Owners Manual
Contents
1. ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 SE 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 fax 46 8 590 025 80 07270 04 Teknisk lllustration OM MX amp Enduro SD 415 425 05 042. Owners Manual MX amp Enduro steering dampers SD 415 425 Including Design features Technical information 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 AWARNING 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 Introduction Ohlins steering dampers are designed to withstand very tough treatment in conjunction with competitions Many years experience and close cooperation with World Championship teams in motocross and enduro has helped us develop unique know how 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 fitting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden AWARNING WARNING 1 Inst
3. alling a steering damper that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the steering damper Contact an Ohlins 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 steering damper 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 referred to when installing the Ohlins steering damper CAUTION Make sure that the steering stops work properly If not its necessary to adjust the steering stops use washer or suchlike If the damper is used as stop it can be damaged Ohlins products are subject to continual improvement and development Consequently al though these instructions include the most up to date information available at the time of printing there may be minor differences between your sus pension 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 n
4. amping 54 Position 4 Damping 90 ev Technical data External measures 70x70x35 mm Seals Low friction type Oil Ohlins part no 01306 01 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 center After washing the motorcycle wipe clean and spray with all round oil CAUTION Never subject to direct high pressure cleaning since water may otherwise 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 In new dampers after 10 hours riding and then every 20 hours riding Use only recommended fluid that is tested and approved by us We cannot guarantee fully acceptable operation using other fluids NOTE Regular maintenance and inspection counteracts possible malfunction If the steering damper needs service Ohlins agents have the proper tools and know how to solve all technical problems NOTE Discarded Ohlins products should be handled over to an authorized work shop or distributor for proper disposal Trouble Shooting Little or no damping 1 Debris in valving or worn parts internally need service 2 Shear pin on bottom has broken due to a crash or over stressing This can be replaced e
5. asily by removing the link arm with a link arm puller 4954 01 and installing a new shear pin Dampens more to one side than the other 1 It s new give it a little time to seat the valving The oil is dirty and it need servicing Knob has come off 1 Dont panic it will still work To repair it remove the set screw put the knob back on and allow it to seat over the o ring Reinsert the steel ball then the spring and finally the set screw until flush with the top of the knob Weld on tower for Ohlins Off Road steering dampers Mounting Instruction 1 Remove the original upper handlebar mounting clamps and the fuel tank of the motorcycle 2 Install the one piece upper handlebar mount provided Tighten the bolts evenly to allow fine adjustment later Keep the gap equal as shown in figure According to the handle bar clamp mounting instruction 8 3 Install the damper to the new handlebar mount Use the two Allen bolts provided NOTE If the damper does not fit between the main bar and the crossbar bow or bend the crossbar slightly to allow clearance Minimum 40 mm is required 4 With the damper fitted and the handlebar bolts evenly seated hold the weld on tower temporarily in position Mark where it must be cut for perfect fit between the frame and the link arm of the damper NOTE The tower pin is not to be installed into the tower yet 5 The weld on tower can be cut at either en
6. d for proper lenght Cutting at the top is usually the easiest way Sometimes grinding at the base of the tower to match the frame is required Cut here for proper lenght CAUTION When installed the tower pin must reach 0 5 mm above the upper surface of the link arm This is spe cially important when handlebar has rubber mounted lower mounts where handlebar is al lowed to flex downvards If the link arm touches the frame bracket the damper can be damaged CAUTION The weld on tower is made of steel and can be welded with standard weldning rod This should be carried out by qualified personnel Tig weldning is prefered Gas welding requires carefull protection of the bearings and seals of the triple clamps 6 With tower cut to correct height deburr the hole in top before installing the tower pin Grease the pin slightly before installation T Weld the tower to the frame tig welding recom mended Make welds om both sides of the tower A tower of correct height will need no additional holding devices to the frame CAUTION To gain a strong weld it is of importance to care fully remove paint and debris AA WARNING WARNING Certain modifications can be necessary to install the weld on tower It is vital that the mounting instruc tions are carefully followed 9 Handlebar clamp for Handlebar clamp Ohlins Off Road steering damper Steering clamper Handlebar clamp Mounting inst
7. ng and counter clockwise to reduce it fig 3 High speed valve The high speed valve fig 4 is set between 11 4 to 2 turns from the bottom position suitable for enduro motocross and off road A WARNING WARNING Forall riding purposes the high speed valve must be loosened at least 1 turn from the bottom Otherwise the damping forces will become too high making the ride hazardous Low speed adjustment D ma o Sweep adjustment Link arm Sweep adjustment ON High speed adjustment Steering damper body Damping sweep controls Damping sweep controls fig 8 are located on each side off the damper body Damping is in position 2 12 o clock when delivered from Ohlins This setting is fitted for enduro motocross and off road riding A WARNING WARNING Always ensure that valve setting is within the permitted ranges NOTE Both damping sweep controls must always be set in identical positions Always use positions according to the clock Suitable starting position Sweep control valve Damping range Located on the side Motocross pos 1 or 2 of the unit 5 Enduro pos 2 or 3 Off Road pos 2 3 or 4 Position 1 9 oclock Position 2 12 o clock Position 3 3 o clock Position 4 6 o clock Sweep controls located on each side are normally set at 9 the twelve o clock position 6 Position 1 Damping 34 Position 2 Damping 44 Position 3 D
8. ot unusual and is in no way detrimental to the steering damper NOTE Please note that all bikes require bars with a mini mum of 40 mm between crossbar and main bar for damper to fit For applications with less than this clearance use PROTAPERS Scotts Renthals or special handlebars with no crossbar You re going to pre assemble everything before permanently mounting or drilling anything This will insure proper alignment and fit otherwise you may find some hid den problems you didnt anticipate 3 Design The Ohlins steering damper is a hydraulic damper that counteracts wobble alleviates shock against the front wheel and prevents head shake cast by the motorcycle which gives safer riding The damper is fitted on the upper fork crown in the centre over the steering stem fig 1 When turning and in the event of wobbling shock etc the link arm of the damper is twisted thus forcing fluid through three independently acting valve systems in the damper cover Setting The steering damper has three external setting possibilites ie setting of the damper valve high speed valve and sweep valve which regulate the damping area fig 2 Low speed valve Ohlins steering damper is delivered with the low speed valve set in a basic position that gives maxi mum basic damping For enduro and motocross it is suitable to set the low speed in position 4 8 depending on the track and the rider Turn clockwise to increase dampi
9. ructions 1 Replace the stock handlebar upper brackets mount with the handlebar clamp provided CAUTION lt is vital that the centre of the steering damper mounting bolts are aligned with the centre of the steering stem 2 When the lower handlebar brackets are reversible the brackets must be positioned Weld Motorcycle according to the above mentioned caution on tower steering column 10 Steering damper 1 Attach the steering damper with the bolts enclosed NOTE The steering damper link arm should be at least 0 5 mm below the upper edge of the lower pin 2 It is possible to make smaller adjustments with the four bolts holding the handlebar clamps If the front bolts are tightened and the rear bolts are slackened the distance is decreased and vice versa NOTE Ensure that the pin is in the middle of the Iink arm groove see illustration CAUTION Make certain that the steering stops are working properly If the damper acts as a stopper it can be damaged Link arm min 1 mm min 1 mm gt it NOTE Make sure that all bolts are tightened to the cor rect torgue and that nothing fouls or restricts the handlebar when beeing turned to each side When testing the damper adjuster must be in soft damp ing position 11 More Info www ohlins com The ultimate suspension site Find out everything about your suspension Download mounting instructions manuals and brochures And a lot more
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