Owners Manual
Contents
1. Screw clockwise six steps and test run again If this was too much then turn back three steps counter clockwise If it feels harsh and too rigid or has a tendency to hop during braking the high speed compression should be decreased Turn counter clockwise six steps Test run and make any necessary correction in three steps at the time When you have sufficient feel of the motorcycle you can make further fine adjustments It is feeling and experience that counts 14 Adjustment of shock absorber length NOTE Ensure that the springs are properly pre loaded before attempting to make any adjustments A simple rule is that increased pre load of the spring should be followed by an increase of rebound damping by two steps When you feel that you have achieved an improve ment 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 10 15 Adjusting the shock absorber length 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 14 The shock absorber can be adjusted up to 12 mm 16 Groove WARNING If the shock absorber has an adjustable end eye bracket this must not be2. Measure the distance e g from the lower edge of the rear mud guard or from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 D Make a similar measurement on the front axle e g from the bottom of the upper fork crown to the front wheel axle The fork must also be fully extended F1 E Allow the motorcycle without rider to apply load on the springs and repeat the measuring procedure R2 F2 F Then take the same measurements with the rider and equipment on the motorcycle R3 F3 F Bike with rider on Ride height R1 R3 F1 F3 NOTE 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 The measurements must not differ from the following sizes Without rider static sag Rear 10 20mm R1 R2 Front 15 30 mm F1 F2 With rider ride height Rear 25 40 mm R1 R3 Front 35 50 mm F1 F3 NOTE Older gear shaft drive driven motorcycles not para lever shaft drive usually raise the rear end during acceleration We recommend that the the static sag R1 R2 is extended to 15 20 mm and the ride height R1 R3 to 35 45 mm on these motorcycles 7 Spring pre load adjusment A Mechanical pre load adjuster B Hydraulic pre load adjuster Adjusting Adjust the pre load with the rings on the shock absorber or by hydraulic pre loading In the first case ho
3. Measures Make sure the damper is connected Check cables and connections for damages Er2 No power to the rear damper Measures Make sure the damper is connected Check cables and connections for damages Er3 No power to front and rear dampers Measures Make sure the dampers are connected Check cables and connections for damages Er4 Er7 Insufficient voltage to the control unit Measures Check battery and alterna tor Check all connections NOTE If you have two dampers connected to the control unit and one of them suffers a cable failure while the power is off the control unit will automatically switch to single damper mode next time it is powered on Er1 and Er2 will only show up if the connection fails Quring power on 12 Rebound damping e Unstable e Loose e Bouncy Unstable Soft Low Increase Setting your motorcycle NOTE Always begin with the basic settings recommended by Ohlins Always make notes adjust in small steps and make only one adjustment at a time Adjust ments 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 motorcycle with all adjustments at their i e delivery setting Choose a short run of varying character ie long and sharp bends hard and sof
4. Owners Manual Ohlins shock absorbers Motorcycle Road amp Track Including a 4 os m i fiss a n i f Fania ai F am bie i pean TU 708 s 7 j ty s ai Tuning the suspension Function Fine tuning ADVANCED SUSPENSION TECHNOLOGY 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 A 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 pre cautions must be taken to avoid dam age 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 Introduction All of Ohlins advanced suspension products are adapted to the brand and model This means that length travel spring action and damping char acteristics are tested individually just for the motorcycle that you have decided to fit with Ohlins suspension Before installation Ohlins Racing AB can not be held responsible for any damage whatsoever to shock absorber or vehicle or injury to persons if the instructions for fit
5. ate 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 Fig 5 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 i e number thickness diameter the characteristics of the damping action can be varied this should only be done by Ohlins authorized service workshops 5 Shims stack Sa S N Compression damping When movement of the motorcycle causes com pression 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 i e in the case of rapid com pression this will not be sufficient and conse quently the shims underneath the piston will open to allow a greater rate of flow Fig 6 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 separating piston is displaced thus increasing the gas pressure ene eT Shims stack G NL Gaz Piston 6 Flow through piston Stop washer Compression flow Rebound flow Rebound damping When the spring presses the shock absorber out again the fluid flows back throu
6. ay 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body and for external damage 4 Check the external reservoir for damages that can restrict the floating piston from moving freely Excessive wear of rubber components Fastening to the wehicle e Check the hose equipped models for leaks in hose and inlet plugs 0 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 hlins service worshop There they have the necessary tools and know how for whatever you need N NOTE Make certain that your shock absorbers are always filled with hlins High Performance Suspension fluid NOTE Regular maintenance and inspection contribute to the prevention of functional disturbances Recommended service intervals Race track Every 10 hours Street Road Every 20 000 30 000 km NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal 11 More info www ohlins com Precision Makes the Difference If You are looking for the ultimate in performance this is the right site Surf around and find out what the ultimate in suspension is all about en Read this years Newsletters Softail for Harley Davidson a The First Volvo S6OR with CES Roenmg Sure Teams amp Riders 2003 and more ore The ultimate
7. e shock absorber piggyback There are also types of shock absorbers where everything is fitted inside the main cylinder tube internal gas reservoir and even a small number of emulsion shock absorbers that do not have a separating piston 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 reservoires also contribute to better cooling of the fluid giving longer service life for both the fluid and components Ohlins shock absorbers have integrated tempera ture compensation As the temperature increases and the fluid flows more easily the flow is controlled Shock absorber 2 Spring pre loading Mechanical adjustment Hydraulic pre loader C spanner accordingly The shock absorbing effect is there fore independent of the temperature The more advanced models permit individual adjustment of compression damping and re bound damping and also certain adjustment of the length of the shock absorber Ohlins shock absorbers provide the possibility for adjustment making them adaptable to most motorcycles riders and ranges of use All of the shock absorbers have adjustable pre loading of the spring action either mechanically or hydraulically 3 Flow through needle valve 4 Piston with apertures Function The function in principle is that fluid is forced through needle valves at a low r
8. ferred to when installing the Ohlins shock absorber NOTE Ohlins products are subject to continual improve ment 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 suspen sion and this manual Please consult your Ohlins dealer if you have any questions with regard to the contents of the manual 1 Design principles Gas and oil 1 Emulsion shock absorber 2 Internal gas reservoir 3 External piggyback reservoir 4 External reservoir with hose connection 1 Tuning the suspension Motorcycle road holding qualities 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 rear and the front ends match each other Changing to Ohlins suspension gives optimum performance only when both the front fork and the rear suspension interact properly It is of the greatest importance that the front and rear loaded height are within the specified values See section Setting the spring pre load piston Design Most of the Ohlins shock absorbers are of the De Carbon type The fluid is put under gas pres sure and the gas and the fluid are kept apart by a separating piston The separating piston is often fitted in a separate fluid chamber connected by hose or fixed directly on top of th
9. gh the needle valve in the piston rod 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 velocity of the piston is high the shims on top of the piston will also open to allow the fluid to flow though Fig 6 F1 R1 A D Bike on a stand Suspension fully extended R1 and F1 Settings Basic settings Always ensure that the basic setting made by hlins is correct It is adapted to the make and model in its original state and for a rider of average weight Spring pre load Pre load on the spring springs is very important because it affects the height of the motorcycle and the fork angle Everything must harmonize In the recommendation table there are Ohlins front fork springs that are specifically adapted to the shock absorbers recommended for your motor cycle If none is noted in the table then intact original springs are the right choice Incorrect spring action can produce a fork angle that is too steep or too flat This in turn will give a tendency for oversteering or understeering which could seriously affect the handling characteristics of the motorcycle F2 R2 3 E Bike on the ground Static sag R1 R2 F1 F2 Setting the spring pre load Measuring Proceed as follows it will be much easier if done by two persons A Place the motorcycle on a stand B Lift up the rear end to a fully extended position C
10. ld the upper ring and adjust the lower one to the desired position Fig 7A Then lock with the upper ring For hydraulic pre loading increase by turning clockwise and reduce by turning counter clock wise Fig 7B NOTE On shock absorbers that have mechanical type adjustment the position of the adjusting pre load 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 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 NOTE The spring pre load affects the ride height it does not affect the spring stiffness Therefore on models with a linkage to the shock absorber the suspension may actually feel harder when you reduce the pre load and the shock absorber gets into the harder range of the link system 8 Front fork spring kit Front fork springs To optimize the road holding qualities of a motor cycle the front fork must match the rear suspension Ohlins springs are available for a large number of motorcycles Fig 8 These in combination with Ohlins shock absorbers contribute to superior road holding qualities The original make of springs should be used if there are none of our springs in the recommendation table However they must be in good condition and not fatigued Remember t
11. locity of the shock absorber It is not necessarily related to the speed of the vehicle EC Electronic Control Settings Setting the damping The electronic controlled compression damping is set with the control panel of the electronic unit You can instantly optimize adjustments to suit your individual way of riding and the condition of the road Compression damping adjustments are made by setting the electronic adjustment device By setting high figures the damping action will in crease and low figures reduces the damping New settings will affect the damping within ten 10 milliseconds High figures are recommended when riding with greater load eg passenger and packing and when riding on a race track To be able to improve the road holding qualities it is of the utmost importance that you fully un derstand the functioning of the shock absorb ers Please refer to the Mounting Instructions as well as page five 5 of this manual for basic setup spring pre load Then you will learn by trial and error how they affect the vehicle The control unit The control unit display has a window with two sections showing how much damping power the shock absorber and the front fork have The up per section shows the front fork damping and the lower section shows the rear wheel damp ing If the electronic control unit operates one shock absorber only the damping force is read in the upper display and the lower display shows the elect
12. o change the fluid in the front fork at least once every year We recommend Ohlins front fork oil See table in the Ohlins Recommendation list NOTE It is important that the recommendation table is followed for new front springs If there are no recommended front springs you must ensure that the existing springs are in good condition Neg lecting to check the front springs could seriously affect the handling qualities of the motorcycle 9 Adjustment of rebound damping Setting the damping The adjusting possibilities of Ohlins shock absorb ers facilitate fine setting You can optimize adjust ments 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 qualities it is of the utmost importance that you fully understand the functioning of the shock ab sorbers Then you can learn by trial and error how they affect the motorcycle Depending on the model there are adjustments for rebound damping compression damping and adjustment of the length of the shock absorber Damping is set with knobs and screws with a nor mal right hand thread By turning them clockwise the damping action is increased and by turning them counter clockwise it is reduced The knobs have definite positions with noticeable clicks making it is easy to count to the right setting Rebound damping action affects the character istics of the motorcycle most The setting kn
13. ob is located at the bottom on the piston rod Fig 9 It can be adjusted in about 40 steps NOTE If no click is felt in the rebound adjuster the shock absorber must be inspected by an author ized service workshop It could be que to low gas pressure or lack of oil The compression damping knob is located at the end of the external reservoir Fig 10 This can be adjusted in about 25 steps Some models PRX have separate adjusters for high speed compression and low speed com pression Fig 11 The low speed compression is adjusted in 25 steps Use a slotted head screw driver The high speed adjuster has a wide range within about 48 clicks Use a 14 mm key NOTE When making new adjustments it is easiest to go back to fully closed and then count forward to the new setting The adjusting device should not be turned too hard 10 Adjustment of compression damping 11 High and low speed compression damping adjusters Low speed CAUTION The hexagon of a two way compression valve is naturally anodized aluminum The high speed ad juster has a key width of 14 mm and a range of 48 steps clicks The low speed adjuster slotted head screw has a range of 25 steps The one way compression adjuster is gold ano dized The adjuster slotted head screw has a range of 25 steps Do not turn the hexagon as this will allow for the oil to spurt out of the shock ab sorber NOTE High and low speed refers to the shaft ve
14. rical voltage of the motorcycle By pressing the OHLINS logotype you choose front or rear setting and by pushing the or buttons you increase or decrease the damping forces The higher the figures the stronger the damping forces 8 Pushing Pushing the minus the plus button button decreases increases damping damping __ Pushing the OHLINS button switches between front and rear settings NOTE The control unit will automatically switch to the correct mode single suspension or front and rear suspension Functions for front and rear suspension A Press for front suspension B Press for rear Suspension C Press for front and rear After C the function returns to A NOTE If the button is pressed for at least one second the display will show the voltage for five seconds Functions for single suspension only A Press for voltage readings B Press to turn the voltage readings off After B the function returns to A WARNING Do not alter the damping when riding in traffic The motorcycle must come to a stop before the damping is set To avoid dangerous situations do not take your eyes and attention off the traffic and your surroundings When the motorcycle is restarted the adjusters will return to the earlier choosen positions If the power supply fails there is always a certain damping force in the shock absorber to contribute to safe riding Troubleshooting Er1 No power to the front damper
15. suspension site Find out everything about your suspension Download mounting instructions manuals and brochures And a lot more ADVANCED SUSPENSION TECHNOLOGY hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your hlins dealer 07241 02 issued 05 03 23 Teknisk Illustration AB
16. t bumps Keep to the same run and adjust only one setting at a time Reduce Increase Start with the rebound damping Fig 12 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 especially over aseries of bumps then the rebound damping should be reduced Turn counter clockwise 4 steps test run and make any necessary correction to 2 steps Compression damping Fig 13 The low speed compression adjuster affects ride height smoothness over small bumps and grip The high speed compression adjuster affects stability firmness in depressions and fast corners If the motorcycle has a low riding position the low speed compression should be increased Screw clockwise four steps and test run again If this was too much then turn back two steps 13 Compression damping e Harsh e Hard e Bad grip Reduce counter clockwise If it feels unsmooth over small continuous bumps or has bad grip the low speed compression should be decreased Turn counter clockwise four steps Test run and make any necessary correction in two steps at the time If the motorcycle feels unstable in fast corners and has a tendency to bottom easily in depressions and chicanes the high speed compression should be increased
17. threaded out more than that one groove is fully visible beneth the lock nut Make sure that the lock nut is tightened after adjustment Groove 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 greater angle of the front fork flat fork angle and consequently slower and smoother steering Each complete turn of the shock absorber gives one millimetre Fig 15 The length may never be altered more than to where the groove Fig 16 that is cut in the thread becomes just visible under the lower nut of the level brachet Make small steps and test run 17 Lift the bump rubber and clean the area below Inspection and maintenance Clean the shock absorbers externally with a soft detergent Use compressed air Lift the bump rubber and clean the area below Fig 17 Keep the shock absorbers clean and always spray them with oil QS 14 WD40 or CRC 5 56 or simular CAUTION Never use detergents that can damage the sur faces of the shock absorber Thinner and brake cleaner will dry the surfaces too much WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required The gas pressure should normally never be altered 18 Inspection points Inspection points Fig 18 1 Check ball joints for possible excessive pl
18. ting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to Contents Safety signals saiiceisaccsuanuatesedvancececisnivvanwcenenks 2 MOGUCIH WN xnctecnetetseacpnaereacaiaees dneeneeeenncee 2 Before installation wacisedencncsveceesenccecedcewssssanbdans 2 Tuning the suspension s ssssseessssserssserrreeenne 3 DESIO saiersce csicncsesuiesenteastcacensencuaiaesctesanioedoeenncene 3 FUNCION sieren onia N 4 UO S AEAEE E ER E EE EEE 5 Setting the spring pre load ccccceeeeeeeees 5 Setting the damping ccccceeeeeeeeeeeeeeeneeees 7 EC Electronic Control settings 00 8 Setting your motorcycle cccceeseeeeeeeeeeeeeees 9 Inspection and maintenance ccseee 11 A WARNING 1 Installing a shock absorber 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 shock absorber Contact an hlins dealer or other qualified person for advice 2 Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this shock absorber kit If you have any questions regarding proper installation procedures contact an Ohlins dealer or other qualified person 3 The vehicle service manual must be re
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