Ohlins 07235-01A5L.p65 User's Manual
Contents
1. Notes 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 www ohlins com 07235 01 Issued 01 06 21 600 ex2. be able to improve the road holding qualities 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 vehicle Depending on the model there are adjustments for rebound damping and compression damping They have a normal right hand thread By turn ing clockwise they increase the damping action and counterclockwise they reduce it see illus trations above The knobs has definite positions with a noticeable click so it is easy to count to the right setting Rebound damping action affects the charac teristics of the vehicle most The setting knob is 13 Compression damping adjusters located at the bottom on the piston rod Fig 12 It can be adjusted in about 40 steps Compression damping is set with aknob or a screw on top of the external reservoir Fig 13 This can be adjusted in about 25 steps NOTE When making new adjustments it is easiest to go fully closed and then count forward to the new setting The adjusting knobs should not be turned in too hard Use fingers only when possible The adjustment should 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 more damping less damping O Setting your vehicle NOTE Always begin with the basic sett
3. Owners Manual Ohlins shock absorbers ATV Including Design features Technical information Cannondale P N 951 6001126 Introduction All of Ohlins advanced suspension products are adepted to the brand and model This means that length travel springaction and damping charac A WARNING 1 Installing a shock absorber that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins 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 O hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden teristics are tested individually just for the vehi cle that you have decided to fit with Ohlins sus pension 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 fi
4. as hard resil lence e g over changes in the riding surface then the compression damping must be reduced Turn anticlockwise 4 steps Test run and make any necessary correction to two steps When you have sufficient feel of the vehicle then you can make further fine adjustments It is feeling and experience that counts Increase 15 Compression damping e Harsh Decrease NOTE Ensure that the springs are properly preloaded be fore attempting to make any adjustments A simple rule is that increased preload of the spring should be followed by an increase of rebound damping When you feel that you have achieved an im provement go back to where you started and check once more Be observant of other relevant factors such as tires temperature etc Test run to make sure whether further fine adjustment should be made A WARNING Never alter gas pressure Special purpose charg ing equipment and access to a nitrogen source is required The gas pressure should normally never be altered 16 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 16 Keep the shock absorbers clean and always spray them with oil QS 14 WD40 or CRC 5 56 or similar after washing the vehicle CAUTION Never use deterg
5. ecause of this it is vital that the suspension is adjustable Any change of components will demand different settings To complicate the situation the technique and skill of the driver will affect the perfomance of the machine Normal vehical steering by turning the front wheels in the intended JH direction Therefore it is extremely hard to recommend specific settings The best recommendation is to proceed by trial and error However good understanding of suspension design and function will give you the best chance to take advantage of the adjustment possibilities This is why we only give basic and simple advice on how to set the dampers shock absorber Read the manual carefully and start your work The hlins shock absorber will give you all possibili ties for fine adjustment to fit you personal desire A WARNING 1 ATVs are extremly depending on which kind of tires are beeing used Soft versus hard tires can completely alter the road holding abilities The suspension must be tuned in after each change of tires 2 Every change in suspension geometry i e change of a arms etc must be followed by new settings of the shock absorbers 11 Measuring of ride height sag PE R Preload Adjustment Setting the spring preload adjusting procedures By turning the rings on the shock absorber body you can adjust the springs tension to suit your weight Hold the upper ring and adjust the lower one to the desired positi
6. ents that can damage the sur faces of the shock absorber Use of thinner and brake cleaner will dry the surfaces too much 17 Inspection points Inspection points Fig 17 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 Excessive wear of rubber components 6 Fastening to the vehicle 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 authorised hlins service workshop There they have the necessary tools and know how for whatever you need Recommended inspection and maintenance intervals Normal use Race track 2 3 times a year Every ten hours Once a year general Change shock absorber oil Use hlins shock absorber oil only NOTE Make certain that your shock absorber are always filled with hlins High performance shock ab sorber oil Product guide 36D 36P 36PR 36PRCL 36PRCLB 36H 4 1 46ER DR 46ERS DRS 46DRLS ii ze 6 46PRCW 46PRC 46PRCL 46PRCLB 46PRCS 46PRCS 46PRCLS 46PRCLS 46PRCQ Horizontal Vertical Horizontal 20 LEY L 7 Fr oe Ps ya lt 10 Shock absorber type 36 46 Piston diameter in mm E Emulsion type of shoc
7. etween your suspen sion and this manual Please consult your hlins dealer if you have any questions with regard to the contents of the manual Oil Separating piston Shock absorber piston Tuning the suspension Road holding gualities All vehicles are designed with a suspension ge ometry that includes wheel movements and an gles 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 and the rear suspension interact properly It is of greatest importance that the front and rear loaded height ride height sag are within the specified values in the Mounting instructions Design Most of hlins suspensions 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 separating piston is often fitted in a separate fluid reservoir connected by hose Fig 1 or fixed direct on top of the shock absorber Fig 2 piggyback There are also models where the separating piston is fitted inside the main shock absorber Fig 3 internal gas reservoir hlins even manufacture a small number of emulsion shock absorbers that do not have a separating piston Fig 4 Pressurization of the fluid is made with nitrogen The pressurization prevents cavitation of the fluid and the shock absorbing action i
8. ings recommended by hlins Always make notes adjust in small steps and make only one adjustment at a time Adjustments should be made in small steps few clicks at a time By utilizing the adjustment possibilities you can test by trial and error and learn how they affect your vehicle Always begin by test driving with all adjustments at their basic setting Choose a short run of varying character ie long and sharp bends hard and soft bumps Keep to the same run and make only one adjustment at a time 14 Rebound damping e Unstable e Hard e Soft e Loose e Bumpy e Low e Bouncy e Bottom Increase Start with the rebound damping Fig 14 If the vehicle feels unstable loose and rather bouncy then the rebound damping should be increased Begin by turning the adjusting knob 4 steps clicks clockwise according to page 7 Test run again and adjust two steps back if it feels too hard and bumpy If the vehicle is hard and bumpy especially over a series of bumps then the rebound damping should be reduced Turn counter clockwise 4 steps test run and make any necessary correction by 2 steps Reduce Compression damping Fig 15 If the vehicle feels soft has low riding position and a tendency to bottom easily in long dips then the compression damping should be increased Screw clockwise 4 steps and test run again If this was too much then turn back two steps counter clockwise If the vehicle feels harsh and h
9. k absorber D De Carbon type of shock absorber with internal res ervoir in the main body P De Carbon type of shock absorber with external piggy back reservoir H De Carbon type of shock absorber with hose mounted external reservoir W Shock absorber delivered without spring K Emulsion type of shock absorber for cruiser bikes Q Progressive damping shock absorber with two pistons IK Compression u MA Rebound r lt Spring preload gt hydraulic IN d Spring preload hydraulic Adjustment features C Adjustable compression damping Adjuster wheel on the reservoir R Adjustable rebound damp ing Adjuster wheel on the piston shaft above the end eye S Hose mounted hydraulic spring preload adjuster Adjuster wheel on the hose B Integrated hydraulic spring preload adjuster Adjuster wheel on the adjuster L Adjustable length Adjuster nuts above the end eye NOTE Your shock absorber may look differ ent from the once pictured On type 46P the compression ad justment knob sometimes is a screw The reservoir could be angled to fit your bike and a horizontal reservoir is used on some models Steering dampers Road amp Track Front fork springs Road amp Track MX amp Enduro Front forks MX amp Enduro Road amp Track Superbike amp RR MX amp Enduro Front fork fluids Road amp Track MX amp Enduro
10. on Then lock with the upper ring To make this adjustment properly you must measure the ride height sag Fig 11 A WARNING Preload on the spring springs is very important because it affects the height of the vehicle and the wheel angles Consequently road holding characteristics can be changed even negatively NOTE For very light or very heavy drivers spring change may be needed to receive correct spring preload Rear end 1 Lift the rear wheels up off the ground 2 With the wheels off the ground measure the dis tance from the top center of the rear axle to a point straight above it on the frame of the ATV A 3 Wear all your riding gear Sit on the seat with your feet on the pegs in correct riding posi tion Have someone to repeat the measuring procedure B The difference between the first and the second measurement ride height sag A B 4 Adjust your spring preload so that your ride height sag is within the limits below or are according to the recommended settings in your Mounting instructions Front end Use the same procedure to measure the sag for the front end Adjust the spring preload to recommended settings 12 Rebound damper adjuster Setting the damping The adjusting possibilities of the advanced Ohlins shock absorbers facilitate fine setting You can optimize adjustments to suit your own vehicles weight and eguipment your individual way of driving and the condition of the road To
11. s therefore more even The external fluid reservoirs also contribute to better cooling of the fluid giving longer service life to both the fluid and components hlins shock absorbers have integrated temperature compensation As the temperature increases and the fluid flows more easily the flow Gas and oil Oil Shock absorber position 1 External reservoir with hose connection 2 External piggyback reservoir 3 Internal gas reservoir 4 Emulsion shock absorber is controlled accordingly The shock absorbing effect is therefore independent of the tempera ture hlins shock absorbers provide the possibility for adjustment making them adaptable to most vehicles drivers and ranges of use All of the shock absorbers equipped with springs have adjustable preloading of the spring action The more advanced models permit individual adjust ment of compression damping and rebound damping WARNING All vehicles are designed with a suspension geometry that includes wheel movements and angles 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 and the rear suspension interact properly lt gt UIT 5 Flow through needle valve Function The function in principle is that fluid is forced through needle valves at a low rate of flow Fig 5 and
12. 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 9 Adjustment possibilities Settings Basic settings Always ensure that the basic setting made by hlins is correct It is adapted to the specific make and model in its original state and for a rider of average weight These adjustments are made to optimize the suspension Fig 9 1 SPRING PRELOAD is when you adjust the spring to match your body weight and weight of your equipment 2 COMPRESSION DAMPING controls how fast the shock absorber compresses when you hit a bump 3 REBOUND DAMPING controls how fast the shock absorber returns to its normal position after it has been compressed 10 ATV steering by sliding Steering by sliding rear end As an ATV has a rear axle without differential it is forced to turn mostly by sliding Fig 10 There fore excessively good road holding capabilities is undesirable The rear end must be able to eas ily break loose to slide and the front wheels must not have too sharp turning radius as this could cause the ATV to flip over The tires are also a very important factor to the ATV s road holding capabilities Pattern sidewall flexibility and air pressure affects these characteris tics Changing the dimensions of A arms swing arm and linkage will also affect the vehicle s abilities B
13. through a number of apertures in the piston at a high rate of flow Fig 6 The flow through these apertures is regulated by shims thin steel wash ers that at high pressure are deflected to open for the fluid Fig 7 On some models the needle valves can be set individually illustration By altering the size of the shims stack ie number thickness diameter Fig 8 the characteristics of the damping action can be varied this shall only be done by Ohlins authorized service workshops 6 Flow through piston Compression damping When movement of the vehicle causes compres sion 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 The fluid that is displaced by the volume of the piston rod is forced into the external fluid chamber via aseparate 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 Compression flow Rebound flow Stop washer 8 Shim stack 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 flowing into the chamber is forced by the pressure of
14. tting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to Contents SJEL dd 0 AE 2 Tuning the SUSPENSION nennnnnnunnnernnnnnnnnneee 3 DEN 3 FORT ION EE 4 Compression damping wwwwwmamanananwa 4 Rebound damping neuen 4 SNE AA E 5 Preload adjustment 2 nenn 6 Setting the damping wwwwwmmmememmawwwura 7 Setting your vehicle wwwo 7 Start with rebound damping 8 Compression damping w w wmamamananwa 8 Inspection and maintenance w w s 9 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 Ifyou have any questions regarding proper installation procedures contact an hlins dealer or other qualified person 3 The vehicle service manual must be referred to when installing the Ohlins shock absorber NOTE hlins 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 b
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