Öhlins Front Fork Kit for Gas Gas EC 300

FGGG 992Owner’s Manual - Mounting Instructions

PartNo PcsFrontForkkit FGGG992 1O-ring 00338-10 2O-ring 00438-97 2Baseplug 15430-07 2Circlip 15440-01 2Spacer2mm 15443-02 2Spacer3mm 15443-03 2Washerspringsupport 15450-01 2Hydraulicstopcup 15456-03 2ÖhlinsSticker 00197-01 2TTXCartridgeSticker 00191-29 2Owner’sManual/MountInstrFGGG992 07296-70 1

Before installing this product, check the contents of the kit. If anything is missing, please contact your Öhlins dealer.

Kit Contents

Please note that during storage and transportation, especially at high ambient temperature, some of the oil and grease used for assembling may leak and stain the packaging. This is in no way detrimental to the product, wipe off the excessive oil/grease with a cloth.

Warning!Before installing this product, read this manual carefully. The front fork is an important part of your vehicle and may affect the stability. The installation procedure requires certain tools.

Note!Order Oil and Spring Kit separately. For correct spring rate see Spring Guide in this manual. Use Öhlins Front Fork fluid 01312-xx only.

Safety Precautions

©ÖhlinsRacingAB.Allrightsreserved.Anyreprintingorunauthorizedusewithoutthewritten

permissionofÖhlinsRacingABisprohibited.PrintedinSweden.

Safety SymbolsInthismanual,mountinginstructionsandothertechnicaldocuments,importantinformationconcerningsafetyisdistinguishedbythefollowingsymbols:

The Safety Alert Symbol means: Warning! Your safety is involved.

Warning!The Warning Symbol means: Failure to follow warning instructions can result in severe or fatal injury to anyone working with, inspecting or using the front fork, or to bystanders.

Caution!The Caution Symbol means: Special precautions must be taken to avoid damage to the front fork.

Note!The Note Symbol indicates information that is important regarding procedures.

Note!The front fork is a very important part of the vehicle and will therefore affect the stability.

Read and make sure that you understand the information in this manual and the mounting instructions before you use this product. If you have any questions regarding installation or maintenance please contact your Öhlins dealer.

Öhlins Racing AB can not be held responsible for any damage to the front fork, vehicle, other property or injury to persons, if the instructions for installing and maintenance are not followed exactly.

Warning!This product was developed and designed exclusively for a specific vehicle model and should only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer.

This product contains pressurized nitrogen gas (N2 ). Do not open, service or modify this product without proper education (authorized Öhlins dealer/distributor) and proper tools.

After installing this product, take a test ride at low speed to make sure that your vehicle has maintained its stability.

If the suspension makes an abnormal noise, or the function is irregular, or if you notice any leakage from the product, please stop the vehicle immediately and return the product to an Öhlins Service Centre.

Note!When working on this product, always consult your Vehicle Service Manual.

This Manual should be considered as a part of the product and should therefore accompany the product throughout its life cycle.

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Contents

Recommended Tools

RecommendedTools 2HowtoInstall 3ReplaceSpring 6Set-up 7 Set-upData 8SpringPreload 8Adjustments 9 OilVolume-ForceDiagram 9SpringGuide 10InspectionandMaintenance 10

OEMForkCapToolSocket22mm(BottomPlug)Socket12mm(ShaftendAdjusterHousing)Pliers(forthesecuritysnapring)Tool01890-01Plug ForkCapTooloctagon50mm

In This Manual

3

How to InstallRemove the fork legs from the vehicle

Warning!It is advisable to have an Öhlins dealer install the front fork kit.

When installing, consult your Vehicle Service Manual.

1

Putthemotorcycleonaworkstandsothatthefrontwheelbarelytouchestheground.

Warning!Make sure the vehicle is securely supported so that it will not tip.

2

Removethefrontwheelandthebrakecaliper.

3

Measurethedistancefromthetopoftheforklegtothetopoftheuppertripleclampaccordingtofigure.

Note!Note this dimension as fork height position.

4

Loosentheuppertripleclampbylooseningthescrews.

5

Loosen(butnotremove)thetopcap1/2turn.UsetheOEMForkCaptoolfromthemotorcyclemanufacturer.

6

Loosenthelowertripleclampbylooseningthescrews.

7

Removethefrontforklegsfromthemotorcycle.

8

Cleantheforklegsthoroughly.Makesuretocleanunderneaththeforkbottoms.

1

Front leg cover

Front wheel

Upper triple clamp

Lower triple clamp

Brake caliper

Top cap

4

6

22

3

5

4

How to InstallDisassemble the original front fork

9

Followyourvehicleservicemanualtoremovetheoriginalfrontforkkitfromtheforkleg.Turntheforklegupsidedowntopourouttheoil.Make sure that the fork spring does not fall out.

Install the Öhlins front fork kit

10

Smearsomeredgreaseorsimilarontheo-ringsandinstallthemontothebaseplugaccordingtofigure.

11

Installthehydraulicstopcupfromtheupperendoftheforktube.Cleancontactsurfacesbetweenthehydraulicstopcupandforkbottomwithcontactcleaner.

Caution!Make sure that the hydraulic stop cup is well seated before tightening.

12

Installandtightenthebaseplugintotheforkbottom,usea22mmsocket(tighteningtorque45Nm).

Caution!If the hydraulic stop cup is turning, carefully use an impact machine.

13

InstallSpringsupportwasher,optionalpreloadwasher(s)15443-xx(optional - see Set-up data, Spring preload), therecommendedÖhlinsspring(see Spring guide)andthecartridgekitintothestandardforkleg.

Note!The preload washers must be below the spring, at the bottom end of the fork leg.

Fork bottomBase plug

O-ring 00438-97 O-ring 00338-1010

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13

Fork leg

Cartridge kitPreload washer (plastic, optional)

Spring

11

Hydraulic stop cup

Spring support washer (steel)

5

How to Install14

Tightenthecartridgeshaftendintothebaseplugbyturningcounterclockwise.Usea12mmsocket(tighteningtorque18Nm).

15

Installthesecuritysnap-ringattheshaftendgrooveaccordingtofigure.

16

PourÖhlinsFrontForkFluidintheforklegaccordingtotherecommendedsettings.

17

TightentheÖhlinsforktopcapgently.Usethe50mmoctagonForkCapTool.Tighteningtorquemaximum10Nm.

18

CheckandsetthereboundandcompressionvalvesclickpositionsaccordingtotherecommendedsettingsinSet-up data.

19

Installthefrontforklegsintothetripleclamps.Use,tobeginwith,thesameheightpositionasbefore.Tighteningtorque-seeyourVehicleServiceManual.Reinstallthebrakecaliperandfrontwheel-makesurethatallremovedpartsarereinstalledastheywerebeforetheinstallationoftheÖhlinsFrontForkKit.

Note!It is very important that the triple clamps are tightened to the correct torque. See your Vehicle Service Manual.

Top cap tool

17

Security snapring

15

Cartridge shaft end/ Base valve plug

14

6

Security snapring

Bottom end

Oil plug

How to InstallReplace Spring (only)

1Followsteps1-8inchapterRemove the fork legs from the vehicle.

2

Removethesecuritysnapringinthebottomoftheforkwithapairofpliers.

3

Loosenthebottomendofthecartridgekitbyturningclockwise.

4

Installthetool01890-01(oilplug)bypushingitintotheforkbottom.Theplugwillkeeptheoilintheforkwhilechangingthespring.

5

Removethecartridgekitfromtheforklegandchangethespring.Notethesteelspringsupportandplasticpreloadwasher(s)(ifany).

Note!The preload washers must be below the spring, at the bottom end of the fork leg.

6

Installthecartridgekitintotheforklegandpushouttheoilplugtool01890-01.

7

Tightentheshaftend(counterclockwise)intotheforkbottomwithtighteningtorque18Nm.

8

Installthesecuritysnapring.

9

TightentheÖhlinsforktopcapgently.Usethe50mmoctagonForkCapTool.Tighteningtorquemaximum10Nm.

10Installthefrontforklegsintothetripleclamps.Use,tobeginwith,thesameheightpositionasbefore.Tighteningtorque-seeyourVehicleServiceManual.Reinstallthebrakecaliperandfrontwheel-makesurethatallremovedpartsarereinstalledastheywerebeforetheinstallationoftheÖhlinsKit.

Cartridge kit

Spring

2

3

4

5

Fork leg

Preload washer (plastic, optional)

Spring support washer (steel)

7

Set-upWarning!

Before riding, always ensure that the basic settings made by Öhlins are intact. Take notes, adjust in small steps and make only one adjustment at a time.

Step 1 Check Sag and Ride Height

Note!The following procedure should be performed on a flat surface.

Putthemotorcycleonaworkstandsothatbothwheelsareoffthegroundandthesuspensionisunloaded.Mark,forexamplewithapieceoftape,apointimmediatelyabovetherearwheelaxle.Measurethedistancefromthemarkedpointtoafixedpoint,forexamplethewheelaxle.(Seefigurebelow:R1)Measurethedistancefromthebottomoftheuppertripleclamptoafixedpoint,forexamplethefrontwheelaxle.(F1)Putthemotorcycleonthegroundsothatthefrontandtherearsuspensionsareslightlycompressed.Repeatthemeasuringprocedures.(R2andF2)Sitonthemotorcycleinnormalridingposition,properlyoutfittedinyourridinggear.Repeatthemeasuringprocedures.(R3andF3)

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2.

3.

4.

5.

6.

Recommended Measures

IfnootherrecommendationsaregivenintheVehicleManualfollowthemeasuresbelow:

Free sag (R1-R2)

Rear 30±10mmRide height (R1-R3), (F1-F3)

Rear 100±10mm Front 45±10mm

Step 2 Adjust spring preload

Ifyourmeasurementsdiffersignificantlyfromtherecommendationsfromthetableabove,adjustthespringpreload.(SeesectionSpringPreloadinthismanual).Iftherideheightstilldiffersfromtherecomendations,youmayneedtochangespring.ContactyourÖhlinsdealerforadvise.

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Warning!Incorrect spring rate may produce a fork angle that is too steep or too flat. This in turn will give a tendency for over- or understeering, which could seriously affect the handling characteristics of the motorcycle.

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Set-up Data and Spring Preload

Forkspringsmaydifferinlength.Thereforewerecommendyoutocheckthepreloadoneachforklegand,ifnecessary,installpreloadwasherstogetthecorrectvalue.Anegativepreloadofuptominus2mmispossible,sincethetop-outspringstillgivesasmallcompressiononthemainspring.Preloadlessthan-2mmwillmaketheforkspringloosewhenthefrontwheelisofftheground,whichincreaseswearinsidethefork.

Caution!Preload washers must be placed below the spring, otherwise they will restrict oil flow and the fork may break.

Measure Spring Preload

A

B

C

Measurethespringpreloadaccordingtothefollowingsteps;1.MeasureA.Forkoutertubeshouldbesliddowntostopandcartridgepulledouttodistinctstop(requiresaforceofabout30kg).2.MeasureB.3.MeasureC.4.Calculatepreload:Preload=B–A–C5.Adjustpreloadaccordingtothedesiredvalueaccordingtoset-updata,byadding/removingpreloadwashersbelowthespring.

Set-up DataRebounddamping 20clickCompressiondamping14clickSpringpreload 1mmOilvolume 0,280litre

Springpreloadrange -2to8mm (canbeadjustedby adding/removing washers15443-xx)

Oilvolumerange 0,250-0,350litreÖhlinsFrontForkfluid01312-xx

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AdjustmentsCompression damping adjuster

Thecompressionadjusterislocatedatthetopoftheforkleg.Adjustbyturningthescrewwitha3mmallenkey.

Rebound damping adjuster

Thereboundadjusterislocatedatthebottomoftheforkleg.Adjustbyturningthescrewwitha3mmallenkey.

To Reset

Theadjustershaveanormalrighthandthread.Turnthedampingadjustersgentlyclockwisetofullyclosed(pos.zero[0]).Toopen,turncounterclockwise,andcounttheclicksuntilyoureachtherecommendednumber.ForrecommendedclicksseeSet-updata.Staticsagcanonlybechangedwithsofterorharderspringrate.

Caution!Do not use too much force, delicate sealing surfaces can be damaged.

Note!The total stroke of the front fork may differ from the original stroke, so that more or less of the steel tube will be visible when the fork is fully compressed.

Oil volume - Force

Stroke

Forc

e

350cc

315cc

285cc250cc

Compression damping adjuster

Rebound damping adjuster

Diagram: Oil Volume - Force

Preventive maintenance and regular inspection reduces the risk of functional disturbance.

Breather plug Makesuretoaeratethefrontforkatregularintervals:

Putthemotorcycleonaworkstandsothatthefrontwheelbarelytouchestheground.Loosenthebreatherplugtoreleaseexcessivepressureinthefrontfork.

Recommended Service Intervals Every25hours.MakeyourserviceandmaintenanceaccordingtoÖhlinsWorkshopmanual.

Disposal

DiscardedÖhlinsproductsshouldbehandedovertoanauthorizedÖhlinsworkshopordistributorforproperdisposal.

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Spring Guide

Inspection and Maintenance

Brand Rider’s weight* Spring Spring rate kg/pounds N/mm

Gas Gas EC 300 70/154 08762-41 4,1 75/165 08762-43 4,3 80/176 08762-45 4,5 85/187 08762-45 4,5 90/198 08762-47 4,7 95/209 08762-47 4,7

*Rider’sweight:Riderwearingallridingequipment

Breather plug

Spring Guide

ÖhlinsRacingABBox722

S-19427UpplandsVäsby,SwedenPhone+46859002500

fax+46859002580

©ÖhlinsRacingAB.Allrightsreserved.AnyreprintingorunauthorizedusewithoutthewrittenpermissionofÖhlinsRacingABisprohibited.

www.ohlins.com

Öhlins products are subject to continuous improvement and development, therefore, although these instructions include the most up-to-date information available at the time of printing, minor updates may occur.

To find the latest information contact your Öhlins distributor. Please

consult your Öhlins dealer if you have any questions regarding the

contents in this document.

Partno.07296-70_0Issued2009-03-06