Ohlins 07235-01A5L.p65 Bedienungsanleitung

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.

Introduction

All of Öhlins 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 vehi-

cle that you have decided to fit with Öhlins sus-

pension.

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.

Any reprinting or unauthorized use

without the written permission of

Öhlins Racing AB is prohibited.

Printed in Sweden.

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

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.

Contents

Saftey signals ................................................ 2

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

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

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

Compression damping ................................ 4

Rebound damping ....................................... 4

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

Preload adjustment ....................................... 6

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

Setting your vehicle: ...................................... 7

Start with rebound damping ........................ 8

Compression damping ................................ 8

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

Design

Most of Öhlins suspensions are of the De Carbon

type. 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 reservoir, connected by hose (Fig.1)

or fixed direct on top of the shock absorber (Fig.2)

(piggyback).

There are also models where the separating

piston is fitted inside the main shock absorber (Fig.3)

(internal gas reservoir). Öhlins even manufacture a

small number of emulsion shock absorbers that do

not have a separating piston (Fig.4).

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 fluid reservoirs also contribute

to better cooling of the fluid, giving longer service

life to 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 tempera-

ture.

Öhlins shock absorbers provide the possibility

for adjustment, making them adaptable to most

vehicles, drivers and ranges of use. All of the

shock absorbers, equipped with springs, have

adjustable preloading of the spring action. The

more advanced models permit individual adjust-

ment of compression damping and rebound

damping.

WARNING!

All vehicles are designed with a suspension

geometry that includes wheel movements and

angles. 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 and the rear suspension

interact properly.

Tuning the suspension

Road holding qualities

All vehicles are designed with a suspension ge-

ometry that includes wheel movements and an-

gles. 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 and the

rear suspension interact properly. It is of greatest

importance that the front and rear loaded height

(ride height sag) are within the specified values

in the Mounting instructions.

Gas

Gas and

oil

Oil

Shock absorber

piston

4312

Oil

Gas

Separating

piston

Oil

1. External reservoir with hose connection

2. External piggyback reservoir

3. Internal gas reservoir

4. Emulsion shock absorber

Shock absorber position

Rebound damping

When the spring presses the shock absorber out

again, 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.

Function

The function, in principle, is that fluid is forced

through needle valves at a low rate of flow (Fig.5)

and through a number of apertures in the piston

at a high rate of flow (Fig.6). The flow through these

apertures is regulated by shims (thin steel wash-

ers) that at high pressure are deflected to open for

the fluid (Fig.7). On some models the needle valves

can be set individually (illustration).

By altering the size of the shims-stack (ie,

number, thickness, diameter) (Fig.8) the

characteristics of the damping action can be varied

(this shall only be done by Öhlins authorized

service workshops).

Compression damping

When movement of the vehicle causes compres-

sion in the shock absorber, the fluid flows through

the needle valve (combined compression and return

valve) in the piston rod. If velocity of the piston is

high, ie, 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.

The fluid that is displaced by the volume of the

piston rod is forced into the external fluid chamber

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.

5. Flow through

needle valve 6. Flow through piston

7. Shim stack

8. Shim stack

Compression flow Rebound flow

Stop washer

Shims stack

Piston

Therefore it is extremely hard to recommend

specific settings. The best recommendation is to

proceed by trial and error.

However, good understanding of suspension

design and function will give you the best chance

to take advantage of the adjustment possibilities.

This is why we only give basic and simple advice

on how to set the dampers/shock absorber.

Read the manual carefully and start your work.

The Öhlins shock absorber will give you all possibili-

ties for fine adjustment to fit you personal desire.

WARNING!

1. ATVs are extremly depending on which kind of

tires are beeing used. Soft versus hard tires can

completely alter the road holding abilities. The

suspension must be tuned in after each change

of tires.

2. Every change in suspension geometry, i e

change of a-arms etc, must be followed by new

settings of the shock absorbers.

Settings

Basic settings

Always ensure that the basic setting made by

Öhlins is correct. It is adapted to the specific make

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

average weight.

These adjustments are made to

optimize the suspension: (Fig.9)

1. SPRING PRELOAD is when you adjust the

spring to match your body weight and weight

of your equipment.

2. COMPRESSION DAMPING controls how fast

the shock absorber compresses when you hit

a bump.

3. REBOUND DAMPING controls how fast the

shock absorber returns to its normal position

after it has been compressed.

As an ATV has a rear axle without differential it is

forced to turn mostly by sliding (Fig.10). There-

fore excessively good road holding capabilities

is undesirable. The rear end must be able to eas-

ily break loose to slide and the front wheels must

not have too sharp turning radius, as this could

cause the ATV to flip over.

The tires are also a very important factor to the

ATV's road holding capabilities. Pattern, sidewall

flexibility and air pressure affects these characteris-

tics. Changing the dimensions of A-arms, swing

arm and linkage will also affect the vehicle's

abilities.

Because of this it is vital that the suspension is

adjustable. Any change of components will

demand different settings.

To complicate the situation, the technique and

skill of the driver will affect the perfomance of

the machine.

Steering by

sliding rear end

Normal vehical

steering by

turning the

front wheels in

the intended

direction

9. Adjustment possibilities 10. ATV, steering by sliding

1. 2. 3.

Preload Adjustment

Setting the spring preload,

adjusting procedures:

By turning the rings on the shock absorber body

you can adjust the springs tension to suit your

weight. Hold the upper ring and adjust the lower

one to the desired position. Then lock with the

upper ring. To make this adjustment properly you

must measure the ride height sag (Fig.11).

WARNING!

Preload on the spring/springs is very important,

because it affects the height of the vehicle and

the wheel angles. Consequently, road holding

characteristics can be changed, even negatively.

NOTE!

For very light or very heavy drivers, spring change

may be needed to receive correct spring preload.

Rear end

1. Lift the rear wheels up off the ground.

2. With the wheels off the ground, measure the dis-

tance from the top center of the rear axle to a

point straight above it on the frame of the ATV. (A)

3. Wear all your riding gear. Sit on the seat with

your feet on the pegs in correct riding posi-

tion. Have someone to repeat the measuring

procedure (B). The difference between the first

and the second measurement ride height sag

(A-B).

4. Adjust your spring preload so that your ride

height sag is within the limits below or are

according to the recommended settings in

your Mounting instructions.

Front end

Use the same procedure to measure the sag for

the front end. Adjust the spring preload to

recommended settings.

11. Measuring of ride height sag

Setting the damping

The adjusting possibilities of the advanced Öhlins

shock absorbers facilitate fine setting. You can

optimize adjustments to suit your own vehicles

weight and equipment, your individual way of

driving and the condition 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 vehicle.

Depending on the model there are adjustments

for rebound damping and compression damping.

They have a normal right-hand thread. By turn-

ing clockwise they increase the damping action

and counterclockwise they reduce it, see illus-

trations above. The knobs has definite positions

with a noticeable “click”, so it is easy to count to

the right setting.

Rebound damping action affects the charac-

teristics of the vehicle most. The setting knob is

located at the bottom on the piston rod (Fig.12).

It can be adjusted in about 40 steps.

Compression damping is set with a knob or a

screw on top of the external reservoir (Fig.13).

This can be adjusted in about 25 steps.

NOTE!

When making new adjustments it is easiest to go

fully closed and then count forward to the new

setting. The adjusting knobs should not be turned

in too hard. Use fingers only when possible. The

adjustment should be made when the shock

absorber is cold.

Setting your vehicle

NOTE!

Always begin with the basic settings recommended

by Öhlins. Always make notes, adjust in small steps

and make only one adjustment at a time.

Adjustments should be made in small steps (few

clicks) at a time.

By utilizing the adjustment possibilities you can

test by trial and error, and learn how they affect

your vehicle.

Always begin by test driving with all adjustments

at their basic setting. Choose a short run of varying

character, ie, long and sharp bends, hard and soft

bumps. Keep to the same run and make only one

adjustment at a time.

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.

= more damping

= less damping

13. Compression damping adjusters12. Rebound damper adjuster

Start with the rebound damping (Fig.14)

If the vehicle feels unstable, loose and rather bouncy

then the rebound damping should be increased.

Begin by turning the adjusting knob 4 steps (clicks)

clockwise, according to page 7.Test run again and

adjust two steps back if it feels too hard and bumpy.

If the vehicle 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 by 2 steps.

Compression damping (Fig.15)

If the vehicle feels soft, has low riding position

and a tendency to bottom easily in long dips then

the compression damping should be increased.

Screw clockwise 4 steps and test run again. If

this was too much then turn back two steps

(counter-clockwise).

If the vehicle feels harsh and has hard resil-

ience, e.g., over changes in the riding surface,

then the compression damping must be reduced.

Turn anticlockwise 4 steps. Test run and make

any necessary correction to two steps.

When you have sufficient feel of the vehicle

then you can make further fine adjustments. It is

feeling and experience that counts.

NOTE!

Ensure that the springs are properly preloaded be-

fore attempting to make any adjustments. A simple

rule is that increased preload of the spring should

be followed by an increase of rebound damping.

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 tires, temperature, etc. Test run

to make sure whether further fine adjustment

should be made.

WARNING!

Never alter gas pressure. Special purpose charg-

ing equipment and access to a nitrogen source

is required. The gas pressure should normally

never be altered.

14. Rebound damping

Reduce

• Unstable

• Loose

• Bouncy

• Hard

• Bumpy

Increase DecreaseIncrease

15. Compression damping

• Soft

• Low

• Bottom

• Harsh

• Hard

Inspection and maintenance

Clean the shock absorbers externally with a soft

detergent . Use compressed air . Be careful that

all dirt and debris is removed.

Lift the bump rubber and clean the area below

(Fig.16).

Keep the shock absorbers clean and always

spray them with oil (QS 14, WD40 or CRC 5-56

or similar) after washing the vehicle.

CAUTION!

Never use detergents that can damage the sur-

faces of the shock absorber. Use of thinner and

brake cleaner will dry the surfaces too much..

Inspection points: (Fig.17)

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 damages.

4. Check the external reservoir for damages that

can restrict the floating piston from moving freely.

5. Excessive wear of rubber components

6. Fastening to the vehicle

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 authorised Öhlins service workshop.

There they have the necessary tools and know-

how for whatever you need.

Recommended inspection and

maintenance intervals:

Normal use 2 - 3 times a year

Race track Every ten hours

Once a year, general:

Change shock absorber oil.

Use Öhlins shock absorber oil only.

3 4

16. Lift the bump rubber

and clean the area below. 17. Inspection points:

NOTE!

Make certain that your shock absorber are always

filled with Öhlins High performance shock ab-

sorber oil

46HR 46HRC 46HRCS 46HRCL 46HRCLS

46PRCW 46PRC 46PRCL 46PRCLB 46PRCS 46PRCS 46PRCLS 46PRCLS

46PRCQ Vertical Horizontal Vertical Horizontal

46ER/DR 46ERS/DRS 46DRLS

Product guide

New!

36E 36D 36K 36P 36PR 36PRCL 36PRCLB 36H

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