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12

e

f

d

Notes

Fasten the fork leg, at the fork
bottom, with soft jaws in a
vice.

Install the compression valve
assembly in the fork bottom.

Tightening torque 45 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 amount
of oil according to the specifi-
cation card.

First, fill up the cartridge tube,
then raise up the outer leg
about 250 mm and add the
remaining oil.

Install the fork top cap and the
lock nut.

Tighten the top cap and the
lock nut against each other,
use a 16 and 24 mm wrench.

Fit the fork legs on the motor-
cycle.

For tightening torques, please
see your bike's work shop
manual.

Adjust the compression- and
the rebound valves according
to the specification card.

Install the damper rod assem-
bly into the cartridge tube.
Use Lotite 542 on the car-
tridge top lid.

Tighten with tool 1797-01.
Tightening torque 40 Nm.

Pump the damper rod up and
down a few times to check
that there is no air left.

Pull out the damper rod as far
as possible and close the
compression- and the rebound
valves.

Install the spring and the
preload spacer.

Summary of Contents for CANNONDALE FG 9910

Page 1: ...ers manual hlins motocross front forks FG 9910 Cannondale Traction handling comfort and safety Including Setting up your bike Fine tuning Service the fork Trouble shooting Technical info Spare parts t...

Page 2: ...ortant information concerning safety is distinguished in this manual by the following notations The Safety alert symbol means Caution Your safety is involved WARNING Failure to follow warning instruct...

Page 3: ...uccessful cooperation with the World Championship winning works motocross teams Spring rates and damping forces are developed just for your bike The design and the settings are conse quently the resul...

Page 4: ...ring preload is adjusted with washers and optional springs are available Preload adjustment 2 The rebound adjuster at the top of the fork leg Rebound adjuster Mounting instructions WARNING 1 It is adv...

Page 5: ...the two measure ments should be 100 10 mm CAUTION Do not try to alter ride height by alter ing the spring preload A new spring is needed D A stiffer spring is needed if the difference is more than 110...

Page 6: ...ters should normally not be adjusted in steps of more than 2 clicks at a time and not outside the usable click range When you think you have made an improvement go back to what you started with and do...

Page 7: ...mping Decrease the spring preload Clean the oil seals and scrapers Use hlins grease 148 01 for regreasing F Can handle the first in a series of bumps but feels hard after a few more bumps Frontal grip...

Page 8: ...p cap Unscrew the top cap use a 24 mm wrench a b Put a box under the front wheel so that the springs are visible Loosen the top cap from damper rod extender and re move it Remove the spring support In...

Page 9: ...pport the preload washer and the spring For free spring length see tech nical information on page 13 NOTE Closing the compression and the rebound valves will keep the damper rod extended making it eas...

Page 10: ...er leg where the bush ings are located The first bushing is located at the bottom end of the outer leg the second approximately 150 mm further up the leg Between them is a sleeve to maintain the dista...

Page 11: ...der on the bench Inspect all parts for wear and damage replace if necessary Clean all parts thoroughly Assemble the compression valve Assembling Apply a thin layer of hlins green grease 148 01 on the...

Page 12: ...fork top cap and the lock nut Tighten the top cap and the lock nut against each other use a 16 and 24 mm wrench Fit the fork legs on the motor cycle For tightening torques please see your bike s work...

Page 13: ...ommended oil level Adjustment range 90 130 mm CAUTION Use only hlins high performance front fork fluid No 5 1305 01 Loctite glue 542 for fork bottom thread and cartridge top lid Tighten torque Triple...

Page 14: ...Sticker 11 00329 02 2 Circlip 12 02021 01 2 Bush 13 02325 01 2 Sleeve 14 02021 01 2 Bush 15 01552 01 2 Washer 16 02336 01 2 Seal 17 02015 01 2 Circlip 18 02014 01 2 Scraper 19 02339 01 2 Cylinder tube...

Page 15: ...2 Spring 28 02320 03 2 Piston holder 29 Shims see spec card 30 01149 01 2 Wave washer see spec card 31 00530 22 2 Shims 32 02335 01 2 Rebound piston 33 01447 02 2 Piston ring 34 Shims see spec card re...

Page 16: ...eknisk Illustration AB OM motocross front fork 99 12 400 ex hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 E mail info ohlins se Traction handling com...

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