07242-01 OM TTX36.indd
Contents
1. to the wheel axle R1 e Measure the distance from the marked point in the front to the front wheel axle F1 e Apply load on the front and the rear suspensions and take the same measurements R2 F2 e Now take the same measurements with a rider fully eguipped on the motorcycle R3 F3 A WARNING Incorrect spring rate may result in a front geometry that is either too steep or too flat This can result in a tendency of under or over steering that could seriously affect the handling characteristics of the motorcycle Rear mark Front mark F1 a Recommendations If no other recommendations are given in the Mounting Instructions follow the measures below Free sag R1 R2 F1 F2 Rear 5 15 mm Front 20 30 mm Ride height R1 R3 F1 F3 Rear 25 35 mm Front 30 40 mm NOTE Always check on the hlins web site www ohlins com or with your Ohlins dealer distributor for latest information Step 2 Adjust spring pre load e If your measures differ significantly from the recommendations in the Mounting Instructions or the table above adjust the spring pre load See section Spring Pre load in this manual e If the ride height still differs from the recommendations you may need to change to softer harder spring Con tact your Ohlins dealer for advice Stability and Traction All motorcycles are designed with a suspension geometry that includes height2. 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 fora ride Go explore Ohlins Racing AB cannot be held re sponsible for any damage to the shock absorber or vehicle or injury to persons if the instructions for installing and main tenance are not followed exactly Similarly the warranty will become null and void if the instructions are not followed Safety Signals In this manual mounting instructions and other technical documents impor tant information concerning safety is distinguished by the following nota tions A The Safety Alert Symbol means Warn ing Your safety is involved A WARNING The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone work ing with inspecting or using the shock absorber or to bystanders CAUTION The Caution Symbol means Special precautions must be taken to avoid damage to the shock absorber NOTE The Note Symbol indicates informa tion that is of importance regarding procedures Safety Precautions E WARNING Installing a shock absorber that is not approved by the vehicle manu facturer may affect the stability of your vehicle hlins Racing AB cannot be held responsible for any personal injury or damage that may occur after installing the shock absorber 2 Please study
3. ING Remember to lock the lock nut after ad justing the length The adjustable end eye bracket must not be threaded out more than that the groove is fully visible beneath the lock nut This is maximum length After adjusting make sure that the lock nut is tightened A WARNING Adjustment and Set up A WARNING When delivered the Ohlins shock absorb er is dialed to the recommended settings for the specific brand and make of the motorcycle Before riding always ensure that the basic settings made by Ohlins have not been changed during delivery Always make notes adjust in small steps and make only one adjustment at a time Setting Spring Pre load Step 1 Measure Spring pre load is a crucial part of setting your motorcycle since it affects the height of the motorcycle and the fork angle NOTE These measures should be taken with the motorcycle on a flat surface e Arrange the motorcycle so that the wheels are off the ground and that the front and the rear suspensions are fully extended For example tilt the motorcycle on its side stand You may need to apply force on the wheels to get the suspensions fully extended so that the top out springs do not compress it e Mark with a piece of tape or similar a point on the seat or rear frame and another point at the bottom of the front fork outer tube e Measure the distance from the marked point in the rear
4. Owners Manual Ohlins Shock Absorber TTX36 Ohlins Racing AB The Story It was the 1970 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 en gine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension Congratulations 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 per formance and reliability Every product has gone through rigor ous 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 Ohlins Racing was established in 1976 and just two years later the company won its first World 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 The product that you now have in your possession is pure racing breed that is built to withstand By installing this shock absorber on your bike you have made a clear state ment you are a serious rider with a focus on getting the maximal handling ability and outstanding feedback from your bike
5. a spring pre load ed shim that opens easily for return flow of fluid when the direction of movement of the shock absorber changes Fig 1 outer white arrows The bleed valve and shim valve are used to build up damping force At slow stroke speeds the percent age going through the bleed valve is higher and at fast strokes the shim valve takes care of most of the flow The check valve together with the bleed valve since it can flow both direc tions handle return flow To control damping force the bleed valve can be changed in size by the external adjuster compression and rebound By altering the stiffness of the shim stack number thickness diameter and shape on the shim valve the charac teristics of the damping action can be changed This should only be done by an author ized Ohlins service workshop Compression Damping When movement of the motorcycle caus es compression of the shock absorber Fig 2 the fluid above the main piston is pressurized more than the set gas pres sure and goes through the e compression adjuster bleed valve e compression adjuster shim valve e _ channel connected to the reservoir e rebound adjuster check valve and between the outer and inner tube to the under side of the main piston During compression stroke the piston rod is entering the main body and the correspondingly displaced volume of damper fluid has to flow into the reser voir the separating piston moves accor
6. and fork angle The changing of compo nents can affect this and it is therefore essential that both the front and the rear ends match each other Changing to Oh lins suspension gives optimum perform ance only when both the front fork and the rear suspension interact properly It is very important that the front and the rear loaded heights are within the specified values Front Fork Springs To optimize the stability and traction of your motorcycle the front fork must match the rear suspension Ohlins Racing has a variety of front fork springs avail able for a large number of motorcycle models The springs in combination with the Ohlins shock absorbers contribute to superior stability and traction See the Ohlins Recommenda tion List by contacting your nearest Ohlins dealer or using our web site A WARNING If there are no matching springs for your motorcycle model use the original springs however they must be in good condition and not fatigued FGK kits and Piston kits Ohlins Racing also produces complete Racing Cartridge Systems for front forks as well as piston kits to upgrade your front fork to a higher performance level Prepare the Settings By adjusting the shock absorber and testing by trial and error you can learn how the different settings affect your motorcycle Always begin your setting by taking a test ride with all adjustments at their rec ommended basic setting Choose a short run o
7. and make certain that you fully understand this manual and the mounting instructions before handling this shock absorber If you have any questions regarding proper installation procedures or mainte nance please contact an Ohlins dealer 3 Refer to the vehicle service manual when installing this shock absorber NOTE Ohlins products are subject to continuous improvement and development There fore although these instructions include the most up to date information available at the time of printing there may be minor differences between your shock absorber and this manual Please consult your Ohlins dealer if you have any questions regarding the contents of the manual Before riding the vehicle always make sure that the basic settings made by Ohlins are correct See the Mounting instructions for recommended Set up data Contact an Ohlins dealer if you have any questions about setting the shock absorber Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden In This Manual Design and Function Spring Pre load Compression and Rebou LEO Adjustment and Set up Congratulations on choosing the Ohlins TTX Road amp Track shock absorber the most unique and powerful racing shock absorber available today The TTX36 shock absorber design is the culmination of two decades of Ohlins successful par tici
8. d ingly Rebound Damping When the spring forces the shock ab sorber to extend again Fig 3 the fluid below the piston is pressurized more than the set gas pressure and has to move In a similar pattern the flow goes through the e rebound adjuster bleed valve e rebound adjuster shim valve e channel connected to the reservoir e compression adjuster check valve and into the inner tube to the upper side of the main piston The fluid that was displaced into the reservoir during compression stroke is now pushed back into the main body by the pressure of the gas the separating piston moves accordingly Spring Pre load When adjusting the spring pre load you move the spring seat This will decrease or increase the initial spring force which will lower or raise the motorcycle rear ride height The spring pre load is fundamental for the function of the suspension If the pre load is incorrectly set any other adjust ments will not help to get the intended performance from the suspension The spring pre load is the difference between A and B A Free spring length B Installed spring length Shock absorber fully extended A B Spring Pre load How to Set the Spring Pre load 1 Turn the Hydraulic Adjuster knob to set the spring pre load Turn clockwise to increase the pre load and turn counter clockwise to decrease If your shock absorber is not equipped with a Hydraulic Adj
9. f varying character for example with long as well as sharp bends hard as well as soft bumps Stay on the same run and adjust only one setting at a time If the vehicle feels e unstable e loose e bouncy increase rebound damping If the vehicle feels e hard e bumpy decrease rebound damping Recommended Adjustment Range Rebound and compression damping 5 clicks from original basic setting When you setup your bike you need to do it together with the front fork and on all types of tracks that you want to optimize there are no setups that will be 100 perfect on all tracks compromises need to be made Keep priority at e safe feeling e stability e comfort This will allow you to ride safer and use less energy Rebound damping If you have got a good feeling for the bike with spring pre load and the ride height feels OK but the bike runs low and packs down under acceleration bumps with lost line and or lost comfort and traction open the rebound adjuster two 2 clicks If the bike is nervous and moving a lot or has a high feeling entering corners close the rebound adjuster two 2 clicks Fine tune one 1 click at the time Test run and make the necessary adjustments For original rebound setting see the Mounting Instructions for your shock absorber If the vehicle If the vehicle feels e feels unstable e harsh e feels soft e hard e feels low e has bad g
10. pation in World Championship events This shock absorber draws on all the expertise developed by Ohlins while winning more than one hundred World Championship titles The TTX36 shock absorber is designed to handle the de manding damping characteristics needed for all types of tracks from winding TT road race course to pure GP Road Racing tracks The Ohlins TTX36 features a patented concept with a unique concentric twin tube design together with a solid main piston that allows for the gas pressure to always back up the low pressure side of the main piston This design creates positive pressure build up on both com pression and rebound stroke As a result the TTX36 has a more direct damping re sponse less risk for cavitation and works with lower gas pressure Compared to a regular piggy back single tube shock absorber that has posi tive pressure build up only on rebound stroke and relies on compression valve resistance together with gas pressure to avoid cavitation on compression stroke the TTX36 design is superior Also the twin tube design with sepa rate channels connecting the compres sion valve to the compression side of the main piston and the rebound valve to the rebound side of the main piston gives the possibility to have completely separated adjusters for compression and rebound damping The whole system is pressurized by nitrogen gas behind a floating piston to ensure separation of the gas and fluid A top out
11. r washing CAUTION Never spray water directly into the ad juster knobs and or the ball joints e Inspection 1 Check ball joints for possible exces sive play or stiction 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body for external damage 4 Check the reservoir for external damage that can restrict the floating piston from moving freely 5 Check for excessive wear of rubber components 6 Check the attachment points of the shock absorber to the vehicle e Recommended Service Intervals Racing every 10 hours of operation Maximum 20 hours of operation without service and oil change Regular street use every 30 000 km e Disposal Discarded Ohlins products should be handed over to an authorized Ohlins workshop or distributor for proper dis posal Clean under the bump rubber Inspection Points NOTE The Ohlins shock absorber should only be filled with the Ohlins High Performance Shock Absorber Fluid art no 01306 xx Contact your Ohlins dealer for advice A WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required Read more at www ohlins com Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Owner s Manual 07242 01 TTX36 Issued 2007 01 15 Illustrations Tiina Harakka Carlsson hlins Racing AB
12. rip e is bottoming decrease compression damping increase compression damping Compression damping If the bike feels soft unstable is using When you feel that you have achieved to much wheel travel and you have the an improvement go back to where you perfect spring for you close the com started and check once more Note other pression adjuster two 2 clicks This will relevant factors such as tires tempera control the wheel during acceleration ture etc Test run to make sure whether more plus it will help ride height and fall further fine adjustments should be made ing through the stroke too quickly If the bike feels high has bad grip at throttle opening and feels unsmooth over small or medium bumps during acceleration open the compression adjuster two 2 clicks Test run and make necessary corrections When you have sufficient feel of the motorcycle you can make further fine adjustments It is feeling and experience that counts 12 Inspection and Maintenance Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for addi tional service please contact an author ized Ohlins workshop e Cleaning Clean the shock absorber externally with a soft detergent Use compressed air Be careful that all dirt is removed Lift the bump rubber and clean the area below Keep the shock absorber clean and spray it with oil WD40 CRC 5 56 or equivalent afte
13. se a 14 mm socket T bar and turn the hexa gon nut on the adjuster knob 2 Turn clockwise to increase damping turn counter clockwise to decrease Length Adjustment By adjusting the length of the shock absorber the steering geometry as well as the chain force can be changed A shorter shock absorber will result in a lower motorcycle The fork angle as well as the trail will increase and normally the chain force will be reduced with less anti squat as a result A slight change of cen tre of gravity is another result of changing the length of the shock absorber A longer shock absorber will result in a higher motorcycle The fork angle and trail will decrease and normally the chain force will increase with more anti squat as a result A slight change of centre of gravity is another result of changing the length of the shock absorber NOTE On modern Hypersport and race bikes all length adjustment should be moderate Also very small adjustments can make a big difference How to Adjust the Length We advise to remove the shock absorber from the vehicle before adjusting the length Use two 24 mm wrenches Hold the upper nut with one hand and at the same time loosen the lock nut lower nut Turn the end eye bracket to the desired length One 1 turn is 1 mm of shock absorber length Please make sure to measure the ride height before and after adjusting the length see page 9 Tightening torque 40 Nm A WARN
14. spring is fitted in the TTX36 for optimum performance during hard brak ing Design and Function The Ohlins shim system offers infinite combinations of shim stacks with a wide spectrum of different character Also dif ferent bleed valves are available The Ohlins TTX36 shock absorber is a user friendly shock absorber with hy draulic main spring pre load adjustment length adjustment easy to set up dial in and rebuild Support is always available from the Ohlins distributors worldwide Function When the shock absorber moves the fluid inside is forced to flow through either the compression valve or rebound valve first depending on direction of move ment followed by going through either the rebound check valve or compression check valve and on to the other side of the main piston Fig 2 and 3 The fluid displaced by the piston rod is directed either into or out of the reservoir The reservoir is connected to the sys tem so regardless of direction of move ment it will be in contact with the low pressure side of the main piston The compression and the rebound valve are both of the same design The valve has three flow paths for the fluid Bleed valve Fig 1 centre black arrows small orifice that creates a flow restriction simply by being small Shim valve Fig 1 outer black arrows fluid pressure has to deflect thin steel washers shims to open up an orifice and allow fluid to flow through it Check valve
15. uster 2 Use a C spanner and move the spring platform to the desired position 2A Spring Pre load Compression and Rebound Damping Compression and Rebound Damping Compression damping controls the en ergy absorption when the shock absorber is being compressed thus controls how easy the shock absorber compresses when the rear wheel is being loaded or hits a bump Rebound damping controls the energy absorption when the shock absorber is being extended and controls how fast the shock absorber returns to its normal position after being compressed Adjust compression and rebound damping by turning the knobs on top of the reservoir The adjusters have a normal right hand thread To reset the adjuster Turn the adjuster clockwise to fully closed position position zero 0 Then turn counter clockwise to open and count the clicks until you reach the recommended number of clicks See rec ommended Set up data in the Mounting Instructions for the shock absorber CAUTION Do not use force delicate sealing sur faces can be damaged How to Adjust Compression Adjust by turning the gold knob labelled COMP on the cylinder head 1 Or use a 14 mm socket T bar and turn the hexagon nut on the adjuster knob 2 Turn clockwise to increase damping turn counter clockwise to decrease How to Adjust Rebound Adjust by turning the black knob labelled CAUTION REB on the cylinder head 1 Or u
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