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3

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 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 Instructions, see section:

Setting the spring pre-load

.

In the legs there are also “air-springs“ (the air
trapped above the oil) that work together with
the “real“ spring. You adjust the air-spring by
raising or lowering the oil level in the legs.

By using different combinations of springs and

air-springs you can alter the characteristic of the
fork. For example, a soft spring in combination
with a small air-spring (high oil level) makes the
fork progressive; see 

Fine-tuning the bike

.

Marking

All Öhlins front forks are marked. You will find the
part number on the inside of the fork bottom.

Design

Öhlins new upside-down (USD) front fork is
designed to combine the advantages of comfort-
able, safe conventional forks and rigid, light USD
forks. The result is a unique combination of being
rigid, precise in corners and during hard braking
yet comfortable, forgiving during “over-landing“
and in big bumps.

Your new Öhlins USD front fork has aluminium

outer legs and 46 mm steel inner legs, with a
polished surface for lowest possible friction.

The new USD fork features the Öhlins cartridge

damping system.

The fork is fully adjustable with external adjuster

for compression and rebound damping.

The compression adjuster is located at the bot-

tom of the fork leg (Fig.1), the rebound adjuster
at the top (Fig.2).

Spring pre-load is adjusted with spring supports

of different heights (Fig.3), and optional springs
are available to suit different tracks and riders.

Recommended settings

The front fork in your kit is adjusted to the Öhlins
recommended setting for your bike. We advise
you to use this as your start setting.

1.
The compression adjuster is
located at the bottom of the
fork leg.

2.
The rebound adjuster
is located at the top of
the fork leg.

3.
Spring pre-load is adjusted
with different spring supports.
Optional springs are available.

Summary of Contents for WR 450 F - 2-TRAC 2005

Page 1: ...1 Owners Manual hlins enduro front fork Yamaha WR 450 F 2 TRAC 2005 Including Setting up your bike Fine tuning Service the fork General handling set up Technical info Spare parts...

Page 2: ...ont fork 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 t...

Page 3: ...number on the inside of the fork bottom Design hlins new upside down USD front fork is designed to combine the advantages of comfort able safe conventional forks and rigid light USD forks The result i...

Page 4: ...Setting the spring pre load Measuring Pre load on the spring springs is very important because it affects the height of the motorcycle and theforkangle Consequently handlingcharacteristics canbechange...

Page 5: ...ct springs and the correct spring pre load before making any adjustments And always start with the hlins rec ommended settings Compression stroke Rebound stroke Flow in compression valve Flow in rebou...

Page 6: ...erent combinations of springs and oil levels air springs you can alter the characteristic of the fork and tailor it to suit different tracks and conditions CAUTION Theoillevelmustbethesameinbothfrontf...

Page 7: ...eel and the springs and balls of the adjuster 2 Unscrew the top cap use a 17 mm wrench and tool 1860 01 or tool 1873 01 and a 1 2 socket wrench Put a box under the front wheel so that the springs are...

Page 8: ...ue of 20 Nm CAUTION The piston shaft must bottom in the top cap before the lock nut is tightened Spring support Optional spacers Adjustment wheel Top cap Spring support Refit the adjustment wheel Tigh...

Page 9: ...ength is 467 mm If the spring length is under 460 mm the spring must be changed Follow instruction 5 on previous page Adjust the compression and the rebound valves according to specification card Fit...

Page 10: ...d of the outer leg A sleeve is fitted above the bushing to main tain the correct position 12 Use the special tool 1702 04 to remove the bushing Install the tool in the top of the inner steel leg Insta...

Page 11: ...parts from the piston holder NOTE If the correct order is lost use the specification card as a guide Put them in the correct order on the bench Clean all parts thoroughly Inspect all parts for wear a...

Page 12: ...separated by the sleeve on the inner steel leg 18 Apply some hlins red grease on the seals Again use tool 1799 04 flip it around to install the seal in the outer leg Install the circlip and the scrap...

Page 13: ...motorcycle Tighten the upper triple clamp to 20 Nm and the lower triple clamp to 10 Nm Adjust the compression and the rebound valves according to the specification card 20 Install the damper rod assem...

Page 14: ...8 41 4 1 N mm 2328 43 4 3 N mm 2328 45 4 5 N mm 2328 47 4 7 N mm Settings Compressing adj 16 clicks Rebound adj 14 clicks L 70 300 200 Oil level When delivered from factory 105 mm Adjustment range 80...

Page 15: ...7 N mm Optional 1 6 02425 03 2 Fork leg outer 1 7 02409 01 2 Guide Sleeve 1 8 02427 02 4 Bushing 1 9 02431 01 2 Sleeve 1 10 02332 05 2 Sticker 1 11 02412 01 2 Washer 1 12 02410 02 2 Seal 1 13 02015 0...

Page 16: ...6 00884 01 4 Ball 2 7 00833 01 4 Spring 2 8 01050 01 2 Screw 2 9 00338 59 2 O ring 2 10 02397 48 2 End cap bump rubber 48mm 2 11 00438 61 2 O ring 2 12 02366 13 2 Adjustment rod 2 13 02402 01 2 Nut M1...

Page 17: ...6 1 leg Shims 00184 14 1 leg Shims 3 32 00641 04 1 leg Washer 3 33 00153 01 4 Washer 3 34 00430 05 2 Nut M8 3 35 01473 02 2 Circlip 3 36 00338 53 2 O ring 3 37 01242 01 2 Adjustment needle 3 38 00884...

Page 18: ...irst in a series of bumps but feels hard after a few more bumps Frontal grip insufficient in rough and bumpy turns Too much rebound damping Decrease the rebound damping Front end rebound too fast afte...

Page 19: ...iction or leakage After every race Clean externally and spray with an all purpose oil after washing with detergent Check externally for damage Put a little hlins red grease 146 01 on the steel tubes a...

Page 20: ...20 07295 23 Issued 05 01 28 Teknisk Illustration 1500 ex hlins Racing AB Box 722 S 194 27 Upplands V sby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your hlins dealer More info www ohlins com...

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