Owner`s Manual
Contents
1. s necessary to adjust the steering stops use washer or suchlike If the damper is used as stop it can be damaged hlins products are subject to continual improvement and development Consequently although these instructions include 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 contents of the manual 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 This is not unusual and is in no way detrimental to the steering damper hlins Racing AB Al rights reserved Any reprinting or unauthorized use without the wi sn permission of hlins Racing AB s prohibited Printed in Sweden Ohlins Racing AB The Story It was the 1970th s a young man named Kenth Ohlin 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 its first W2. steering damper is out of position which can happen after a crash A Check that the bracket that replaces the outer bearing is aligned properly If not tap it with an hammer into the correct position see mounting instruction Be careful so that the bracket not will be damaged B Check that the damper still is in correct position If not reinstall it according to the mounting instruction Also make sure that the two small pins that goes into the top triple clamp still are in place If not contact your Ohlins dealer Leakage occurs Check that all bolts and nuts are tightened or contact an Ohlins dealer The damper does not fit in between the handlebar and the triple clamp C Some bike has bolted handlebar clamps those clamps can be raised up with spacers Otherwise a new upper triple clamp may be needed Maintenance and inspection The steering damper is a precision instrument with extremely fine tolerances It is therefore essential that it is maintained in a correct manner Maintenance and service should be carried out by an authorised service centre After washing the motorcycle wipe clean and spray with all round oil CAUTION Never subject to direct high pressure cleaning since water may penetrate the damper CAUTION Ensure that there is no leakage of fluid and that there is no visible damage to the housing and mounts Change the fluid regularly every 20 hours Use only recommende
3. Owner s Manual Steering damper SD500 MX amp Enduro Technical information Basic adjustments Design features Safety precautions Safety signals Important information concerning safety is distinguished in this manual by following notations A This 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 A WARNING 1 Installing a steering damper that is not approved by the vehicle manufacturer may affect the stability of your vehicle hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an hlins dealer for advice 2 Please study and make certain that you fully understand the contents in the mounting instruction s and the owner s manual s before handling this suspension kit If you have any questions regarding installation procedures contact an hlins dealer 3 The vehicle service manual must be referred to when installing the hlins suspension CAUTION Make sure that the steering stops work properly If not it
4. d fluid that is tested and approved by hlins We cannot guarantee fully acceptable operation using other fluids NOTE Regular maintenance and inspection counteracts possible malfunction If the steering damper needs service contact an Ohlins dealer who have the proper tools and know how to solve all technical problems NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal D Owner s Manual 07270 05 Issued 20080205 hlins Racing AB Annette Asph UI Ekengren hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80
5. gh speed flow The RTC valve Return To Centre controls the damping back to centre position 0 See figure 3 The Ohlins steering damper is delivered with the adjusters set in a suggested basic position see the recommendation below Tum clockwise to increase damping and counter clockwise to decrease it fig 2 Tum the damping adjusters clockwise to fully closed centre position zero 0 Then turn counter clockwise to open and count the clicks until you reach the recommended number of clicks Technical data External measures mounted on a bike 97x88 5x50 mm Seals of Low friction type Pressurized reservoir Ohlins Damper Fluid part no 01303 01 Maximum steering angle 47 fig 4 Recommended basic settings Motocross DL valve 12 clicks ATC valve 6 clicks Enduro DL valve 12 clicks ATC valve 8 clicks Adjustments and Set up DL valve With the standard setting 12 clicks the damper will have a minimal amount of low speed damping and more or less only have damping from the high speed valve This is very easy to get used to for someone that has not ridden with a steering damper before If more stability is required try closing the DL valve one or two clicks at a time We do not recommend going under 4 clicks A rider who is used to riding with a steering damper can use more DL than someone who is not used to one Rider type general RTC valve When the RTC valve is completely closed the amou
6. ing damper or vehicle or injury to persons if the instructions for installing and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to NOTE Make sure that there is no interference between the handle bar and the top lid It is vital that the upper bearing outer ring will be mounted correct Check that the tower pin hole is aligned to the centre line in the frame The damper unit must also be aligned to the bearing tower pin hole Incorrect mounting may damage the damper unit NOTE Make certain that the steering stops are working properly If the damper acts as a stop it can be damaged Check that all bolts are tightened to the correct torque and that nothing fouls or restricts the handlebar when turned to each side Design The hlins steering damper is a hydraulic damper that counteracts head shake and alleviates shock against the front wheel which gives a safer riding The damper is fitted on the upper triple clamp in the centre over the steering stem fig 1a and fig 1b When tuming and in the event of wobbling shock etc the damper is rotated thus forcing fluid through the valve system in the damper top lid Two valves are adjustable see Settings on the next page Adjustments and Set up Setting The steering damper has two external adjusters fig 2 The DL valve Damping Level controls the combined low and hi
7. nt of damping back to center will be equal to the damping out from center controlled by the DL valve Fully open there is almost no damping at all back to center position An increase in RTC gives more stability into corners and makes it easier to hit the correct line A rider who is used to riding with a steering damper can use more RTC than someone who is not used to one RTC General Very precise rider Not much steering correction Aggressive rider A lot of steering corrections Increase RTC Decrease RTC Note Just like a very precise rider an aggressive rider can also benefit from an increase in RTC but risk Using up more energy because of the numerous steering corrections Track conditions DL RTC Fast tracks Rutted tracks or deep sand High speed head shake Low speed head shake Tight enduro trail More stability into corners and to make it easier to hit the correct line Desert racing See also adjusters in fig 2 on page 5 Increase DL Decrease DL and or decrease RTC often fully open Increase DL possibly also increase RTC Increase DL keep RTC Decrease RTC Increase RTC keep DL Increase DL increase RTC Troubleshooting and Maintenance Trouble Shooting There is little or no damping Debris in valving or worn parts internally need service The damper units is moving at the top of the triple clamp Tighten the top nut for the steering stem with the tool provided in the kit The
8. orld Championship title Despite being in the business for 30 years the search for perfection and new functions is still the main focus of the company 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 Ohlins 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 Congratulations The product that you now have in your possession is pure racing breed that is built to withstand By installing an Ohlins shock absorber on your vehicle you have made a clear statement you are a serious rider with a focus on getting the maximal handling ability and outstanding 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 Introduction and Design The Ohlins steering damper are designed to withstand very tough treatment in conjunction with competitions Many years of experience and in close cooperation with World Championship teams in Motocross and Enduro has helped us develop unique know hows Before installation Ohlins Racing AB can not be held responsible for any damage whatsoever to the steer
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