Ohlins FG 012 Owner's Manual

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Ohlins FG 012 Manual Information:

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Summary of Contents:

[Page 1] Ohlins FG 012

1 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 ...

[Page 2] Ohlins FG 012

2 Contents Safety signals ............................. 2 Introduction................................ 3 Design ....................................... 3 Before you start ......................... 3 Marking...................................... 3 Rec...

[Page 3] Ohlins FG 012

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 are available to suit different tracks and riders. In the legs there are also “air- springs�...

[Page 4] Ohlins FG 012

4 F Spring preload is adjusted with spacers, see “Preload adjustment“ on page 8. Maximum allowed spring preload is 13 mm. If you need to preload the springs more than 13 mm, we recommend you to change to a “stiffer“ spring. Checking rear stat...

[Page 5] Ohlins FG 012

5 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. Measure the distance between the up- per fork crown and the front wheel axle, fig 4 distance A. Ma...

[Page 6] Ohlins FG 012

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 from the top of the outer leg, with the top nut off, ...

[Page 7] Ohlins FG 012

7 General handling set-up A Front end falls into the curves (over- steering) 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.  Lo...

[Page 8] Ohlins FG 012

8 Preload adjustment 1 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....

[Page 9] Ohlins FG 012

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 unscrew the top cap, use a 24 mm wrench. Loosen the screws that hold the fork legs in the lower fork cro...

[Page 10] Ohlins FG 012

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 screw- driver, release an...

[Page 11] Ohlins FG 012

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...

[Page 12] Ohlins FG 012

12 Notes19 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 le...

[Page 13] Ohlins FG 012

13 Technical 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 compression...

[Page 14] Ohlins FG 012

14 Spare parts Pos. Part No. Pcs. DescriptionType/remarks 1 02338-01 2 Nut 2 02306-02 2 Top cap 3 00438-17 2 O-ring 4 02337-01 2 Spring support 5 02319-01 Preload washersee spec. card 6 02328-39 2 Spring front fork 3,9 N/mm 02328-41 2 4,1 N/mm 02328-...

[Page 15] Ohlins FG 012

15 Spare parts Pos. Part No. Pcs. Description Type/remarks 1 02338-01 2 Lock nut 2 01050-01 2 Screw 3 00338-59 2 O-ring 4 02306-02 2 Top 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 ...

[Page 16] Ohlins FG 012

16 07295-08 Teknisk Illustration AB, OM Motocross front fork FG 012 GasGas, 02 02. 200 ex. More info www.ohlins.com The ultimate suspension site. Find out everything about your suspension. Download mounting instructions, manuals and brochures. And a...