07251-02A OM MX Enduro.indd - Öhlins
Contents
1. as the spring is proba bly too soft will cause the spring to extend too fast e Change to a harder spring in order to achieve a balanced position using less spring preload e Check the static sag and ride height Rear end kicks up over bumps with sharp 13 Trouble Shooting edges but can handle bumps with round edges Compression damping too hard Decrease the compression damping Rear end becomes too low in series of bumps Traction not satisfactory in washboard type curves or when decelerating on washboard ground Rebound damping too slow e Decrease the rebound damping Rear end very unstable Shock absorber does not respond to adjustments Shock absorber damping is gone caused by low gas pressure bad oil is used or compo nents are broken in the shock absorber Service is needed e Gas filling reguired Change shock oil Repair the shock absorber NOTE Recommended measures are not listed in order of importance One of the listed measures can be sufficient to solve a particular handling problem Preventive maintenance and regular inspec tion reduces the risk of functional distur bance If there is any need for additional service please contact an authorized hlins workshop Cleaning Clean the shock absorber externally with a soft detergent Use compressed air Be careful that all ice water dirt and debris is removed Lift the bump rubber and clean the area below from ice and dirt2. Keep the shock absorber clean and al ways spray it with oil QS 14 WD40 or CRC 5 56 after washing Lift the bump rubber and clean the area below NOTE The Ohlins shock absorber should only be filled with the Ohlins High Performance Shock Absorb er Oil Inspection 1 Check ball joints for possible excessive play or stiction 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body for external damage 4 Check the external reservoir for damage that can restrict the floating piston from moving freely 5 Check for excessive wear of rubber compo nents 6 Check the attachment of the shock absorb er to the vehicle 7 Check the hose equipped models for leaks in the hose and inlet plugs Recommended Service intervals MX Enduro Every 20 hours of operation Off Road 2 3 times year A WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required 14 What and How Often Disposal Discarded Ohlins products should be handed over to an authorized Ohlins workshop or dis tributor for proper disposal www ohlins com Owner s Manual 07251 02 Issued 2006 11 17 Ohlins Racing AB Tiina Harakka Carlsson
3. its first World Championship title Despite being in the business for 30 years the search for per fection and new functions is still the main focus of the company Congratulations You are now the owner of an Ohlins Shock Absorber More than one hundred World Championships and other major world titles are definitive proof that hlins shock absorbers offer outstanding performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible experience from our 30 years within the racing sport MN The Story The product that you now have in your pos session is pure racing breed that is built to withstand By installing this shock absorber on your vehicle you have made a clear state ment you are a serious rider with a focus on getting the maximal handling ability and out standing feedback from your vehicle Along comes the fact that your shock absorber will be a long lasting friend delivering the very best of comfort and performance every time you go for a ride Go explore Contents Before Installing Ohlins Racing AB The Ohlins Shock Absorber Design Function Adjustments General Spring Preload Rebound and Compression High and low speed Compression Ride Height and Free Sag Set Up Your Motorcycle General Handling Set up Inspection and Maintenance Design Most of hlins suspensions are a high pressure mono
4. C spanner or turn the spring by hand Rebound and Compression damping If your motorcycle is eguipped with rebound and compression damping the damping is set with knobs and or screws with a normal right hand thread By turning them clockwise the damping action increases and by turning them counter clockwise it will be reduced Most of the ad justers have definite positions with a noticeable click which makes it easy to count to the right setting Rebound damping adjuster with knob NOTE If you cannot feel the clicks on the rebound knob the shock absorber must be inspected by an authorized hlins service workshop It could be due to low gas pressure or lack of oil Adjustments Rebound and Compression Damping Rebound damping adjuster with screw Compression damping adjuster with knob High and Low speed Some models called PRX have separate adjust ers for high and low speed compression The low speed compression is adjusted in 25 steps The high speed adjuster has a wide range without steps The compression damping affects the energy absorption during compression and thus the force needed to compress the suspension More compression damping will make the suspension firmer and make the vehicle run a little bit higher On PRX shock absorbers the X stands for high and low speed compression adjuster e Low speed circuit More damping will make the ride f
5. OWNER S MAN SAL Ohlins Shock Absorber for Mx C En du hlins Racing AB cannot be held responsible for any damage to the shock absorber or vehicle or injury to persons if the instructions for installing and main tenance are not followed exactly Similarly the warranty will become null and void if the instructions are not followed NOTE hlins 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 there may be minor differences between your shock absorber and this man ual Please consult your hlins dealer if you have any questions regarding the contents of the manual Before riding the vehicle always make sure that the basic settings made by Ohlins are correct See the Mounting instructions for recommended Set up data Contact an Ohlins dealer if you have any questions about setting the shock absorber Safety Signals In this manual mounting instructions and other technical documents important infor mation concerning safety is distinguished by the following notations A The Safety alert symbol means Warning Your safety is involved A WARNING The Warning symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspect ing or using the shock absorber or to bystanders CAUTION The Caution symbol means Special
6. This will lower or raise the ride height e Compression damping controls the energy absorption when the shock absorber is be ing compressed thus controls how easy the shock absorber compresses when you hit a bump e Rebound damping controls the energy ab sorption when the shock absorber is being extended and thus controls how fast the shock absorber returns to its normal posi tion after being compressed Spring Preload The spring preload is fundamental for the function of the suspension If the preload is incorrectly set any other adjustments to the shock absorber will not help to get the intended performance from the suspension Ohlins shock absorbers are delivered with the spring preload carefully set for a good balance in the vehicle with a 80 kg or 175 Ib rider The spring preload is the difference between A and B O A Free spring length B Installed spring length A B Spring preload Setting Spring Preload Shock absorber with spring platform and lock nut Use a C spanner Turn the spring platform nut A to set the spring preload Lock the setting with the lock nut B Spring platform nut Spring Preload Shock absorber with spring platform and a spring platform clamp Loosen the platform clamp screw Turn the spring platform clamp as far up as needed to move the spring Or turn the spring by hand to the desired posi tion Loosen the platform clamp screw Use a
7. gs have adjust able preload of the spring action External reservoir with hose connection Function Fluid is forced through needle valves at a low rate of flow Fig 6 and through a number of orifices in the piston Fig 7 at a high rate of flow The flow through these orifices is regulated by shims thin steel washers that at high pressure are deflected to open for the fluid On most models the needle valve can be adjusted from the outside By altering the size of the shim stack Fig 8 i e number thickness diameter the charac teristics of the damping action can be changed This should only be done by an authorized Ohlins service workshop Compression damping When movement of the motorcycle causes com pression of the shock absorber the fluid flows through the needle valve combined compres sion and rebound valve in the piston rod If the velocity of the compression movement is high i e in the case of rapid compression this will not be sufficient and consequently the shims under neath the piston will open to allow for a greater rate of flow The fluid that is displaced by the vol ume of the piston rod is forced into the external reservoir via a separate compression valve The separating piston is displaced thus increasing the gas pressure Fig 6 Flow through needle valve Fig 7 Flow through piston Function Fig 8 Shim stack Stop washer Shim stack Compression flow Pis
8. he spring pre load Clean the oil seals and scrapers Use Ohlins red grease 00146 01 Can handle the first in a series of bumps but feels hard after a few more bumps Frontal grip insufficient in rough and bumpy turns Too much rebound damping e Decrease the rebound damping Front end rebound too fast after a bump Front wheel grip insufficient in bumpy curves Not enough rebound damping or too much spring pre load e Increase the rebound damping e Decrease the spring pre load Rear suspension Rear suspension stroke is not used to its full capacity Suspension feels harsh Traction not satisfactory in bumpy curves Suspension hard in general or too much com pression damping too much spring pre load e Decrease the compression damping e Decrease the rebound damping o Change to softer spring Suspension is bottoming feels soft during the entire wheel travel Spring too soft compression damping too low Increase the compression damping e Change to harder spring Suspension is bottoming feels harsh and sags down too much with the rider in the saddle Spring too soft or compression damping too low e Increase the spring pre load check ride height 95 5 mm e Change to harder spring if the load is more than 100 mm Increase compression damping Rear wheel jumps over small bumps during deceleration or when going downhill Traction not satisfactory in washboard curves Too much spring pre load
9. irmer and higher e High speed circuit More damping gives a firmer ride and more resistance against bot toming The rebound damping affects the energy absorp tion during rebound and thus the force needed to extend the shock absorber More rebound damping will make the extension slower and vice versa The external rebound adjustment actually also affects the compression damping by the ra tio of approximately 90 rebound damping and 10 compression damping Adjustments High and Low Speed Compression Damping NOTE The damping forces are related to the speed between the shock absorber piston and the shock absorber body The damping forces do not vary with the position of the piston inside the shock absorber High and Low speed Compression damping High speed Hexagon screw Low speed Slotted centre screw The spring preload is very important since it af fects the height of the motorcycle and the front fork angle Therefore handling characteristics can be changed even negatively Measure ride height and free sag e Put the motorcycle on a stand so that the front fork and the rear end are in fully ex tended position e Measure the distance from the lower edge of the rear mudguard or from another point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 e Take a similar measurement on the front axle for example from the bottom of the up per triple clamp to the fr
10. ont wheel axle F1 e Apply load on the springs and repeat the measuring procedure R2 F2 e Take the same measurements with the rider and equipment on the motorcycle R3 F3 It is important that the rider has a correct riding posture so that the weight is bal anced on the front and the rear wheel in the same way as when riding Motorcycle with rider on 10 Setting Ride Height and Free Sag Recommended Ride Height and Free Sag If no recommendations are given in the Mounting Instructions use the following Free sag R1 R2 F1 F2 Rear 3045 mm Front 3045 mm Ride height R1 R3 F1 F3 Rear 100 5 mm 30 of the total stroke Front 80 5 mm Adjust the Spring Preload If your measures differ from the recommenda tions in the Mounting Instructions or above ad just the spring preload according to the section Adjustments How to Set the Spring Preload in this manual A WARNING Incorrect spring action may produce a fork angle that is too steep or too flat This in turn will give a tendency for over or under steering which could seriously affect the handling characteristics of the motorcycle How to prepare the settings With the adjustment possibilities explained ear lier in this manual you can test by trial and error and learn how they affect your vehicle Start with a test ride with all adjustments at their basic setting Choose a short run of varying char acter for e
11. precau tions must be taken to avoid damage to the shock absorber NOTE The Note symbol indicates information that is of importance regarding procedures Safety Precautions A WARNING Installing a shock absorber that is not approved by the vehicle manufacturer may affect the stability of your vehi cle hlins Racing AB cannot be held responsible for any personal injury or damage that may occur after installing the shock absorber Please study and make certain that you fully understand this manual and the mounting instructions before handling this shock absorber If you have any questions regarding proper installation procedures or maintenance please con tact an hlins dealer Refer to the vehicle service manual when installing this shock absorber hlins Racing AB All rights reserved Any reprinting or unau thorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden hlins Racing AB It was the 1970 s a young man named Kenth hlin spent most of his spare time pursuing his favourite sport motocross A careful observer Kenth s attention was continually drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension Ohlins Racing was established in 1976 and just two years later the company won
12. tely 5 mm in triple clamp o Change the front fork springs to hard er ones Front end unstable during deceleration Front fork angle too steep during braking Front end too low or rear end too high o Increase the oil level in the front fork Change to harder fork springs O Increase the front fork compression damping Front suspension Front fork travel is not used to its full capacity Harsh feeling front wheel grip is not satisfac tory in bumpy turns Suspension too hard e Decrease the front fork compression damping e Change to softer springs Suspension bottoming too soft during entire travel Spring too weak or compression damping too soft Increase oil level 5 mm Increase compression damping Change to stiffer springs 12 Trouble Shooting Suspension bottoming but can handle smaller bumps Damping force not progressive enough Increase the oil level Can handle smaller bumps but is too hard during the last part of the travel Damping force is too progressive Decrease the oil level Front end feels low initially feels soft but is not bottoming The initial spring rate is too soft or spring preload is too low e Increase the spring pre load Feels harsh over small bumps but using tull wheel travel Too much spring pre load or too much com pression damping Increase the oil level or change to softer springs e Decrease the compression damping Decrease t
13. tigued Change the oil in the front fork at least once every year Contact an hlins dealer for recommended front fork oil A WARNING When delivered the hlins shock absorber is dialed to the recommended settings for the spe cific brand and make of the motorcycle Before riding always ensure that the basic settings made by hlins are correct Always make notes adjust in small steps and make only one adjustment at a time To set the adjuster compression and rebound The turn adjusters have a normal right hand thread Turn the damping adjusters clockwise to fully closed position zero 0 Then turn counter clockwise to open and count the clicks until you reach the recommended number of clicks See Set up data in the Mounting Instructions for the shock absorber Do not use force delicate sealing surfaces can be damaged Hanadtighten only General Adjustments Most hlins shock absorbers for motorcycle are eguipped with spring preload compression and rebound damping adjusters Due to limited space in some vehicles it is not possible to have all ad justers in certain models The three adjusters mentioned above will be discussed in the following chapters A deeper understanding for the different types of adjust ments will give you a good knowledge of how you can get better performance from your hlins shock absorber e Spring preload when adjusting the spring preload you move the spring seat
14. ton Rebound damping When the spring forces the shock absorber to extend again the fluid flows back through the needle valve The fluid flowing into the chamber is forced by the pressure of the gas back into the shock absorber via a separate non return valve If the piston velocity is high the shims on top of the piston will also open to allow the fluid to flow through Stability and traction All motorcycles are designed with a suspension geometry that includes height and fork angle The changing of components can affect this and it is therefore essential that both the front and the rear ends match each other Changing to hlins suspension gives opti mum performance only when both the front fork and the rear suspension interact properly It is very important that the front and the rear loaded heights are within the specified values Front Fork Springs To optimize the stability and traction of your mo torcycle the front fork must match the rear sus pension hlins Racing has a variety of front fork springs available for a large number of motorcy cle models The springs in combination with the hlins shock absorbers contribute to superior stability and traction See the hlins Recom mendation List by contacting your nearest hlins dealer or using our web site A WARNING If there are no matching spring for your motor cycle model use the original springs however they must be in good condition and not fa
15. tube type The fluid is put under gas pres sure and the gas and the fluid are kept apart by a separating piston The piston is usually fitted in an external reservoir connected by a hose Fig 1 4 or fixed directly on top of the shock ab sorber Fig 1 3 In some models everything is fitted inside the main shock absorber Fig 1 2 A few shock absorbers are of emulsion type oil and gas mixed inside the shock absorber Fig 1 1 Fig 1 Design types 13 N2 Separating piston Emulsion shock absorber The Ohlins Shock Absorber Pressurisation of the fluid is made with nitrogen The pressurisation prevents cavitation of the fluid and the shock absorbing action is therefore more even The external reservoir also contributes to better cooling of the fluid giving longer service life for the fluid as well as the components Ohlins shock absorbers with external rebound adjustment have an integrated temperature com pensation As the temperature increases and the fluid flows more easily the flow is controlled ac cordingly The shock absorbing effect is therefore independent of the temperature Internal gas reservoir 4 External piggyback reservoir Design The more advanced models permit individual ad justment of compression and rebound damping Ohlins shock absorbers provide the possi bility of adjustment making them adaptable to most motorcycles riders and ranges of use All of the shock absorbers with sprin
16. xample long and sharp bends hard and soft bumps Keep to the same run and adjust only one setting at a time Recommended Adjustment Range e Rebound Low speed compression damp ing 5 clicks from original basic setting e High speed compression damping 1 turn from original basic setting Start with Rebound Damping If the motorcycle feels unstable loose and rather bouncy increase the rebound damping Begin by turning the adjuster knob two steps clicks Test run again and adjust one step back if it felt too hard and bumpy If the motorcycle feels hard and bumpy es pecially over a series of bumps reduce the rebound damping Turn two steps test run and make the necessary adjustments For original re bound setting see the Mounting Instructions for your shock absorber If the motorcycle feels unstable loose e bouncy increase rebound damping If the motorcycle feels hard bumpy decrease rebound damping Compression Damping If the motorcycle feels soft has low riding posi tion and a tendency to bottom easily in long dips increase the compression damping If the motorcycle feels harsh and has hard resil ience reduce the compression damping If your shock absorber is equipped with high and low speed compression damping adjuster adjust the high speed compression only Turn turn at a time Test run and make nec essary corrections When you have sufficient feel of the motorc
17. ycle you can make further fine adjustments It is feeling and experience that counts 11 If the motorcycle feels soft feels low is bottoming increase compression damping lf the motorcycle feels harsh hard decrease compression damping NOTE Make sure that the springs are properly preload ed before attempting to make any adjustments A simple rule is that increased preload of the spring should be followed by an increase of rebound damping by two steps When you feel that you have achieved an im provement go back to where you started and check once more Note other relevant factors such as tires temperature etc Test run to make sure whether further fine adjustments should be made Front end falls into the corners over steering especially in sand Steep front fork angle Front end too low in comparison to rear end e Increase the front fork compression damping o Change to harder springs e Lower fork leg approximately 5 mm in the triple clamp Front end ploughs understeers Shallow front fork angle Front end too high in comparison to rear end e Decrease the front fork compression damping e Raise the fork legs approximately 5 mm in the triple clamp o Change to softer fork springs Front end unstable at high speed unstable when accelerating out of curves Front fork angle too steep Front end too low in comparison to rear end e Lower the fork legs approxima
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