User manual CANNONDALE FG9910 OHLINS FORK

[. . . ] Owners manual Öhlins motocross front forks FG 9910 Cannondale Including: Setting up your bike Fine-tuning Service the fork Trouble shooting Technical info Spare parts & tools Traction, handling, comfort and safety 1 Öhlins motocross front forks FG 9910 Cannondale Contents Safety signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Safety signals Important 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 instructions could result in severe or fatal injury to anyone working with, inspecting or using the suspension, 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 procedures Kit contents Before installing the front fork, please check the contents of the kit, listed in the mounting instruction. If anything is missing, contact your Öhlins dealer. NOTE! During storage and transportation, especially at high ambient temperature, the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material. [. . . ] Make a note of the measurement. B Race dressed sit on the bike, straight above the foot pegs, with the feet barely touching the ground. Have somebody to measure between the same point as before, fig 4 distance C. B Race dressed sit on the bike, straight above the foot pegs, with the feet barely touching the ground. Make sure that you have the correct springs and the correct spring preload before making any adjustments. And always start with the Öhlins recommended settings: In general, compression damping changes should be used to influence the bike's stability and response, while rebound damping changes should be used to influence comfort and traction. When you need more damping force, you should mainly try to increase compression damping and use as little rebound damping as possible. This usually means that you gain comfort and performance in handling. CAUTION! Adjust the oil level with the fork leg fully compressed and no preload washer nor spring installed. NOTE! See mounting instruction for recommended oil level. The oil level is measured from the top of the outer leg, with the top nut off, see fig 6. We recommend a change of 5 mm at a time and not outside the range of 80-130 mm. Oil level adjustment As the air trapped between the oil and the top nut acts as an air-spring, a change in oil level will effect the damping forces. Not in the early stage of fork travel, but a great deal in the later stage. A general description of how the oil level/air-spring effects the damping forces are shown in fig 5. The air-spring gives the Öhlins USD fork a progressive spring rate, preventing it from bottoming out hard. By using different combinations of springs and oil levels/air-springs you can alter the characteristic of the fork and tailor it to suit different tracks and conditions. Maintenance Telescopic front forks depend on a smooth, friction free action. Do not use strong solvents, such as brake cleaner, to clean the front forks. This will dry out the seals and the steel tubes and cause friction or leakage. After every race: Clean externally and spray with an all-purpose oil after washing with detergent. Put a little Öhlins green grease (148-01) on the steel tubes and work it in by pushing the fork up and down. Every 20 hours: Dismantle the fork and check all parts for wear and damage, replace if necessary, see page 10. NOTE! See mounting instruction for recommended settings. NOTE! Higher click numbers give less damping force. When making adjustments; keep notes, make adjustments one at a time. . . The adjusters 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 double check to be sure. 6 CAUTION! The oil level must be the same in both front fork legs. When the oil level is raised: The air-spring in the later half of travel is strong, and thus the front fork hard. When the oil level is lowered: The air-spring in the later half stage of travel is soft, and thus the front fork soft. Oil level General handling set-up A Front end falls into the curves (over-steering) especially in sand. Change to harder spring. D Can handle smaller bumps but is too hard during the last part of the travel. [. . . ] Mount the lower bushings. NOTE If the right order is lost, use the specification card as a guide. Put them in the right order on the bench. Assemble the damper rod. 1799-02 Remove the compression valve assembly from the fork bottom, use a 17 mm socket. Again, use tool 1799-02 turn it around to install the seal in the outer leg. Install the circlip and the scraper. CAUTION! Make sure the circlip is fitted correctly into the groove in the outer leg. d Fasten the fork leg, at the fork bottom, with soft jaws in a vice. [. . . ]