2
Contents
Safety signals ............................. 2
Introduction ................................ 3
Design ....................................... 3
Before you start ......................... 3
Marking ...................................... 3
Recommended settings ............. 3
Mounting instructions ................. 4
Setting up the bike ..................... 4
Checking front sag ..................... 4
Checking rear sag ...................... 4
Checking front ride height .......... 5
Checking rear ride height ........... 5
Fine-tuning the bike ................... 5
Making adjustments ................... 6
Oil level adjustment .................... 6
Maintenance .............................. 6
General handling set-up ............. 7
Preload adjustment .................... 8
Changing springs ....................... 9
Dismantling the front fork ......... 10
Assembly of the front fork ........ 11
Service tools ............................ 13
Technical specifications ............ 13
Spare parts .............................. 14
Before installation
Öhlins Racing AB can not be held
responsible for any damage what-
soever to shock absorber or vehicle,
or injury to persons, if the instruc-
tions for fitting and maintenance are
not followed exactly.
Similarly, the warranty will become
null and void if the instructions are
not adhered to.
WARNING!
1. Installing a front fork, that is not
approved by the vehicle manufac-
turer, may affect the stability of your
vehicle. Öhlins Racing AB cannot
be held responsible for any per-
sonal injury or damage whatsoever
that may occur after fitting the front
fork. Contact an Öhlins dealer or
other qualified person for advice.
2. Please study and make certain
that you fully understand all the
mounting instructions and the own-
ers manuals before handling this
front fork kit. If you have any ques-
tions regarding proper installation
procedures, contact an Öhlins
dealer or other qualified person.
3. The vehicle service manual must
be referred to when installing the
Öhlins front fork.
Öhlins products are subject to con-
tinual improvement and develop-
ment. Consequently, although these
instructions include the most up-to-
date information available at the time
of printing, there may be minor dif-
ferences between your suspension
and this manual. Please consult your
Öhlins dealer if you have any
questions with regard to the contents
of the manual.
NOTE!
During storage and transportation,
especially at high ambient tempera-
ture, the oil and grease used for
assembling may run out inside the
packing and damage the expanded
polystyrene packing material. This is
not unusual and is in no way detri-
mental to the shock absorber.
Safety signals
Important information concerning
safety is distinguished in this
manual by the following nota-
tions:
The Safety alert symbol means:
Caution! Your safety is involved.
WARNING!
Failure to follow warning instruc-
tions could result in
severe or
fatal injury
to anyone working
with, inspecting or using the sus-
pension, or to bystanders.
CAUTION!
Caution indicates that special
precautions must be taken to
avoid damage to the suspension.
NOTE!
This indicates information that is
of importance with regard to pro-
cedures.
© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
Öhlins motocross
front fork FG 012 GasGas
