Owners Manual

MX & Enduro steering dampers SD 415, 425

Including:

Safety

Design
features

Basic
adjustments

Technical
information

1
Safety signals Introduction
Important information concerning safety is Öhlins steering dampers are designed to
distinguished in this manual by the following withstand very tough treatment in conjunction
notations: with competitions. Many years experience and
close cooperation with World Championship
teams in motocross and enduro has helped us
The Safety alert symbol means: develop unique know-how.
Caution! Your safety is involved.
Before installation
Öhlins Racing AB can not be held responsible for
WARNING! any damage whatsoever to shock absorber or
Failure to follow warning instructions could result vehicle, or injury to persons, if the instructions
in severe or fatal injury to anyone working with, for fitting and maintenance are not followed
inspecting or using the suspension, or to exactly.
bystanders. Similarly, the warranty will become null and void
if the instructions are not adhered to.
CAUTION!
Caution indicates that special precautions
must be taken to avoid damage to the
suspension.
© Öhlins Racing AB.
All rights reserved.
NOTE! Any reprinting or unauthorized use
without the written permission of
This indicates information that is of importance
Öhlins Racing AB is prohibited.
with regard to procedures. Printed in Sweden.
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 WARNING!
1. Installing a steering damper, that is not Öhlins products are subject to continual
approved by the vehicle manufacturer, may affect improvement and development. Consequently, al-
the stability of your vehicle. Öhlins Racing AB though these instructions include the most up-to-
cannot be held responsible for any personal injury date information available at the time of printing,
or damage whatsoever that may occur after there may be minor differences between your sus-
fitting the steering damper. Contact an Öhlins pension and this manual. Please consult your
dealer or other qualified person for advice. Öhlins dealer if you have any questions with regard
to the contents of the manual.
2. Please study and make certain that you fully NOTE!
understand all the mounting instructions and the
owners manuals before handling this steering During storage and transportation, especially at
damper kit. If you have any questions regarding high ambient temperature, the oil and grease
proper installation procedures, contact an Öhlins used for assembling may run out inside the
dealer or other qualified person. packing and damage the expanded polystyrene
packing material. This is not unusual and is in no
3. The vehicle service manual must be referred way detrimental to the steering damper.
to when installing the Öhlins steering damper. NOTE!
Please note that all bikes require bars with a mini-
mum of 40 mm between crossbar and main bar for
CAUTION! damper to fit. For applications with less than this
Make sure that the steering stops work properly. clearance use: PROTAPERS, Scotts Renthals or
If not, it´s necessary to adjust the steering stops special handlebars with no crossbar. You´re going
(use washer or suchlike). If the damper is used to pre-assemble everything before permanently
as stop it can be damaged. mounting or drilling anything. This will insure proper
alignment and fit, otherwise you may find some hid-
den problems you didn´t anticipate.
3
Design Setting
The Öhlins steering damper is a hydraulic The steering damper has three external setting
damper that counteracts wobble, alleviates possibilites, ie, setting of the damper valve, high-
shock against the front wheel and prevents head speed valve and sweep valve, which regulate
shake/cast by the motorcycle, which gives safer the damping area (fig.2).
riding.
The damper is fitted on the upper fork crown, Low speed valve
in the centre over the steering stem (fig.1). When Öhlins steering damper is delivered with the low
turning, and in the event of wobbling, shock, etc, speed valve set in a basic position that gives maxi-
the link arm of the damper is twisted, thus forcing mum basic damping. For enduro and motocross
fluid through three independently acting valve it is suitable to set the low speed in position 4-8,
systems in the damper cover. depending on the track and the rider.
Turn clockwise to increase damping and
1 counter clockwise to reduce it (fig.3).
High speed valve
The high-speed valve (fig.4) is set between 11/4
to 2 turns from the bottom position, suitable
for enduro, motocross and off-road.

WARNING!
For all riding purposes the high-speed valve must
be loosened at least 1 turn from the bottom.
Otherwise the damping forces will become too
high, making the ride hazardous.

4
 Low speed adjustment Damping sweep controls
Sweep 2
Damping sweep controls (fig.8) are located on each
adjustment side off the damper body. Damping is in position
2, (12 o´clock), when delivered from Öhlins. This
setting is fitted for enduro, motocross and
off-road riding.

WARNING
Always ensure that valve setting is within the
permitted ranges.

High speed NOTE!

adjustment Both damping sweep controls must always be
Sweep
adjustment set in identical positions.
Steering Always use positions according to the clock.
damper body
Link arm

3 4

5
 Sweep control valve Damping range Suitable starting position:
Located on the side Motocross pos.1 or 2
of the unit 5 Enduro pos.2 or 3
Off-Road pos.2, 3 or 4
Position 1 Position 1
Damping 34° Technical data
9 o´clock
External measures 70x70x35 mm
Seals Low friction type
Oil Öhlins part no.
Position 2 Position 2 01306-01
12 o´clock Damping 44°
Maintenance and inspection
The steering damper is a precision instrument,
Position 3
with extremely fine tolerances. It is therefore
Position 3 essential that it is maintained in a correct manner.
3 o´clock Damping 54°
Maintenance and service should be carried out
by an authorised service center.

Position 4 Position 4 - After washing the motorcycle wipe clean and

6 o´clock Damping 90° spray with all-round oil.

12 CAUTION!
Sweep controls located on Never subject to direct high-pressure cleaning
each side are normally set at 9 3 since water may otherwise penetrate the damper.
the twelve o´clock position.
6
6
 Trouble Shooting
CAUTION!
Ensure that there is no leakage of fluid and that Little or no damping
there is no visible damage to the housing and 1
mounts. Debris in valving or worn parts internally, need
service.
Change the fluid regularly. In new dampers after 2
10 hours riding and then every 20 hours riding. Shear pin on bottom has broken due to a crash
or over stressing. This can be replaced easily by
Use only recommended fluid that is tested and removing the link-arm with a link-arm puller
approved by us. We cannot guarantee fully (4954-01) and installing a new shear pin.
acceptable operation using other fluids.
Dampens more to one side
than the other
NOTE!
1
Regular maintenance and inspection counteracts
possible malfunction. It´s new, give it a little time to seat the valving.
2
The oil is dirty and it need servicing.
If the steering damper needs service, Öhlins
agents have the proper tools and know-how to Knob has come off
solve all technical problems. 1
Don´t panic, it will still work. To repair it, remove
NOTE! the set screw, put the knob back on and allow it
Discarded Öhlins products should be handled to seat over the o-ring. Reinsert the steel ball,
over to an authorized work shop or distributor then the spring and finally the set screw until
for proper disposal. flush with the top of the knob.

7
Weld-on tower for 3
Öhlins Off Road steering dampers Install the damper to the new handlebar mount.
Use the two Allen bolts provided.
NOTE!
If the damper does not fit between the main bar
and the crossbar, bow or bend the crossbar slightly
to allow clearance. Minimum 40 mm is required.

4
With the damper fitted and the handlebar bolts
evenly seated, hold the weld-on tower temporarily
in position. Mark where it must be cut for perfect fit
between the frame and the link-arm of the damper.
NOTE!
Mounting Instruction The ”tower pin” is not to be installed into the
tower yet.
1
5
Remove the original upper handlebar mounting
clamps and the fuel tank of the motorcycle. The weld-on tower can be
cut at either end for proper
2 lenght. Cutting at the top is Cut here for
Install the one-piece upper handlebar mount provided. usually the easiest way proper lenght
Tighten the bolts evenly to allow fine adjustment later. Sometimes grinding at the
Keep the gap equal as shown in figure. According to base of the tower to match
the handle bar clamp mounting instruction. the frame is required.
8
 CAUTION!
When installed the tower pin must reach 0.5 mm
above the upper surface of the link-arm.This is spe-
cially important when handlebar has rubber
mounted lower mounts, where handlebar is al-
lowed to flex downvards. If the link-arm touches
the frame bracket the damper can be damaged.

CAUTION!
0,5 mm
The weld-on tower is made of steel and can be
welded with standard weldning rod. This should be
carried out by qualified personnel. Tig weldning is
prefered.. Gas welding requires carefull protection
of the bearings and seals of the triple clamps.
Weld

6 CAUTION!
With tower cut to correct height, deburr the hole To gain a strong weld it is of importance to care-
in top before installing the tower pin. Grease the fully remove paint and debris.
pin slightly before installation.
7
WARNING!
Weld the tower to the frame (tig welding recom-
mended). Make welds om both sides of the Certain modifications can be necessary to install the
tower. (A tower of correct height will need no weld-on tower. It is vital that the mounting instruc-
additional holding devices to the frame) tions are carefully followed.
9
Handlebar clamp for Handlebar clamp
Öhlins Off Road steering damper

Alignment
Steering
Mounting instructions clamper
1
Handlebar
Replace the stock handlebar upper brackets clamp
mount with the handlebar clamp provided.

CAUTION!
It is vital that the centre of the steering damper
mounting bolts are aligned with the centre of the
steering stem

2
When the lower handlebar brackets are
reversible, the brackets must be positioned Weld Motorcycle
according to the above mentioned caution. on tower steering column
10
Steering damper
1
Attach the steering damper with the bolts 0.5 mm
enclosed.
NOTE!
The steering damper link arm should be at least
0.5 mm below the upper edge of the lower pin. Link arm

2
It is possible to make smaller adjustments with the
four bolts holding the handlebar clamps. If the front
bolts are tightened and the rear bolts are slackened
the distance is decreased and vice versa.
NOTE!
Ensure that the pin is in the middle of the link min 1 mm min 1 mm
arm groove (see illustration).

NOTE!
CAUTION!
Make sure that all bolts are tightened to the cor-
Make certain that the steering stops are working rect torgue and that nothing fouls or restricts the
properly. If the damper acts as a stopper it can handlebar when beeing turned to each side. When
be damaged. testing, the damper adjuster must be in soft damp-
ing position)
11
 More info
www.ohlins.com

07270-04, Teknisk Illustration,OM MX & Enduro SD 415, 425. 05 04.

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

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