve bleed circuit. NOTE! The rebound damping adjuster is located at the[...]

Setting up your forks Here is some basic guidelines, how to set up your Öhlins front forks. However you must remember that the fr ont 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. 1 Put your bike on a front stand and fit the Öhlins front fork. NOTE[...]

Changing springs 12 17 mm socket 1. Unload the spring pre-load completely by turning the adjustment nut counter clockwise as far as possible. Use a 17 mm wrench or socket. 2. Loosen the screws that hold the fork legs in the upper triple clamps. 3. Remove the T op nut assembly . Use tool 797-01. 4. Remove the top nut assembly from the piston shaft. [...]

180 0 1st, Circlip 2nd, Seal 3rd, W asher Changing seals 1. Remove the fork legs from the motor cycle. Put the fork legs in upright position for about 5 minutes to allow the oil to settle. 2. Fasten the fork leg in a vice. Use soft jaws. 3. Carry out instructions 1 to 5 in “Changing springs”, page 6. 4. Drain the cylinder tube from oil. 5. Remo[...]

Dismantling the Forks 1. Remove the fork legs from the motor cycle. Put the fork legs in upright position for about 5 minutes to allow the oil to settle. 2. Fasten the fork leg in a vice. Use soft jaws. 3. Unload the spring pre-load completely by turning the adjustment nut counter clockwise as far as possible. Use a 17 mm wrench or socket. 4. Loose[...]

! W ARNING! Releasing high pressure gas from the front fork can be hazardous. Do not perform any kind of service until gas pr essure is com- pletely released. 9. Remove the circlip. 10. Use tool 720-03 to lift up the reservoir end cap. Install the tool 720-02 into the gas piston. 11. Use tool 1797-04 and 1765-03 to unscrew the seal head from the ca[...]

13. Remove the Piston holder . Use a 14 mm wrench. 14. Remove the T opout spring, the Sleeve, the Spacer and the O-ring. 15. Remove the Seal head. Check the O-ring and the X-ring. Change them if necessary . 16. Remove the needle and change the O-ring if necessary . 17. Drain the cylinder tube from oil. 18. Remove the gas piston in the reservoir , u[...]

22 23 Upper bushing Lower bushing Heat air gun 22. Remove the outer tube, clean the seal and check the condition. If the seal is in good condition apply some red gr ease (146-01) to it. A damaged seal must be replaced! 23. First remove the cir clip, then the seal and finally the washer . 24. Heat the tube where the bushings ar e posi- tioned. Use a[...]

Assembly of the forks 1. Use T ool 786-07 to r efit the reservoir tube. Tighten to 45 Nm. 2. Use T ool 786-05 to r efit the inner tube of the fork leg. Tighten to 80 Nm. 3. Put the outer tube standing up on a soft surface, seal side up. Fit the bushings from the seal side of the outer leg. Install first the upper bushing then the lower one. Use ins[...]

6. 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: 7. Apply some front fork oil (1311-01) to the inner tube surf[...]

10. Grip the piston shaft with soft jaws 727-02. Fit the O-ring on the adjustment needle. Apply plenty of red gr ease on the O-ring so that the needle slides easily into the piston shaft. 11. Check the X-ring and O-ring on the seal head. Replace if necessary . Smear plenty of white grease on the X-ring befor e you fit it. Use tool 0715-01 to get th[...]

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. 14. Fit the Seal [...]

! W ARNING! Use of infl ammable gas for pressurising the soch absorber can be hazardous. Use nitrogen gas (N2) only! 19. Check the gas pressur e stipulated in the spec. card. Dip the needle of the gas tool (1781-01) in red gr ease and insert the nee- dle through the gas filler valve. Char ge with gas to the correct pr essure, according to the spec[...]

Oil level adjustment Compared with conventional type of fr ont forks, the upside down front forks ar e very sensitive to variations in oil level. Therefor e, 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 ef fect at the end of the tra[...]

T roubleshooting Below are a few examples of how to adjust for the most common road holding pr ob- lems in Road Racing driving. 1. 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 . • This is caused by the fact that the fork is working too low in the travel [...]

Guidelines The settings on this pressurised Fr ont Fork are based on what curr ently is being used in Moto GP racing, furthermore the delivery spec is something we like to refer to as a “balanced setting”. This means that the pressur e drop over the bottom valves (base valves) and the top pistons (ø25mm) are matched. In order to avoid an unnec[...]

Individual adjustments Individual adjustments Below you can find the recommended ad- justment range for the top left compression leg adjuster , with differ ent positions on the bottom base valve. From soft to har d: Base 19 clicks, top 17-20 clicks Base 16 clicks, top 14-18 clicks Base 12 clicks, top 1 1-14 clicks Base 10 clicks, top 10-12 clicks B[...]

Notes 21[...]

T echnical 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”. Maximum open [...]

1 - 2 T op nut assembly See page 24 2 01408-04 2 Adjustment driver 3 04744-95 04744-10 04744-90 2 2 2 Spring Option spring Option spring 25.5/260/9.5 25.5/260/10.0 25.5/260/9.0 4 01438-04 4 Guide ring 5 01460-37 2 Preload tube 6 01900-05 2 Fork leg outer 7 01683-02 2 Bushing, upper 8 01684-02 2 Bushing, lower 9 04758-01 2 W asher 10 04720-02 2 Seal[...]

1 04747-02 2 Cap 2 04756-01 2 Adjuster 3 00884-04 4 Ball 4 04727-01 2 Spring 5 04722-07 2 O-ring 6 04748-01 2 Bolt spring adjuster 7 04722-04 4 O-ring 8 04749-02 2 Plate, center 9 02801-01 2 Adjustment housing 10 00338-61 2 O-ring 11 04751-02 2 W asher 12 04752-01 2 W asher 13 04753-01 2 W asher 14 04762-03 2 Spring seat Pos. Part No. Pcs. Descript[...]

1 01654-07 1 Piston holder 2 00530-22 1 Shims 3 01149-01 1 W ave washer 4 00520-20 1 Shims 5 - 1 W asher See spec. card 6 - - Shim stack (comp.) See spec. card 7 01447-02 1 Piston ring 8 02061-03 1 Piston 9 - - Shim stack (reb.) 10 - 1 W asher See spec. card 11 01674-01 1 W asher 12 00153-01 1 W asher See spec. card 13 01675-01 1 Nut Pos. Part No. [...]

26 1 00727-02 1 Soft jaws (one pair) 2 00786-05 1 Inner tube tool 3 00786-07 1 Cartridge tube tool 4 01781-01 1 Gas tool 5 00797-01 1 T op nut socket 6 01757-01 1 Attachment bar 7 01759-07 1 Dismantling bar 8 01759-08 1 Installing sleeve 9 01758-04 1 Guide ring 10 00720-02 1 Measure pin 11 00720-03 1 Pin tool 12 04705-01 1 Spanner 13 01765-03 1 Pul[...]

Notes 27[...]

Mor e 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 07280-11, Issued 06 07 26. Öhlins Racing AB, Mattias Johansson/Update: Tiina Harakka[...]