Owners Manual
Contents
1. 7 Adjustment of rebound damping Adjusting knob NOTE When making new adjustments it is easiest to go back to fully closed and then count forward to the new setting The adjusting knobs should not be screwed in too hard Never use tools when attempting to adjust the shock absorber On MX Enduro dampers the adjust ment must be made when the shock absorber is cold NOTE If no click is felt the shock absorber must be inspected by an authorized service workshop It could be due to incorrect or lack of gas pressure Setting the shock absorber length Sensitivity of the steering can be adjusted by altering the length of the shock absorber without affecting other characteristics The length is adjusted using two nuts down and the treaded clevis at the end of the piston rod Fig 9 The shock absorber can be adjusted up to 12 mm The length may never be altered more than to where the groove that is cut in the thread becomes just visible Fig 10 8 Adjustment of compression damping Adjusting knob Adjustment nuts 9 Adjustment of shock absorber length lf the shock absorber has an adjustable end eye bracket this must not be treaded out more than that one groove is fully visible beneath the lock nut Make sure that the lock nut is tightened after adjustment Groove avast Setting your motorcycle NOTE Always begin with the basic settings recommended by Ohlins Always make2. The fluid that is displaced by the volume of the piston rod is forced into the external fluid chamber via a separate compression valve Even this valve is fitted with shims that open at high piston velocity The sepa rating piston is displaced thus increasing the gas pressure Rebound damping When the spring presses the shock absorber out again the fluid flows back through the needle valve in the piston rod The fluid flow ing into the chamber is forced by the pres sure of the gas back into the shock absorber via a separate nonreturn valve If velocity of the piston is high the shims on top of the piston will also open to allow the fluid to flow though 3 Flow through needle valve Piston with apertures 5 Shims stack Washer Clamp shim Shim Centering shim Preload shim Sealing shim Main piston 4 Flow through piston Settings Basic settings Always ensure that the basic setting made by Ohlins is correct It is adapted to the make and model in its original state and for a rider of average weight Everything must harmonize In the recommendation table there are Ohlins front fork springs that are specifically adapted to the shock absorbers recom mended to your motorcycle If none is noted in the table then intact original springs is the right choice Incorrect spring action can give a fork angle that is too steep or too flat This in turn will give a tendency for overstee
3. Adjusting Adjust the preload with the rings on the shock absorber or by hydraulic preloading In the first case hold the upper ring and adjust the lower one to the desired position Fig 6 Then lock with the upper ring For hydraulic preloading increase by turn ing clockwise and reduce by turning anti clockwise Fig 6 6 Spring preloading A Mechanical B Hydraulic preloading preloading adjustment adjustment NOTE On shock absorbers that have me chanical type adjustment the position of the adjusting preload rings can be adjusted On a shock absorber that has hydraulic setting the basic position can be adjusted Such changes should be attended to by an Ohlins authorized service workshop Front fork springs To optimize the road holding qualities of a motorcycle the front fork must match the rear suspension Ohlins springs are available for a large number of motorcycles These in combination with Ohlins shock absorbers contribute to superior road holding qualities 6 The original make of springs should be used if there are none of our springs in the recom mendation table However they must be in good condition and not fatigued Remem ber to change the fluid in the front fork at least once every year We recommend Ohlins front fork oil See table NOTE It is important that the recommenda tion table is followed for new front springs If there are no recommended front springs you must ensure that t
4. Owners Manual hlins shock absorbers ROAD amp TRACK Including Safety Tuning the suspension Design features Function Basic adjustments Fine tuning Inspection maintenance Traction handling comfort and safety em ADVANCED SUSPENSION TECHNOLOGY Introduction All of Ohlins advanced suspension pro ducts are adapted to the brand and model This means that length travel springaction and damping characteristics are tested individually just for the motorcycle that you have decided to fit with Ohlins suspension 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 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 Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Before installation Installing a shock absorber that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins Racing AB cannot be held responsible for a
5. g Adjustment Cc Adjustable compression damping R Adjustable rebound damping S Hydraulic preloading of spring Ad justing device connected by hose r Dp Hydraulic preloading of spring Ad justable device integrated L Adjustable length 10 L 46ER DR aa lll 46PRCLS 36D 36H 36P 36PR 36PRCLB 5 H um 46ERS DRS 46PRCW 46PRC 46PRCL A6PRCLB A6PRCS 46 PRCQ L m m gt 46HRCS 46HRCLS Horisontal 11 Notes Traction handling comfort and safety oig OHLINS ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 E mail info ohlins se 07241 01 Issuep 99 0614
6. h each other _ Changing to Ohlins suspension gives op timum performance only when both the front fork and the rear suspension interact prop erly It is of the greatest importance that the front and rear loaded height are within the specified values See section Setting the spring preload Design Most of the Ohlins shock absorbers are of the De Carbon type The fluid is put under gas pressure and the gas and the fluid are kept apart by a separating piston The sepa rating piston is often fitted in a separate fluid chamber connected by hose Fig 1H or fixed direct on top of the shock absorber piggyback Fig 1P There are also cases where everything is fitted inside the main shock absorber inter nal gas chamber Fig 1D and even a small number of emulsion shock absorbers that do not have a separating piston Fig 1E Pressurization of the fluid is made with nitrogen The pressurization prevents cavi tation of the fluid and the shock absorbing action is therefore more even The external fluid chambers also contribute to better 1 Design principles cooling of the fluid giving longer service life for both the fluid and components Ohlins shock absorbers have integrated temperature compensation As the tempera ture increases and the fluid flows more eas ily the flow is controlled accordingly The shock absorbing effect is therefore independ ent of the temperature Ohlins shock absorbers provide the pos sibilit
7. he existing springs are in good condition Neglecting to check the front springs could seriously affect the handling qualities of the motorcycle The original setting of the shock absorber when delivered from Ohlins should always be a base when the settings are changed by use of the adjustment devices Setting the damping The adjusting possibilities of Ohlins shock absorbers facilitate fine setting You can optimize adjustments to suit your own weight and equipment your individual way of riding and the condition of the road To be able to improve the road holding quali ties it is of the utmost importance that you fully understand the functioning of the shock absorbers Then you can learn by trial and error how they affect the motorcycle Depending on the model there are ad justments for rebound damping compres sion damping and adjustment of the length of the shock absorber Damping is set with the knobs they have a normal right hand thread By turning clockwise they increase the damping action and anticlockwise they reduce it The knobs have definite positions with a noticeable click so it is easy to count to the right setting Rebound damping action affects the char acteristics of the motorcycle most The set ting knob is at the bottom on the piston rod Fig 7 It can be adjusted in about 40 steps The compression damping knob is located at the end of rhe reservoir Fig 8 This can be adjusted in about 25 steps
8. must be reduced Screw anticlockwise 4 steps Test run and make any necessary correction to two steps When you have sufficient feel of the motorcycle then you can make further fine adjustments It is feeling and experience that counts 8 NOTE Ensure that the springs are properly preloaded 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 improvement go back to where you started and check once more Be observant of other relevant factors such as tyres temperature etc Test run to make sure whether further fine adjustment should be made Adjusting the shock absorber length A long shock absorber results in steeper inclination of the front fork steeper fork angle and consequently sensitive quicker steering A short shock absorber gives a bigger angle of the front fork flat fork angle and consequently slower and smoother steering Each complete turn of the shock ab sorber gives one millimetre The length may never be altered more than to where the groove that is cut in the thread becomes just visible under the lower nut of the level brachet Make small steps and test run Never alter the gas pressure Special purpose charging equipment and ac cess to nitrogen is required The gas ne should normally never be al fered Inspection and maintenance Keep the sh
9. notes adjust in small steps and make only one adjustment at a time Adjustments should be made with two steps clicks at a time Adjustments should not be more than four steps from the basic setting By utilizing the adjustment possibilities you can test by trial and error and learn how they affect your motorcycle Always begin by test riding the motorcy cle with all adjustments at their i e delivery setting Choose a short run of varying char acter ie long and sharp bends hard and soft bumps Keep to the same run and ad just only one setting at a time Start with the rebound damping If the motorcycle feels unstable loose and rather bouncy then the rebound damping should be increased Begin by turning the adjusting knob 4 steps clicks clockwise Test run again and adjust two steps back if it felt too hard and bumpy If the motorcycle is hard and bumpy es pecially over a series of bumps then the re bound damping should be reduced Turn an ticlockwise 4 steps test run and make any necessary correction to 2 steps Compression damping If the motorcycle feels soft has low riding position and a tendency to bottom easily in long dips then the compression damp ing should be increased Screw clockwise 4 steps and test run again If this was too much then turn back two steps anti clockwise If the motorcycle feels harsh and has hard resilience eg over changes in the road paving then the compression damp ing
10. ny personal injury or damage whatsoever that may occur after fitting the shock absorber Contact an Ohlins dealer or other qualified person for advice Ohlins Racing AB can not be held responsi ble for any damage whatsoever to shock absorber or vehicle or injury to persons if the instructions for fitting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to Please study and make certain that you fully understand all the mounting instruc tions and the owner s manuals before handling this shock absorber kit If you have any questions regarding proper installation procedures contact an Ohlins dealer or other qualified person The vehicle service manual must be referred to when installing the Ohlins shock absorber NOTE Ohlins products are subject to continual improvement and development Conse guently although these instructions in clude the most up to date information available at the time of printing there may be minor differences between your Suspension and this manual Please consult your Ohlins dealer if you have any questions with regard to the con tents of the manual Tuning the suspension Motorcycle road holding qualities All motorcycles are designed with a sus pension geometry that includes height and fork angle The changing of components can affect this and it is therefore essential that both the rear and the front ends matc
11. ock absorbers clean and always spray them with oil QS 14 WR40 or CRC 5 56 after washing the motorcycle Inspection points e Ball joints possible excessive play e Spring preload as above e Any external damage to the piston rod and shock absorber body e Fastening to the motorcycle Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for additional service please get in touch with an authorized Ohlins service workshop There they have the necessary tools and know how for whatever you need NOTE Make certain that your shock absorb ers are always filled with Ohlins High Performance Shock Absorber Oil NOTE Regular maintenance and inspection contribute to the prevention of func tional disturbances Recommended service intervals Road Every 30 000 km Track Every 20 hours of operation di WARNING The shock absorber is provided with a separate type reservoir filled with high pressure nitrogen gas To prevent dan ger of explosion study and make cer tain that you fully understand the follow ing information before handling the shock absorber The manufacturer can not be held responsible for damage to property or personal injury that may re sult from improper handling 1 Never tamper with or attempt to dis assemble the cylinder or the reservoir 2 Never expose the shock absorber to an open flame or other excessive heat The shock abso
12. rber may othervise explode due to too high pressure 3 Be careful not to damage any part of the gas reservoir A damaged gas res ervoir will impair the damping perform ance or cause malfunction 4 Take care not to scratch the contact surface of the piston rod of the cylinder oil could othervise leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas reservoir Any attempt to remove the plug implies serious danger 6 When scrapping the shock absorber follow the instructions for disposal Ohlins Racing AB can not be held re sponsible for any damage whatsoever to shock absorber motorcycle or in jury to persons if the instructions for fitting and maintenance are not fol lowed exactly Similarly the guarantee will become null and void if the instruc tions are not adhered to hlins shock absorbers Shock absorbers avaliable from Ohlins Racing AB The symbols stands for type and qualities of each shock absorber Types 36 46 Piston diameter in mm E Emulsion type oil and gas are mixed in the shock absorber D De Carbon type with a separating piston for gas and oil inside the shock absorber body P De Carbon type with the separat ing piston inside a fixed separate fluid chamber De Carbon type with the separat ing piston inside ahose connected separated fluid chamber W Shock absorber without a spring Q Shock absorber with twin piston for progressive dampin
13. ring or understeering which could seriously affect the handling characteristics of the motorcycle Setting the spring preload 1 Measuring Preload on the spring springs is very im portant because it affects the height of the motorcycle and the fork angle Conse quently handling characteristics can be changed even negatively Proceed as fol lows it will be much easier if done by two persons e Place the motorcycle on a smooth flat surface e Lift up the rear end to a fully extended position e Measure the distance eg from the lower edge of the rear mudguard or from a point marked by a piece of tape imme diately above the rear wheel axle to the wheel axle e Make a similar measurement on the front axle eg from the bottom of the upper fork crown to the front wheel axle The fork must also be fully extended e Allow the motorcycle without rider to apply load on the springs and repeat the measuring procedure Then take the same measurements with the rider and equipment on the motor cycle It is important that the rider has a correct riding posture so that the weight is balanced on the front and rear wheel in the Same way as when riding N The difference may not deviate from the following sizes Without rider A B Rear Road and Track 5 10 mm Front Road and Track 25 30 mm With rider A C Rear Road and Track 30 40 mm Front Road and Track 35 48 mm Setting the spring preload 2
14. y for adjustment making them adapt able to most motorcycles riders and ranges of use All of the shock absorbers have ad justable preloading of the spring action ei ther mechanically or hydraulically Fig 2 The more advanced models permit indi vidual adjustment of compression damping and rebound damping and also certain ad justment of the length of the shock absorber 2 Spring preloading Mechanical adjustment Hydraulic preloader Adjuster Function The function in principle is that fluid is forced through needle valves at a low rate of flow Fig 3 and through a number of apertures in the piston Fig 4 at a high rate of flow The flow through these apertures is regulated by shims thin steel washers that at high pressure are deflected to open for the fluid On most models the needle valves can be set individually By altering the size of the shims stack Fig 5 ie number thickness diameter the characteristics of the damping action can be varied this shall only be done by Ohlins authorized service workshops Compression damping When movement of the motorcycle causes compression in the shock absorber the fluid flows through the needle valve combined compression and return valve in the piston rod If velocity of the piston is high ie in the case of rapid compression this will not be sufficient and consequently the shims underneath the piston will open to allow a greater rate of flow
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