Ohlins SHOCK ABSORBERS MOTORCYCLE ROAD & TRACK User's Manual
Contents
1. The separating piston is often fitted in a separate fluid chamber connected by hose or fixed direct on top of the shock absorber piggyback There are also types of shock absorbers where everything is fitted inside the main cylinder tube internal gas reservoir and even a small number of emulsion shock absorbers that do not have a separating piston Pressurization of the fluid is made with nitrogen The pressurization prevents cavitation of the fluid and the shock absorbing action is therefore more even The external reservoires also contribute to better cooling of the fluid giving longer service life for both the fluid and components Ohlins shock absorbers have integrated tempera ture compensation As the temperature in creases and the fluid flows more easily the flow is 2 Spring preloading Mechanical adjustment Hydraulic preloader Separating C spanner piston Shock absorber piston Adjuster controlled accordingly The shock absorbing effect is therefore independent of the temperature The more advanced models permit individual adjustment of compression damping and re bound damping and also certain adjustment of the length of the shock absorber Ohlins 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 preloading of the spring action either mechanically or hydraulically 3 Flow thr2. soft bumps Keep to the same run and adjust only one setting at a time Reduce Increase Start with the rebound damping Fig 12 If the motorcycle feels unstable loose and rather bouncy then the rebound damping should be increased Begin by turning the adjusting knob 4 steps clicks clockwise Test run again and adjust two 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 counter clockwise 4 steps test run and make any necessary correction to 2 steps Compression damping Fig 13 The low speed compression adjuster affects ride height smoothness over small bumps and grip The high speed compression adjuster affects stability firmness in depressions and fast corners If the motorcycle has low riding position the low speed compression should be increased Screw clockwise four steps and test run again If this was too much then turn back two steps 13 Compression damping e Harsh e Hard e Bad grip Reduce counter clockwise If it feels unsmooth over small continuous bumps or has bad grip the low speed compression should be decreased Turn counter clockwise four steps Test run and make any necessary correction in two steps at the time If the motorcycle feels unstable in fast corners and has a tendency to bottom easily in depressions and chicanes the high speed compression should be increased
3. Owners Manual Ohlins shock absorbers Motorcycle Road amp Track Including 2 E E AA Tuning the n Vo suspension Oryg Suz na A TNN Ji Function Fine tuning 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 adepted to the brand and model This means that length travel springaction and damping charac teristics 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 followed exactly Similarly the warranty will become null and v
4. Screw clockwise six steps and test run again If this was too much then turn back three steps counter clockwise If it feels harsh and too rigid or has a tendency to hop under braking the high speed compression should be decreased Turn counter clockwise six steps Test run and make any necessary correction in three steps at the time When you have sufficient feel of the motorcycle you can make further fine adjustments It is feeling and experience that counts NOTE Ensure that the springs are properly preloaded before attempting to make any adjustments A simple rule is that increased preload of the spring should be followed by an increase of rebound damping by two steps 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 tyres temperature etc Test run to make sure whether further fine adjustment should be made 14 Adjustment of shock absorber lenght Setting the shock absorber length Sensitivity of the steering can be adjusted by altering the length of the shock absorber without affecting other characteristics The length is adjusted using two nuts down and the treaded clevis at the end of the piston rod Fig 14 The shock absorber can be adjusted up to 12 mm Adjusting the shock absorber length A long shock absorber results in steeper inclination of the front fork steeper fork angle and consequently sensitive qui
5. ad rings can be adjusted On a shock absorber that has hydraulic setting the basic position can be adjusted Such changes should be attended to by an Ohlins authorized service workshop The original setting of the shock absorber when delivered from Ohlins should always be a base when the settings are changed by use of the adjustment devices NOTE The spring preload affects the ride height it does not affect the spring stiffness Therefore on models with a linkage to the shock absorber the suspension may actually feel harder when you reduce the preload and the shock absorber gets into the harder range of the link system 8 Front fork spring kit Front fork springs To optimize the road holding qualities of a motor cycle the front fork must match the rear suspension Ohlins springs are available for a large number of motorcycles Fig 8 These in combination with Ohlins shock absorbers contribute 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 See table NOTE It is important that the recommendation table is followed for new front springs If there are no rec ommended front springs you must ensure that the existing springs are in good condition Neglecting to
6. arate adjusters for high speed compression and low speed compres sion Fig 11 The low speed compression is ad justed in 25 steps The high speed adjuster has a wide range within about 48 clicks NOTE High and low speed referes to the shaft velocity of the shock absorber It is not necessarily re lated to the speed of the vehicle 11 High and low speed compression damping adjusters NOTE When making new adjustments it is easiest to go back to fully closed and then count forward to the new setting The adjusting knobs should not be screwed in too hard 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 12 Rebound damping e Unstable e Loose e Bouncy e Hard Unstable Soft Low Bottom Increase Setting your motorcycle NOTE Always begin with the basic settings recom mended 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 at a time Adjustments should not be more than four steps from the basic setting By utilizing the adjustment possibilities you can test by trial and error and learn how they affect your motorcycle Always begin by test riding the motorcycle with all adjustments at their i e delivery setting Choose a short run of varying character ie long and sharp bends hard and
7. check the front springs could seriously affect the handling qualities of the motorcycle 9 Adjustment of rebound damping z ge LLI E y D a Nv i SONG Setting the damping The adjusting possibilities of Ohlins shock ab sorbers facilitate fine setting You can optimize adjustments to suit your own weight and equip ment your individual way of riding and the con dition of the road To 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 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 the knobs they have a nor mal right hand thread By turning clockwise they increase the damping action and counter clock wise they reduce it The knobs have definite po sitions with noticeable clicks so it is easy to count to the right setting Rebound damping action affects the character istics of the motorcycle most The setting knob is located at the bottom on the piston rod Fig 9 10 Adjustment of compression damping more damping O less damping er a LAA It can be adjusted in about 40 steps The com pression damping knob is located at the end of the reservoir Fig 10 This can be adjusted in about 25 steps Some models PRX have sep
8. cker steering A short shock absorber gives a bigger angle of the front fork flat fork angle and consequently slower and smoother steering Each complete turn of the shock absorber gives one millimetre Fig 15 The length may never be altered more than to where the groove Fig 16 that is cut in the thread becomes just visible under the lower nut of the level brachet Make small steps and test run 15 Adjusting the shock absorber length 16 Groove WARNING If the shock absorber has an adjustable end eye bracket this must not be threaded out more than that one groove is fully visible beneth the lock nut Make sure that the lock nut is tightened after adjustment Groove 17 Lift the bump rubber and clean the area below Inspection and maintenance Clean the shock absorbers externally with a soft detergent Use compressed air Lift the bump rub ber and clean the area below Fig 17 Keep the shock absorbers clean and always spray them with oil QS 14 WD40 or CRC 5 56 or simular CAUTION Never use detergents that can damage the sur faces of the shock absorber Thinner and brake cleaner will dry the surfaces too much 10 18 Inspection points Inspection points Fig 18 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 damage 4 Check the external reservoir for damages that can restri
9. ct the floating piston from moving freely 5 Excessive wear of rubber components 6 Fastening to the wehicle e Check the hose equipped models for leaks in hose and inlet plugs 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 authorized Ohlins service worshop 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 Suspension fluid NOTE Regular maintenance and inspection contribute to the prevention of functional disturbances Recommended service intervals Race track Every 10 hours Street Road Every 20 000 30 000 km WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required The gas pressure should normally never be altered WARNING The shock absorber is provided with a separate type reservoir filled with high pressure nitrogen gas To prevent danger of explosion study and make certain that you fully understand the fol lowing information before handling the shock ab sorber The manufacturer cannot be held respon sible for damage to property or personal injury that may result from improper handling 1 Never tamper with or attempt to disassem ble the cylinder or the reservoir 2 Never expose the shock absorber to an open flame o
10. in the fluid flows back through the needle valve in 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 6 F1 R1 A D Bike on a stand Settings Basic settings Always ensure that the basic setting made by hlins is correct It is adapted to the make and model in its original state and for a rider of aver age weight Everything must harmonize In the recommendation table there are hlins front fork springs that are specifically adapted to the shock absorbers recommended to your motor cycle If none is noted in the table then intact original springs is the right choice Incorrect spring action can give 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 R2 E Bike on the ground Setting the spring preload Measuring Preload on the spring springs is very important because it affects the height of the motorcycle and the fork angle Consequently handling char acteristics can be changed even negatively Proceed as follows it will be much easier if done by two persons A Place the motorcycle on a stand B Lift up the rear end to a fully extended p
11. oid if the instructions are not adhered to Contents Saftey Signals sarossaneisenn i 2 Tuning the suspension ccccseseeeeeeeeeeeeeeeees 3 PS SIO EE N E EE AE 3 POM aE EEE E E E a 4 Compression damping sceceeeesseeeeeeees 4 Rebound damping ccceeseececeessseeeeeeeeaeees 4 SaS EP AE E EEA ET E 5 Basic setings seis ck etnewsacaantnaceancontesabinnncctins 5 Setting the spring preload cccccesseeeeeeees 5 DNS AG ce erts ees cee ciect earen naa ANA 5 POSTING srini naaa GAS 6 Front FORK SPNG sereni 6 Setting the damping ssssseeennnnnnnenenesnnn nenne T Setting the shock absorber lenght 7 Setting your motocycle ccccceeeeeeeeeeeeeees 8 Start with rebound damping ccccceeee 8 Compression damping ccceeeeseeeeeeeees 8 Adjusting the shock absorber lenght 9 Inspection and maintenance 26ce 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
12. osition C Measure the distance eg from the lower edge of the rear mud guard or from a point marked by a piece of tape immediately above the rear wheel axle to the wheel axle R1 D Make a similar measurement on the front axle e g from the bottom of the upper fork crown to the front wheel axle The fork must also be fully extended F1 F Bike with rider on E Allow the motorcycle without rider to apply load on the springs and repeat the measuring procedure R2 F2 F Then take the same measurements with the rider and equipment on the motorcycle 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 R3 F3 The measurements may not differ from the following sizes Without rider Rear 5 10mm R1 R2 Front 25 30 mm F1 F2 With rider Rear 30 40 mm R1 R3 Front 35 48 mm F1 F3 7 Spring preload adjusment A Mechanical preload adjuster B Hydraulic preload adjuster Adjusting Adjust the preload with the rings on the shock absorber or by hydraulic preloading In the first case hold the upper ring and adjust the lower one to the desired position Fig 7A Then lock with the upper ring For hydraulic preloading increase by turning clockwise and reduce by turning counter clock wise Fig 7B NOTE On shock absorbers that have mechanical type adjustment the position of the adjusting prelo
13. ough needle valve Function The function in principle is that fluid is forced through needle valves at a low rate of flow Fig 3 and through a number of apertures in the piston Fig 4 at a high rate of flow The flow through these apertures is regulated by shims thin steel wash ers Fig 5 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 ie number thickness diameter the characteristics of the damping action can be varied this shall only be done by Ohlins authorized service workshops 4 Piston with apertures 5 Shims stack Compression damping When movement of the motorcycle causes com pression in the shock absorber the fluid flows through the needle valve combined compres sion and return valve in the piston rod If velocity of the piston is high ie in the case of rapid com pression this will not be sufficient and conse quently the shims underneath the piston will open to allow a greater rate of flow Fig 6 The fluid that is displaced by the volume of the piston rod is forced into the external fluid cham ber via a separate 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 6 Flow through piston Stop washer Rebound damping When the spring presses the shock absorber out aga
14. proper installation procedures contact an Ohlins dealer or other qualified person 3 The vehicle service manual must be referred to when installing 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 Gas and oil 1 Emulsion shock absorber 2 Internal gas reservoir 3 External piggyback reservoir 4 External reservoir with hose connection 1 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 Ohlins 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 height are within the specified values See section Setting the spring preload Design Most of the Ohlins shock absorbers are of the De Carbon type The fluid is put under gas pres sure and the gas and the fluid are kept apart by a separating piston
15. r other excessive heat The shock ab sorber may othervise explode due to too high pressure 3 Be careful not to damage any part of the gas reservoir A damaged gas reservoir will impair the damping performance or cause malfunction 4 Take care not to scratch the contact surface of the piston rod of the cylinder oil could other wise leak out 5 Never attempt to remove the plug at the bot tom of the nitrogen gas reservoir Any attempt to remove the plug implies serious danger 6 When scrapping the shock absorber follow the instructions for disposal 11 More info www ohlins com D Netscape 0th PA i 3 4 Back Forord Relos Home Location J http www abling corn j d Precision makes the difference Navigation scroll Home Company Motorcycle Car Snowmobile News amp links hlins Racing AB Box 722 194 27 Upplands Visby Sveden 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 al about The ultimate suspension site Find out everything about your suspension Download mounting instructions manuals and brochures And a lot more 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 Your Ohlins dealer 07241 02 Issued 02 01 04 5000 ex
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