1

Including:

Safety

Tuning thesuspension

Designfeatures

Function

Basicadjustments

Fine tuning

Inspection,maintenance

Owners ManualÖhlins shock absorbers, VOR MX, Enduro, Super Motard

2

Safety signalsImportant information concerning safety isdistinguished in this manual by thefollowing notations:

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injuryto anyone working with, inspecting orusing 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 ofimportance with regard to procedures.

IntroductionAll of Öhlins advanced suspension products areadapted to the brand and model. This meansthat length, travel spring action and dampingcharacteristics, are tested individually just forthe motorcycle that you have decided to fit withÖhlins suspension.

© Öhlins Racing AB.All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofÖhlins Racing AB is prohibited.

Printed in Sweden.

WARNING!1. Installing a shock absorber, that is notapproved by the vehicle manufacturer, mayaffect the stability of your vehicle. ÖhlinsRacing AB cannot be held responsible forany personal injury or damage whatsoeverthat may occur after fitting the shockabsorber. Contact an Öhlins dealer or otherqualified person for advice.

2. Please study and make certain that youfully understand all the mounting instructionsand the owners manuals before handling thisshock absorber kit. If you have any questionsregarding proper installation procedures,contact an Öhlins dealer or other qualifiedperson.

3. The vehicle service manual must bereferred to when installing the Öhlins shockabsorber.

NOTEÖhlins products are subject to continual improve-ment and development. Consequently, althoughthese instructions include the most up-to-dateinformation available at the time of printing, theremay be minor differences between your suspen-sion and this manual. Please consult your Öhlinsdealer if you have any questions with regard tothe contents of the manual.

ContentsSafety signals ................................................ 2Introduction ................................................... 2Before installation .......................................... 2Tuning the suspension ................................... 3Design ........................................................... 3Function ........................................................ 4Settings ......................................................... 5Setting the spring pre-load ............................ 5Setting the shock absorber lenght ................. 6Setting the damping ...................................... 7Setting your motorcycle ................................. 8Inspection and maintenance ......................... 9General handling setup ................................ 10

Before installationÖhlins Racing AB can not be held responsible forany damage whatsoever to shock absorber orvehicle, or injury to persons, if the instructions forfitting and maintenance are not followed exactly.

Similarly, the warranty will become null and voidif the instructions are not adhered to.

3

Tuning the suspension

Motorcycle road holding qualitiesAll motorcycles are designed with a suspensiongeometry that includes height and fork angle. Thechanging of components can affect this and it istherefore essential that both the rear and the frontends match each other.

Changing to Öhlins suspension gives optimumperformance only when both the front fork andthe rear suspension interact properly. It is of thegreatest importance that the front and rear loadedheights are within the specified values.In the Mounting Instruction, see section: Settingthe spring pre-load.

Design

2. Spring pre-loading

C-spanner

Mechanical adjustment

The external fluid chambers also contribute to bet-ter cooling of the fluid, giving longer service life forboth the fluid and components.

Öhlins shock absorbers have integratedtemperature compensation. As the temperatureincreases and the fluid flows more easily the flowis controlled accordingly. The shock absorbingeffect is therefore independent of the temperature.

The more advanced models permit individualadjustment of compression damping and rebounddamping.

Öhlins shock absorbers provide the possibilityfor adjustment, making them adaptable to mostmotorcycles, riders and ranges of use. All of theshock absorbers have adjustable pre-loading of thespring action (Fig.2).

A few models have an adjustable end eye, mak-ing it possible to alter the lenght of the shockabsorber by 12 mm (Fig.3).

1. Design principles

1. 2. 4.3.

1. External reservoirwith hose connection

2. External piggybackreservoir

3. Internal gas reservoir4. Twin piston

shock absorber

Gas

Oil

Shock absorberpiston

Oil

Gas

Separatingpiston

Oil

Gas

3. Adjustment of shockabsorber length

- +

Adjustment nut

Twinpiston

Most of the Öhlins shock absorbers are of theDe Carbon type (Fig.1). The fluid is put under gaspressure and the gas and the fluid are kept apartby a separating piston. The separating piston isoften fitted in a separate fluid chamber, connectedby hose (Fig.1:1), or fixed directly on top of theshock absorber (piggyback) (Fig.1:2).

There are also cases where everything is fittedinside the main shock absorber (internal gasreservoir) (Fig.1:3).

The most advanced shock absorber has twinpistons. This ensures position sensitive dampingin relation to the degree of compression. One ofthe pistons is active throughout the entire lenghtof stroke, while the second piston begins to workin the event of powerful compression of the shockabsorber (Fig.1:4)

Pressurisation of the fluid is made with nitrogen.The pressurisation prevents cavitation of the fluid andthe shock absorbing action is therefore more even.

4

FunctionThe function, in principle, is that fluid is forcedthrough 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 throughthese apertures is regulated by shims (thin steelwashers) that at high pressure are deflected toopen for the fluid. On most models the needlevalves 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 (thisshould only be done by Öhlins authorized serviceworkshops).

Compression dampingWhen movement of the motorcycle causescompression in the shock absorber, the fluid flowsthrough the needle valve (combined compressionand return valve) in the piston rod. If the velocityof the piston is high, i.e., in the case of rapidcompression, this will not be sufficient andconsequently the shims underneath the pistonwill 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 aseparate compression valve. The separating pistonis displaced, thus increasing the gas pressure.

Rebound dampingWhen the spring forces the shock absorber to ex-tend again, the fluid flows back through the needlevalve into the piston rod. The fluid flowing into thechamber is forced by the pressure of the gas backinto the shock absorber via a separate non-returnvalve.

If velocity of the piston is high, the shims ontop of the piston will also open to allow the fluidto flow though (Fig.7).

5. Piston with apertures4. Flow throughneedle valve

6. Shims stack

Stop washer

Shims stack

Piston

Compression flow Rebound flow

7. Flow through piston

5

Settings

Basic settingsAlways ensure that the basic setting made byÖhlins is correct. It is adapted to the make andmodel (in its original state) and for a rider ofaverage weight.

WARNINGIncorrect spring action may produce a fork anglethat is too steep or too flat. This in turn will give atendency for oversteering or understeering, whichcould seriously affect the handling characteristicsof the motorcycle.

The original settings of the shock absorber, whendelivered from Öhlins, should always be a basewhen the settings are changed by use of theadjustment devices.

RecommendationsThe difference should not deviate from thefollowing sizes, if no other recommended settingsare given in the Mounting instructions:

Free sag: (R1-R2), (F1-F2)Rear: MX/Enduro 30±5 mm

Supermotard 30±5 mmFront: MX/Enduro 30±5 mm

Supermotard 30±5 mm

Ride height: (R1-R3), (F1-F3)Rear: MX 100±5 mm

Enduro 30% of the total strokeSupermotard 30% of the total stroke

Front: MX/Enduro 80±5 mmSupermotard 80±5 mm

Setting the spring pre-load

Step 1. MeasuringPre-load on the spring/springs is very important,because it affects the height of the motorcycle andthe fork angle. Consequently, handling characteristicscan be changed, even negatively. Proceed as follows(it will be much easier if done by two persons):

• Place the motorcycle on a stand, so thefront fork and the rear end are in fullyextended position.

• Measure the distance, e.g., from thelower edge of the rear mudguard orfrom a point marked by a piece of tape,immediately above the rear wheel axle,to the wheel axle (R1).

• Make a similar measurement on the front axle,e.g., from the bottom of the upper fork crownto the front wheel axle (F1).

• Allow the motorcycle (without rider) toapply load on the springs and repeat themeasuring procedure (R2, F2).

• Then take the same measurements withthe rider and equipment on themotorcycle (R3, F3). It is important that the riderhas a correct riding posture, so that theweight is balanced on the front and rearwheel in the same way as when riding.

Bike on a stand.

F1

R1

Bike on the ground.

F2

R2

Bike with rider on.

F3

R3

6

Step 2. AdjustingAdjust the pre-load with the rings on the shockabsorber.

Hold the upper ring and adjust the lower oneto the desired position (Fig.8). Then lock with theupper ring.

NOTE!If ride height is higher than recommended, softerspring/springs must be used.If ride height is lower than recommended,harder spring/springs must be used.Contact your Öhlins dealer for advice.

Front fork springsTo optimize the road holding qualities of amotorcycle the front fork must match the rearsuspension. Öhlins springs are available for alarge number of motorcycles (Fig.9). These, incombination with Öhlins shock absorbers, con-tribute to superior road holding qualities. Theoriginal make of springs should be used if thereare none of our springs in the recommendationtable. However, they must be in good conditionand not fatigued. Remember to change the fluidin the front fork at least once every year. Werecommend Öhlins front fork oil.

WARNING!It is important that the recommendation table isfollowed for new front springs. If there are norecommended front springs you must ensure thatthe existing springs are in good condition.Neglecting to check the front springs could seriouslyaffect the handling qualities of the motorcycle.

8. Spring pre-loading

Setting the shock absorber lengthSensitivity of the steering can be adjusted byaltering the length of the shock absorber, with-out affecting other characteristics. The lengthis adjusted with the two nuts and the threadedclevis at the end of the piston rod.

The shock absorber can be adjusted up to 12 mm.The length may never be altered more than to wherethe groove that is cut in the thread becomes fullyvisible (Fig.10).

Mechanicalpre-loading adjustment

9. Front spring kit 10. Adjustable end eye

WARNING!If the shock absorber has an ad-justable end eye/bracket, thismust not be threaded out so thatmore than one groove is fully vis-ible beneath the lock nut. Makesure that the lock nut is tightenedafter adjustment.

Groove

7

Rebound damping action affects the characteristicsof the motorcycle most. The setting knob is locatedat the bottom on the piston rod (Fig.11). It can beadjusted in about 40 steps.

The compression damping adjuster is located atthe end of the reservoir (Fig.12).

Compression damping is set with separate ad-justers for high speed compression and low speedcompression (Fig.12). The low speed compressionis adjusted in 25 steps.

The high speed adjuster has a wide range withinfour (4) turns. Adjust a half turn (180°) at a time.

Setting the dampingThe adjusting possibilities of Öhlins shockabsorbers facilitate fine setting. You can optimizeadjustments to suit your own weight andequipment, your individual way of riding and thecondition of the road. To be able to improve theroad holding qualities it is of the utmost importancethat you fully understand the function of the shockabsorbers. From there you can learn by trial anderror how they affect the motorcycle.

Depending on the model there are adjustmentsfor rebound damping, compression damping andadjustment of the length of the shock absorber.Damping is set with knobs and screws with a normalright-hand thread. By turning you can increase thedamping action or reduce it. The adjuster havedefinite positions with a noticeable “click”, so it iseasy to count to the right setting.

NOTE!When making new adjustments it is easiest to goback to fully closed, and then count forward tothe new setting. The adjusting device should notbe turned too hard.

NOTE!If no ”click” is felt on the rebound adjustingknob the shock absorber must be inspectedby an authorized service workshop. It could bedue to low gas pressure or lack of oil.

11. Adjustment of rebound damping

= more damping

= less damping

+

+-

-

+

-

High speed

Low speed

12. High and low speed compression damping adjusters

+

-MX/Enduro: 3 turnsSupermotard: 2 turns

MX: 15 clicksEnduro: 14 clicksSupermotard: 2 turns

MX: 28 clicksEnduro: 24 clicksSupermotard: 18 clicks

8

Setting your motorcycle

NOTE!Always begin with the basic settings recommendedby Öhlins. Always make notes, adjust in small stepsand make only one adjustment at a time.Adjustments should be made with two steps (clicks)/1/2 turn at a time. Adjustments should not be morethan six steps/2 turns from the basic setting.

Normally changes are made by high speed com-pression adjuster only.

Turn 1/2 turn at a time. Test run and makenecessary corrections.

When you have sufficient feel of the motorcycleyou can make further fine adjustments. It is feel-ing and experience that counts.

NOTE!Ensure that the springs are properly pre-loadedbefore attempting to make any adjustments. Asimple rule is that increased pre-load of the springshould be followed by an increase of rebounddamping by two steps.

When you feel that you have achieved animprovement, go back to where you started andcheck once more. Be observant of other relevantfactors such as tyres, temperature, etc. Test runto make sure whether further fine adjustmentshould be made.

Start with the rebound damping (Fig.13)If the motorcycle feels unstable, loose and ratherbouncy then the rebound damping should beincreased. Begin by turning the adjusting knob 2steps (clicks). Test run again and adjust one stepsback if it felt too hard and bumpy.

If the motorcycle is hard and bumpy, especiallyover a series of bumps, then the rebounddamping should be reduced. Turn 2 steps, testrun and make any necessary correction. For origi-nal rebound setting see Mounting Instructions.

13. Rebound damping

Reduce

• Unstable• Loose• Bouncy

• Hard• Bumpy

Increase ReduceIncrease

14. Compression damping

• Soft• Low• Bottom

• Harsh• Hard

How to prepare the settingsBy utilizing the adjustment possibilities you cantest by trial and error, and learn how they affectyour motorcycle.

Always begin by test riding the motorcycle withall adjustments at their basic setting. Choose ashort run of varying character, i.e., long and sharpbends, hard and soft bumps. Keep to the samerun and adjust only one setting at a time.

Compression damping (Fig.14)If the motorcycle feels soft, has low riding positionand a tendency to bottom easily in long dips thenthe compression damping should be increased.

If the motorcycle feels harsh and has hardresilience, e.g., during changes in the road paving,then the compression damping must be reduced.

9

NOTE!Regular maintenance and inspection contributeto the prevention of functional disturbances.

Inspection and maintenanceClean the shock absorbers externally with a softdetergent . Use compressed air . Be careful thatall dirt and debris is removed.

Lift the bump rubber and clean the area below(Fig.15).

Inspection points (Fig.16):

1. Check ball joints for possible excessive play.

2. Check the piston shaft for leakage and damage.

3. Check the shock absorber body and forexternal damages.

4. Check the external reservoir for damages thatcan restrict the floating piston from moving freely.

5. Check for excessive wear of rubber components

6. Check the fastening to the vehicle

• Check the hose equipped models for leaks inhose and inlet plugs.

Keep the shock absorbers clean and always spraythem with oil (QS 14, WR40 or CRC 5-56) afterwashing the motorcycle.

Preventive maintenance and regular inspectionreduces the risk of functional disturbance. If thereis any need for additional service, please get intouch with an authorized Öhlins service workshop.There they have the necessary tools and know-how for whatever you need.

NOTE!Make certain that your shock absorbers arealways filled with Öhlins High Performance ShockAbsorber Oil.

1

1

3 4

32

55

6

15. Lift the bump rubber andclean the area below.

16. Inspection points:

NOTE!Discarded Öhlins products should be handledover to an authorized work shop or distributor forproper disposal.

Recommended service intervals:MX & Enduro Approximately

20 hours of operation

Off Road 2 - 3 times a year

WARNING!Never alter the gas pressure. Special purposecharging equipment and access to nitrogen isrequired. The gas pressure should normally neverbe altered.

10

General handling set-up

Front suspension

Front fork travel is not used to its fullcapacity. Harsh feeling, front wheel grip isnot satisfactory in bumpy turns.Suspension too hard.

• Decrease the front forkcompression damping.

• Change to softer springs.

Suspension bottoming, too soft duringentire travel.Spring too weak or compression damping too soft.

• Increase oil level 5 mm.• Increase compression damping.• Change to stiffer springs.

Suspension bottoming, but can handlesmaller bumps.Damping force not progressive enough.

• Increase the oil level.

Can handle smaller bumps but is too hardduring the last part of the travel.Damping force is too progressive.

• Decrease the oil level.

Front end feels low, initially feels soft, but isnot bottoming.The initial spring rate is too soft or spring preloadis too low.

• Increase the spring pre-load.

Feels harsh over small bumps, but using fullwheel travel.Too much spring pre-load or too much compres-sion damping.

• Increase the oil level or changeto softer springs.

• Decrease the compression damping.• Decrease the spring pre-load.• Clean the oil seals and scrapers. Use Öhlins

red grease 146-01 for regreasing.

Can handle the first in a series of bumps butfeels hard after a few more bumps. Frontalgrip insufficient in rough and bumpy turns.Too much rebound damping.

• Decrease the rebound damping.

Front end rebound too fast after a bump.Front wheel grip insufficient in bumpycurves.Not enough rebound damping, or too muchspring pre-load

• Increase the rebound damping.• Decrease the spring pre-load.

Front end ”ploughs”, understeers.Shallow front fork angle. Front end too high incomparison to rear end.

• Decrease the front forkcompression damping.

• Raise the fork legs approximately5 mm in the triple clamp.

• Change to softer fork springs.

Front end unstable at high speed, unstablewhen accelerating out of curves.Front fork angle too steep. Front end too low incomparison to rear end.

• Lower the fork legs approximately5 mm in triple clamp.

• Change the front fork springs toharder ones.

Front end unstable during deceleration.Front fork angle too steep during braking. Frontend too low or rear end too high.

• Increase the oil level in the front fork.• Change to harder fork springs.• Increase the front fork

compression damping.

Front end falls into the curves (over-steering) especially in sand.Steep front fork angle. Front end too low in com-parison to rear end.

• Increase the front forkcompression damping.

• Change to harder springs.• Lower fork leg approximately

5 mm in the triple clamp.

11

Rear suspension

Rear suspension stroke is not used to its fullcapacity. Suspension feels harsh. Tractionnot satisfactory in bumpy curves.Suspension hard in general or too much com-pression damping, too much spring pre-load.

• Decrease the compression damping.• Decrease the rebound damping.• Change to softer spring.

Suspension is bottoming, feels soft duringthe entire wheel travel.Spring too soft, compression damping too low.

• Increase the compression damping.• Change to harder spring.

Suspension is bottoming, feels harsh and sagsdown too much with the rider in the saddle.Spring too soft or compression damping too low.

• Increase the spring pre-load,check ride height: 95 ± 5 mm.

• Change to harder spring if the load is morethan 100 mm.

• Increase compression damping.

Rear wheel jumps over small bumps duringdeceleration or when going downhill. Tractionnot satisfactory in washboard curves.Too much spring pre-load, as the spring is probablytoo soft, will cause the spring to extend too fast.

• Change to a harder spring in order to achievea balanced position using less spring pre-load.

• Check the static sag and ride height.

Rear end kicks up over bumps with sharpedges, but can handle bumps with roundedges.Compression damping too hard.

• Decrease the compression damping.

Rear end becomes too low in series ofbumps. Traction not satisfactory in wash-board type curves or when decelerating onwashboard ground.Rebound damping too slow.

• Decrease the rebound damping.

Rear end very unstable. Shock absorberdoes not respond to adjustments.Shock absorber damping is gone, caused by lowgas pressure, bad oil is used, or components arebroken in the shock absorber. Service is needed.

• Gas filling required.• Change shock oil.• Repair or change the shock absorber.

NOTE!Recommended measures are not listed in orderof importance.One of the listed measures can be sufficient tosolve a particular handling problem.

12

0725

1-02

, Iss

ued

03 0

9 03

. Tek

nisk

Illu

stra

tion.

The ultimate suspension site.Find out everything about your suspension.

Download mounting instructions, manuals and brochures.And a lot more.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80

Your Öhlins dealer:

More infowww.ohlins.com