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1. hlins Shock Absorber for MC Road amp Track Owner s Manual ADVANCED SUSPENSION TECHNOLOGY hlins Racing AB The Story It was the 1970 s a young man named Kenth hlin 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 engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension 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 Congratulations You are now the owner of an Ohlins Shock Absorber More than two hundred World Championships and other major world titles are definitive proof that Ohlins shock absorbers offer outstanding performance and reliability Every product has gone through rigorous 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 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 statement you are a serious rider with a focus on getti2. optimize the stability and traction of your motorcycle the front fork must match the rear suspension hlins Racing has a variety of front fork springs available for a large number of motorcycle models The springs in combination with the hlins shock absorbers contribute to superior stability and traction See the hlins Recommendation List contact an hlins dealer 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 hlins 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 recommended basic setting Choose a short run of 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 Adjustments Most hlins shock absorbers for motorcycle are equipped with spring preload compression and rebound adjusters Due to limited space in some vehicles it is not possible to have all adjusters in certain models The three adjusters mentioned above will be discussed in the following chapter
3. If no other recommendations are given in the Mounting Instructions follow the recommended 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 Ohlins web site www ohlins com or with your Ohlins dealer distributor for the latest information Adjust spring preload 1 If your measures differ significantly from the recommendations in the Mounting Instructions or the table above adjust the spring preload See chapter Spring Preload in this manual 2 If the ride height still differs from the recommendations you may need to change to softer harder spring Contact an Ohlins dealer for advise 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 er g gt Stability and Traction All motorcycles are designed with a suspension geometry that includes height and fork angle Changing components can affect this and it is therefore essential that both the front and the rear 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 very important that the front and the rear loaded heights are within the specified values Front Fork Springs To
4. action 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 feels e hard e bumpy decrease rebound damping 12 Compression Damping If the bike feels soft unstable is using to much wheel travel and you have the perfect spring for you close the compression adjuster two 2 clicks This will control the wheel during acceleration more plus it will help ride height and falling 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 fe If the vehicle e feels unstable e feels soft e feels low e is bottoming increase compression damping When you feel that you have achieved an improvement go back to where you started and check once more Note other relevant factors such as tires temperature etc Test run to make sure whether further fine adjustments should be made If the vehicle feels e harsh
5. ately and return the product to an Ohlins Service Centre N The product warranty shall only apply if this product has been operated and maintained in accordance with recommendations in this manual If you have any questions regarding usage service inspection and maintenance please contact Ohlins Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distinguished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the shock absorber or to bystanders m Caution The Caution Symbol means Special precautions must be taken to avoid damage to the shock absorber Note The Note Symbol indicates information that is important regarding procedures Note When working on this product always read the Vehicle Service Manual This Manual shall be considered a part of the product and shall therefore accompany the product throughout its life cycle hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden In This Manual Introduction Safety Precautions Contents Design and Functioning Setting Up your Vehicle Adj
6. e hard e has bad grip decrease compression damping 13 Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for additional service please contact an authorized hlins Service Centre 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 after washing Wipe off excessive oil with a cloth Mm Caution Never spray water directly into the adjuster knobs and or the ball joints Inspection 1 Check ball joints for possible excessive 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 Recommended Service Intervals Racing Every 20 hours of operation Regular street use Every 30 000 km or Note Every 3 years Use only Ohlins Shock Absorber Fluid Contact an Ohlins dealer for advice Disposal A Warning Discarded Ohlins products should be handed Do not change the gas pressure Special purpose over to an authorized Ohlins workshop or charging equipmen
7. flows back through the needle valve 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 the piston velocity is high the shims on top of the piston will also open to allow the fluid to flow through CI 3 Stop washer Shim stack A Warning Before riding always ensure that the basic settings made by Ohlins are intact Take notes adjust in small steps and make only one adjustment at a time Spring Preload Free Sag Ride Height Spring preload is a crucial part of setting your motorcycle since it affects the height of the motorcycle and the fork angle Note Perform the following procedure on a flat surface 1 Put the motorcycle on a workstand so that both wheels are off the ground and the suspension is unloaded 2 Mark e g with a piece of tape a point immediately above the rear wheel axle 3 Measure the distance from the marked point to a fixed point e g the wheel axle R1 4 Measure the distance from the bottom of the upper triple clamp to a fixed point e g the front wheel axle F1 5 Put the motorcycle on the ground so that the front and the rear suspensions are slightly compressed Repeat the measuring procedures R2 and F2 6 Sit on the motorcycle in normal riding position properly outfitted in your riding gear Repeat the measuring procedure R3 and F3 Recommended Measures
8. he 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 chapter Setting Up your Vehicle Tightening torque 40 Nm A Warning Remember to lock the lock nut after adjusting the length A Warning 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 Note After adjusting the length check the headlight angle of your vehicle 11 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 you will need to compromise Keep priority at e safe feeling e stability e comfort This will allow you to ride safer and use less energy If the vehicle feels e unstable e loose e bouncy increase rebound damping Rebound Damping If you have got a good feeling for the bike with spring preload 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 tr
9. ion function If the preload is incorrectly set any other adjustments will not help to get the intended performance from the suspension Spring Preload A Free spring length B Installed spring length How to Set the Spring Preload 1 Mechanical Adjuster Shock absorber fully extended Use a C spanner Loosen the lock nut 1A A B Spring Preload Move the lower spring platform 1B to the Spring Preload is the difference between desired position Turn clockwise to increase the the measures A and B preload turn counter clockwise to decrease it 2 Hydraulic Adjuster Turn the Hydraulic Adjuster knob to set the spring preload Turn clockwise to increase the preload and turn counter clockwise to decrease 3 Integrated Hydraulic Adjuster Turn the hexagon screw on the hydraulic adjuster to set the spring preload Turn clockwise to increase turn counter clockwise to decrease 4 Mechanical 3 Step Adjuster Use two C spanners Turn the adjustment rings There are three 3 adjustment positions A B and C 5 Mechanical Adjuster Unlock the nylon screw on the spring adjuster with a screwdriver 5A Use tool 03199 01 and turn the spring adjuster clockwise to increase the preload 5B turn counter clockwise to decrease it TE 4C io Compression damping controls the energy absorption when the shock absorber is being compressed thus controls ho
10. nd ranges of use All of the shock absorbers with springs have adjustable preload of the spring action External Reservoir with Hose Connection External Piggyback Reservoir Fluid is forced through needle valves at a low rate of flow Fig 6 and through a number of orifices in the piston Fig 7 at a high rate of flow The flow through these orifices is regulated by shims thin steel washers that at high pressure are deflected to open for the fluid On most models the needle valve can be adjusted from the outside By altering the size of the shim stack Fig 8 i e number thickness diameter the characteristics of the damping action can be changed This should only be done by an authorized hlins service workshop Compression damping When movement of the motorcycle causes compression of the shock absorber the fluid flows through the needle valve combined compression and rebound valve in the piston rod If the velocity of the compression movement 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 for a greater rate of flow The fluid that is displaced by the volume of the piston rod is forced into the external reservoir via a separate compression valve The separating piston is displaced thus increasing the gas pressure Rebound damping When the spring forces the shock absorber to extend again the fluid
11. ng the maximal handling ability and outstanding feedback from your bike 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 for a ride Go explore Note The shock absorber is an important part of the vehicle and will affect the stability Read and make sure that you understand the information in this manual and the mounting instructions before you use this product If you have any questions regarding installation or maintenance please contact Ohlins Ohlins Racing AB can not be held responsible for any damage to the shock absorber vehicle other property or injury to persons if the instructions for installing and maintenance are not followed exactly A Warning This product was developed and designed exclusively for a specific vehicle model and shall only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer AN This product contains pressurized nitrogen gas N Do not open service or modify this product without proper education authorized Ohlins dealer distributor and proper tools A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability ZX If the suspension makes an abnormal noise or the function is irregular or if you notice any leakage from the product please stop the vehicle immedi
12. s A deeper understanding for the different types of adjustments will give you a good knowledge of how you can get better performance from your Ohlins shock absorber When you adjust the spring preload you move the spring seat This will lower or raise the ride height Compression damping controls the energy absorption when the shock absorber is being compressed thus controls how easy the shock absorber compresses when you hit a bump Rebound damping controls the energy absorption when the shock absorber is being extended and thus controls how fast the shock absorber returns to its normal position after being compressed Note When riding with a passenger or changing the load the spring preload must be adjusted for proper function and vehicle balance 1 First check the headlight angle by placing the vehicle about 5m from a wall with the rider in normal riding position 2 Turn on the headlight 3 Mark the centre of the light on the wall with a piece of tape When you have a passenger or when you put packing on the vehicle the headlight angle will be too high 4 Adjust the spring preload until the headlight angle is the same as before but with the passenger or extra load on the bike When adjusting the spring preload 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 preload is fundamental for the suspens
13. t and access to nitrogen is distributor for proper disposal required 14 hlins Owner s Manual Shock Absorber R amp T Part No 07241 02_7 Issued 2011 06 13 2011 hlins Racing AB Your hlins retailer SIFIE SAIFIE Wa ISO 9001 ISO 14001 ED a z 4 6 Q gt Q a amp Cert Ohlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands Vasby Fax 46 0 8 590 025 80 Sweden www ohlins com ADVANCED SUSPENSION TECHNOLOGY www ohlins com
14. ustments Spring Preload Compression Damping Rebound Damping Adjust Length Adjustment and Set up Inspection and Maintenance gt T Many of hlins suspensions are high pressure monotube type shock absorbers The fluid is put under gas pressure and the gas and the fluid are kept apart by a separating piston The piston is usually fitted in an external reservoir connected by a hose Fig 4 or fixed directly on top of the shock absorber Fig 3 In some models everything is fitted inside the main shock absorber Fig 2 A few shock absorbers are of emulsion type oil and gas mixed inside the shock absorber Fig 1 The fluid is pressurized by nitrogen The pressurisation prevents cavitation of the fluid and the shock absorbing action is therefore more even The external reservoir also contributes to better cooling of the fluid giving longer service life for the fluid as well as the components Internal Gas Reservoir Emulsion Shock Absorber hlins shock absorbers with external rebound adjustment have an 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 and rebound damping hlins shock absorbers provide the possibility of adjustment making them adaptable to most vehicles drivers a
15. w easy the shock absorber compresses when the rear wheel is being loaded or hits a bump Compression Damping Adjuster Adjuster Type 1 Adjust by turning the knob on top of the reservoir Turn clockwise to increase damping turn counter clockwise to decrease Adjuster Type 2 Adjust by turning the knob on top of the reservoir Turn clockwise to increase damping turn counter clockwise to decrease Adjuster Type 3 Adjust on top of the reservoir Turn the slotted screw clockwise to increase damping turn counter clockwise to decrease Adjuster Type 4 Adjust on top of the reservoir High speed Turn the hexagon screw Low speed Turn the slotted centre screw Turn clockwise to increase damping turn counter clockwise to decrease Reset the adjuster 1 Turn the adjuster clockwise to fully closed position position zero 0 2 Turn counter clockwise to open and count the clicks until you reach the recommended number of clicks See recommended Set up data in the Mounting Instructions for the shock absorber Mm Caution Do not use force delicate sealing surfaces can be damaged 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 Rebound Damping Adjuster Turn the wheel on the piston shaft above the end eye bracket Turn clock
16. wise to increase damping turn counter clockwise to decrease it 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 recommended Set up data in the Mounting Instructions for the shock absorber m Caution Do not use force delicate sealing surfaces can be damaged 10 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 centre 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 Adjust Length We advise to remove the shock absorber from the vehicle before adjusting the length Use two 24 mm wrenches Hold t
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