2006 Ohlins Shock Owners Manual.pdf

Owners Manual

Öhlins shock absorbers, MX/ENDURO/OFF ROAD

Including:

Safety

Tuning the

suspension

Design

features

Function

Basic

adjustments

Fine tuning

Inspection,

maintenance

Safety signals

Important information concerning safety is

distinguished in this manual by the

following notations:

Introduction

All of Öhlins advanced suspension products are

adapted to the brand and model. This means

that length, travel spring action and damping

characteristics, are tested individually just for

the motorcycle that you have decided to fit with

Öhlins suspension.

WARNING!

1. Installing a shock absorber, that is not

approved by the vehicle manufacturer, may

affect the stability of your vehicle. Öhlins

Racing AB cannot be held responsible for

any personal injury or damage whatsoever

that may occur after fitting the shock

absorber. Contact an Öhlins 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 proper installation procedures,

contact an Öhlins dealer or other qualified

person.

3. The vehicle service manual must be

referred to when installing the Öhlins shock

absorber.

The Safety alert symbol means:

Caution! Your safety is involved.

Before installation

Öhlins 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!

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.

Contents

Safety signals ................................................ 2

Introduction ................................................... 2

Before installation .......................................... 2

Tuning the suspension ................................... 3

Design ........................................................... 3

Function ........................................................ 4

Settings ......................................................... 5

Setting the spring pre-load ............................ 5

Setting the shock absorber lenght ................. 6

Setting the damping ...................................... 7

Setting your motorcycle ................................. 8

Inspection and maintenance ......................... 9

General handling setup ................................ 10

NOTE!

This indicates information that is of

importance with regard to procedures.

NOTE

Öhlins 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 Öhlins

dealer if you have any questions with regard to

the contents of the manual.

Any reprinting or unauthorized use

without the written permission of

Öhlins Racing AB is prohibited.

Printed in Sweden.

1. Design principles

Gas

2. Spring pre-loading

3. Adjustment of shock

absorber length

Oil

Gas

1. External reservoir

with hose connection

2. External piggyback

reservoir

3. Internal gas reservoir

4. PDS piston

shock absorber

Oil

Gas

C-spanner

Separating

piston

PDS

piston

Adjustment

nut

Shock absorber

piston

Mechanical adjustment

Tuning the suspension

Design

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 Öhlins 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

heights are within the specified values.

In the Mounting Instruction, see section: Setting

the spring pre-load .

Most of the Öhlins shock absorbers are of the

De Carbon type (Fig.1). 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 chamber, connected

by hose (Fig.1:1), or fixed directly on top of the

shock absorber (piggyback) (Fig.1:2).

There are also cases where everything is fitted

inside the main shock absorber (internal gas

reservoir) (Fig.1:3).

To obtain a progressive damping system (PDS),

the most advanced shock absorber has two pis-

tons. This ensures position sensitive damping in

relation to the degree of compression. One of the

pistons is active throughout the entire lenght of

the stroke, while the second piston begins to work

in the event of powerful compression of the shock

absorber (Fig.1:4)

Pressurisation of the fluid is made with nitrogen.

The pressurisation prevents cavitation of the fluid and

the shock absorbing action is therefore more even.

The external fluid chambers also contribute to bet-

ter cooling of the fluid, giving longer service life for

both the fluid and components.

Öhlins shock absorbers have 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 damping and rebound

damping.

Öhlins 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 pre-loading of the

spring action (Fig.2).

A few models have an adjustable end eye, mak-

ing it possible to alter the lenght of the shock

absorber by 12 mm (Fig.3).

4. Flow through

needle valve

5. Piston with apertures

6. Shims stack

7. Flow through piston

Stop washer

Shims stack

Compression flow Rebound flow

Piston

Function

The function, in principle, is that fluid is forced

through needle valves at a low rate of flow (Fig.4)

and through a number of apertures in the piston

(Fig.5) at a high rate of flow. The flow through

these apertures is regulated by shims (thin steel

washers) 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 (Fig.6)

(i.e., number, thickness, diameter) the character-

istics of the damping action can be changed (this

should only be done by Öhlins authorized service

workshops).

Compression damping

When movement of the motorcycle causes

compression in the shock absorber, the fluid flows

through the needle valve (combined compression

and return valve) in the piston rod. If the velocity

of the piston 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 a greater rate of flow (Fig.7).

The fluid that is displaced by the volume of the pis-

ton rod is forced into the external fluid chamber 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 ex-

tend again, the fluid flows back through the needle

valve into 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.7).

Bike on a stand.

Bike on the ground.

Bike with rider on.

Settings

Setting the spring pre-load

•

Allow the motorcycle (without rider) to

apply load on the springs and repeat the

measuring procedure (R2, F2).

Basic settings

Always ensure that the basic setting made by

Öhlins is correct. It is adapted to the make and

model (in its original state) and for a rider of

average weight.

Step 1. Measuring

Pre-load on the spring/springs is very important,

because it affects the height of the motorcycle and

the fork angle. Consequently, handling characteristics

can be changed, even negatively. Proceed as follows

(it will be much easier if done by two persons):

•

Then take the same measurements with

the rider and equipment on the

motorcycle (R3, F3). 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.

WARNING

Incorrect spring action may produce 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.

•

Place the motorcycle on a stand, so the

front fork and the rear end are in fully

extended position.

Recommendations

The difference should not deviate from the

following sizes, if no other recommended settings

are given in the Mounting instructions:

Free sag: (R1-R2), (F1-F2)

Rear: MX/Off-Road 30 ± 5 mm

Front: MX/Off-Road 30

•

Measure the distance, e.g., from the

lower edge of the rear mudguard or

from a point marked by a piece of tape,

immediately above the rear wheel axle,

to the wheel axle (R1).

The original settings of the shock absorber, when

delivered from Öhlins, should always be a base

when the settings are changed by use of the

adjustment devices.

5 mm

Ride height: (R1-R3), (F1-F3)

Rear: MX

•

Make a similar measurement on the front axle,

e.g., from the bottom of the upper fork crown

to the front wheel axle (F1).

5 mm

Off Road 30% of the total stroke

Front: MX/Off-Road 80

100

5 mm

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