Owners Manual
Contents
1. If ride height is higher than recommended softer spring springs must be used If ride height is lower than recommended harder spring springs must be used Contact your Ohlins dealer for advice 9 Front spring kit 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 Fig 9 These in combination with Ohlins shock absorbers con tribute 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 to change the fluid in the front fork at least once every year We recommend Ohlins front fork oil A WARNING 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 Neglecting to check the front springs could seriously affect the handling qualities of the motorcycle 10 Adjustable end eye WARNING If the shock absorber has an ad justable end eye bracket this must not be threaded out so that more than one groove is fully vis ible beneath the lock nut Make sure that the lock nut is tightened after adjustment Groove Setting the shock absorber length Sensitivity of the steering can be adjusted by alte2. Fig 1 1 or fixed directly on top of the shock absorber piggyback Fig 1 2 There are also cases where everything is fitted inside the main shock absorber internal gas reservoir Fig 1 3 The most advanced shock absorber has twin pistons This ensures position sensitive damping in relation to the degree of compression One of the pistons is active throughout the entire lenght of stroke while the second piston begins to work in the event of powerful compression of the shock absorber Fig 1 4 Pressurisation of the fluid is made with nitrogen The pressurisation prevents cavitation of the fluid and the shock absorbing action is therefore more even 2 Spring pre loading Mechanical adjustment 3 Adjustment of shock absorber length Y Adjustment nut C94 The external fluid chambers also contribute to bet ter cooling of the fluid giving longer service life for both the fluid and components hlins shock absorbers have integrated temperature compensation As the temperature increases and the fluid flows more easily the flow is controlled accordingly The shock absorbing effect is therefore independent of the temperature The more advanced models permit individual adjustment of compression damping and rebound damping hlins 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 sp
3. Owners Manual Ohlins shock absorbers VOR MX Enduro Super Motard Including Safety Tuning the suspension Design features Function Basic adjustments Fine tuning Inspection maintenance 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 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 hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Introduction All of hlins advanced suspension products are adapted to the brand and model This means that length travel spring action and damping characteristics are tested individually just for the motorcycle that you have decided to fit with hlins suspension Before installation hlins 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 fol
4. ders 2003 and more The ultimate 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 07251 02 Issued 03 09 03 Teknisk Illustration
5. ed 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 absorbers are always filled with Ohlins High Performance Shock Absorber Oil NOTE Regular maintenance and inspection contribute to the prevention of functional disturbances Recommended service intervals MX amp Enduro Approximately 20 hours of operation Off Road 2 3 times a year WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required The gas pressure should normally never be altered NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal General handling set up Front end falls into the curves over steering especially in sand Steep front fork angle Front end too low in com parison to rear end e Increase the front fork compression damping e 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 e Change to softer fork springs Front end unstable at high speed unstable when accelerating out of curves Front fork angle too s
6. ing 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 1 External reservoir with hose connection 2 External piggyback reservoir 3 Internal gas reservoir 4 Twin piston shock absorber 1 piston 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 hlins 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 heights are within the specified values In the Mounting Instruction see section Setting the spring pre load Shock absorber Design Most of the hlins shock absorbers are of the De Carbon type Fig 1 The fluid is put under gas pressure 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
7. lowed exactly Similarly the warranty will become null and void if the instructions are not adhered to Contents Safety signals iscntonsainccudacteiccesnsdnceinestewotecsbawss 2 IIs POCUIGTEOM ogc tiecUnadamcniacsusansteswtiedamencseautereaeseact 2 Before installation sscohesseccestssxoccectexsictanteswevmnese 2 Tuning the suspension c ssceiscicecsdecesmsecnaceesseaens 3 DEE aeaa EE E E A 3 EER a AE A A E NAT 4 SETAE e AT EEA E E 5 Setting the spring pre load cceeeessstseeees 5 Setting the shock absorber lenght 6 Setting the damping ceeessseeeeeeeeeeeeeeeees T Setting your MOtOICyCle cccccceeeeeeeeeeeeeees 8 Inspection and maintenance c cseceeeees 9 General handling setup cccceeeeeeeseeees 10 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 referred to when install
8. n not satisfactory in washboard curves Too much spring pre load as the spring is probably 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 pre load e Check the static sag and ride height Rear end kicks up over bumps with sharp edges but can handle bumps with round edges Compression damping too hard e Decrease the compression damping Rear end becomes too low in series of bumps Traction not satisfactory in wash board 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 components are broken in the shock absorber Service is needed e Gas filling required e Change shock oil e Repair or change 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 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 Read this years Newsletters y 7 Sees am r Harley Davidson _ The First Volvo S6OR with CES fof tom ROEMMG Onis Teams amp Ri
9. ost The setting knob is located at the bottom on the piston rod Fig 11 It can be adjusted in about 40 steps The compression damping adjuster is located at the end of the reservoir Fig 12 Compression damping is set with separate ad justers for high speed compression and low speed compression Fig 12 The low speed compression is adjusted in 25 steps The high speed adjuster has a wide range within four 4 turns Adjust a half turn 180 at a time MX Enduro 3 turns Supermotard 2 turns MX 15 clicks Enduro 14 clicks Supermotard 2 turns 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 NOTE If no click is felt on the rebound adjusting knob the shock absorber must be inspected by an authorized service workshop It could be due to low gas pressure or lack of oil 13 Rebound damping e Unstable e Loose e Bouncy 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 Adjustments should be made with two steps clicks 1 2 turn at atime Adjustments should not be more than six steps 2 turns from the basic setting How to prepare the settings By utilizing the adjustment possibilities you can test by trial and error and learn how they affect
10. ough piston Stop washer Compression flow Rebound flow Rebound damping When the spring forces the shock absorber to ex tend again the fluid flows back through the needle valve into 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 7 Bike on a stand 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 WARNING Incorrect spring action may 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 The original settings of the shock absorber when delivered from hlins should always be a base when the settings are changed by use of the adjustment devices Bike on the ground Setting the spring pre load Step 1 Measuring Pre load on the spring springs is very important because it affects the height of the motorcycle and the fork angle Consequently handling characteristics can be changed even negatively Proceed as follows it will be much easier if done by two persons Place the motorcycle on a stand so
11. ring action Fig 2 A few models have an adjustable end eye mak ing it possible to alter the lenght of the shock absorber by 12 mm Fig 3 4 Flow through needle valve 5 Piston with apertures Function The function in principle is that fluid is forced through needle valves at a low rate of flow Fig 4 and through a number of apertures in the piston Fig 5 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 6 i e number thickness diameter the character istics of the damping action can be changed this should only be done by Ohlins authorized service workshops 6 Shims stack 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 the velocity of the piston is high i e 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 Fig 7 The fluid that is displaced by the volume of the pis ton rod is forced into the external fluid chamber via a separate compression valve The separating piston is displaced thus increasing the gas pressure Piston 7 Flow thr
12. ring the length of the shock absorber with out affecting other characteristics The length is adjusted with the two nuts and the threaded clevis at the end of the piston rod 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 fully visible Fig 10 11 Adjustment of rebound damping MX 28 clicks Enduro 24 clicks Supermotard 18 clicks 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 qualities it is of the utmost importance that you fully understand the function of the shock absorbers From there 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 anormal right hand thread By turning you can increase the damping action or reduce it The adjuster have definite positions with a noticeable click so it is easy to count to the right setting more damping less damping 12 High and low speed compression damping adjusters High speed O T l _ Rebound damping action affects the characteristics of the motorcycle m
13. rings e Decrease the compression damping e Decrease the spring pre load e Clean the oil seals and scrapers Use Ohlins red grease 146 01 for regreasing 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 e Change to softer spring Suspension is bottoming feels soft during the entire wheel travel Spring too soft compression damping too low e 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 e Increase compression damping Rear wheel jumps over small bumps during deceleration or when going downhill Tractio
14. teep Front end too low in comparison to rear end e Lower the fork legs approximately 5 mm in triple clamp e Change the front fork springs to harder ones Front end unstable during deceleration Front fork angle too steep during braking Front end too low or rear end too high e Increase the oil level in the front fork e Change to harder fork springs e Increase the front fork compression damping 10 Front suspension Front fork travel is not used to its full capacity Harsh feeling front wheel grip is not satisfactory 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 e Increase oil level 5 mm e Increase compression damping e Change to stiffer springs Suspension bottoming but can handle smaller bumps Damping force not progressive enough e Increase the oil level Can handle smaller bumps but is too hard during the last part of the travel Damping force is too progressive e 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 full wheel travel Too much spring pre load or too much compres sion damping e Increase the oil level or change to softer sp
15. the front fork and the rear end are in fully extended position e Measure the distance e g from the lower edge of the rear mudguard or from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 Make asimilar measurement on the front axle e g from the bottom of the upper fork crown to the front wheel axle F1 Allow the motorcycle without rider to apply load on the springs and repeat the measuring procedure R2 F2 Bike with rider on e Then 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 balanced on the front and rear wheel in the same way as when riding Recommendations The difference should not deviate from the following sizes if no other recommended settings are given in the Mounting instructions Free sag R1 R2 F1 F2 Rear MxX Enduro 30 5 mm Supermotard 30 5mm Front MxX Enduro 30 5 mm Supermotard 30 5mm Ride height R1 R3 F1 F3 Rear MX 100 5 mm Enduro 30 of the total stroke Supermotard 30 ofthe total stroke Front MxX Enduro 80 5 mm Supermotard 80 5mm 8 Spring pre loading Mechanical pre loading adjustment Step 2 Adjusting Adjust the pre load with the rings on the shock absorber Hold the upper ring and adjust the lower one to the desired position Fig 8 Then lock with the upper ring NOTE
16. unts 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 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 15 Lift the bump rubber and clean the area below Inspection and maintenance Clean the shock absorbers externally with a soft detergent Use compressed air Be careful that all dirt and debris is removed Lift the bump rubber and clean the area below Fig 15 Inspection points Fig 16 1 Check ball joints for possible excessive play 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body and for external damages 4 Check the external reservoir for damages that can restrict the floating piston from moving freely 5 Check for excessive wear of rubber components 6 Check the fastening to the vehicle Check the hose equipped models for leaks in hose and inlet plugs 16 Inspection points Keep the shock absorbers clean and always spray them with oil QS 14 WR40 or CRC 5 56 after washing the motorcycle Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any ne
17. your motorcycle Always begin by test riding the motorcycle with all adjustments at their basic setting Choose a short run of varying character i e long and sharp bends hard and soft bumps Keep to the same run and adjust only one setting at a time e Hard e Soft e Low e Bottom Reduce Increase Start with the rebound damping Fig 13 If the motorcycle feels unstable loose and rather bouncy then the rebound damping should be increased Begin by turning the adjusting knob 2 steps clicks Test run again and adjust one steps back if it felt too hard and bumpy If the motorcycle is hard and bumpy especially over a series of bumps then the rebound damping should be reduced Turn 2 steps test run and make any necessary correction For origi nal rebound setting see Mounting Instructions Compression damping Fig 14 If the motorcycle feels soft has low riding position and a tendency to bottom easily in long dips then the compression damping should be increased If the motorcycle feels harsh and has hard resilience e g during changes in the road paving then the compression damping must be reduced 14 Compression damping e Harsh Reduce Normally changes are made by high speed com pression adjuster only Turn 1 2 turn at a time Test run and make necessary corrections When you have sufficient feel of the motorcycle you can make further fine adjustments It is feel ing and experience that co
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