Instruction/ maintenance manual of the product SUPERBIKE FG 570 Ohlins
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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.
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.
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.
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.
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 .
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.
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.
! 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.
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 .
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 .
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.
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.
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 .
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.
! 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.
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.
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 .
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.
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.
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”.
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.
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.
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.
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 Dismantli.
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.
An important point after buying a device Ohlins SUPERBIKE FG 570 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Ohlins SUPERBIKE FG 570 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Ohlins SUPERBIKE FG 570 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Ohlins SUPERBIKE FG 570 you will learn all the available features of the product, as well as information on its operation. The information that you get Ohlins SUPERBIKE FG 570 will certainly help you make a decision on the purchase.
If you already are a holder of Ohlins SUPERBIKE FG 570, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Ohlins SUPERBIKE FG 570.
However, one of the most important roles played by the user manual is to help in solving problems with Ohlins SUPERBIKE FG 570. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Ohlins SUPERBIKE FG 570 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
