Mounting Instructions
Contents
1. During storage and transportation espe cially 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 not unusual and is in no way detrimental to the shock absorber Kit contents Before installing the shock absorber please check the contents of the kit listed on the front page of this instruction If anything is missing contact your hlins dealer Description Pcs Part No Hydraulic pre loader 1 CA 805M Guide nut 1 03608 01 Lock nut 1 03609 01 Bolt M8x30 1 01046 30 Nut 1 00430 05 Washer 8 4 26 5 1 00426 02 Tie rap L 188 1 00231 01 C spanner 1 00710 01 Sticker 2 00192 01 Set up data Spring position 0 mm Spring pre load 9 mm Mounting instructions WARNING It s advisable to have an Ohlins dealer or other qualified person to fit your hydralic spring pre load adjuster 1 Put the motorcycle on a stand so the rear wheel is clear of the ground The swing arm must be free so the suspension is unloaded Make sure its steadily fixed so it will not fall over CAUTION The OEM bikestand for rear axle will not be suffi cient fot this 2 Remove the rear fairing seat unit with the quick connectors 3 Remove the two side covers from the left and the right side of tank 4 Remove the fuel tank CAUTION When removing the fuel tank always remove the right hand tank bracket first by loosen2. 13 Put the pre load adjuster cylinder into correct position and refit the spring by compressing it Refit the spring clip CAUTION Make sure that there is enough clearance for the unit and the hose when the suspension is com pressed or released 14 Refit the Ohlins shock absorber in reverse order First fit the lower shock absorber mounting bolt Tighten to 42 Nm 15 Mount the pre load adjuster on the inside of the rear foot rest bracket Use the bolt the washer and lock lock nut provided 16 Make sure the hose curves softly Fix it with the tie rap provided m m 17 Bring the link back in position again and fit the pivot bolt and nut Tighten to 52 Nm Then fit the upper shock absorber mounting bolt and tighten to 42 Nm 18 Refit the fuel tank and fit the right side tank bracket NOTE Do not forget to connect the electric cable for the tank reserve warning light Mount the side covers of the tank on the left and the right 19 Put the rear fairing seat unit back in position NOTE Make sure that all bolts are tightened to the correct torque and that nothing fouls or restricts movement of the hydraulic spring pre load adjuster when the suspension is being fully compressed or extended 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 CA 805M Is
3. ing the 3 bolts Othervise the fuel injector jet of cylinder 4 can be damaged when the fuel tank is removed 5 Loosen the lower shock absorber mounting bolt 6 Loosen the upper shock absorber mounting bolt T Loosen the nut of the pivot bolt going through the center of the upper link and pull the bolt out The rear bolt connected to the pushrod can stay in position 8 Lift the forward end of the link away from the shock absorber 9 Turn the shock absorber 90 to the left and pull it out uppwards WARNING Do not remove the spring if you do not have the proper tools for compressing the spring for ex ample hlins tool 00747 01 10 Remove the spring by compressing and then remove the spring seat Use tool 0747 01 11 Remove the pre load adjuster by sliding it down ward on the shock absorber cylinder and remove the lock ring and the guide ring NOTE The original guide ring and lock ring can be used to fix the new pre load adjuster 12 Mount the lock nuts provided for the pre load adjuster The guide nut 03608 01 should be on top of the lock nut 03609 01 Turn the guide nut to the correct postion see drawing below and lock it with the lock nut
4. nformation that is of importance with regard to procedures 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 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 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 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 between your suspen sion and this manual Please consult your hlins dealer if you have any questions with regard to the contents of the manual NOTE
5. sued 04 06 16 Mounting Instructions Ohlins hydraulic spring pre load adjuster 3649 03 replacement for shock absorber CA 805M type 46 PRCB MV Augusta F4S Guide nut Lock nut Adjuster knob Hydraulic pre load adjuster Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden Ohlins hydraulic pre load adjuster Your new hydraulic pre load adjuster is a unit specially designed to replace the original pre loade adjuster on Ohlins shock absorber CA 805 NOTE This kit is first and foremost intended for use with Ohlins damper CA 805 to replace the original pre load device Adjustments By turning the adjuster screw clockwise the pre load is set harder and reverse when turning coun ter clockwise The adjuster ratio is 2 1 Each turn by the adjuster adjusts the spring height with 1 m m 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 FANN RNIN ed 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 i
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