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Ohlins FG 012 GasGas Owner's Manual

Manual is about: motocross front forks

Summary of FG 012 GasGas

  • Page 1

    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

    2 contents safety signals ............................. 2 introduction ................................ 3 design ....................................... 3 before you start ......................... 3 marking ...................................... 3 recommended settings ............. 3 mounting instr...

  • Page 3

    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“ (the air trapped above the oil) that work together w...

  • Page 4

    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 static sag a put your bike on a stand. Arrange the stand so th...

  • Page 5

    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. Make a note of the measurement. B race dressed sit o...

  • Page 6

    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, see fig 6. A change in oil level should be made in...

  • Page 7

    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. Lower fork leg approximately 5 mm in the triple clamp. B front e...

  • Page 8

    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. 2 put a box under the front wheel so that the spr...

  • Page 9

    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 crown. Remove the fork legs from the motorcycle. 5 fa...

  • Page 10

    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 and remove the circlip. 11 caution! The fork legs have two fix...

  • Page 11

    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 w...

  • Page 12

    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 correct am...

  • Page 13

    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 valve: 20 clicks. Free spring length: all forks: 46...

  • Page 14

    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 02328-43 2 4,3 n/mm 02328-45 2 4,5 n/mm 02328-47 2 4,7 n...

  • Page 15

    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 10 02366-12 2 adjustment rod 11 00338-76 2 o-ring ...

  • Page 16

    16 07295-08 t eknisk illustration ab, om motocr oss fr ont 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 lot more. Öhlins racing ab, box 722, s-194 27 u...