1
Owners Manual
Öhlins 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
Страница 1: ...1 Owners Manual Öhlins 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 ...
Страница 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 to Öhlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited Printed in Sweden NOTE Öhlins products are subject to continu...
Страница 3: ...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...
Страница 4: ...m 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 canbechanged evennegatively Proceedasfollows it will be much easier if done by two persons Place the motorcycle on a stand so the front fork and the rear end are in fully extended position Measure the distance...
Страница 5: ...ect springs and the correct spring pre load before making any adjustments And always start with the Öhlins rec ommended settings Compression stroke Rebound stroke Flow in compression valve Flow in rebound valve Flow in compression valve Flow in rebound valve NOTE Higher click numbers give less damping force When making adjustments keep notes make adjustments one at a time and in small steps The ad...
Страница 6: ...fferent 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 Theoillevelmustbethesameinbothfrontforklegs Riding a bike with different oil levels will cause instability When the oil level is raised The air spring in the later half of travel is strong and thus the front fork hard When the oil lev...
Страница 7: ...heel 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 visible 3 Removethetopcapfromthedamperrodextender Use two 17mm wrenches and tool 1860 01 Adjustment wheel Balls and springs Tool 1860 01 Top cap 24 mm wrench Damper rod assy Damper rod extender 17 mm...
Страница 8: ...que 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 Tighten the bolt in the top fork crown to 20 Nm and the lower triple clamp to 10 Nm NOTE The top nut only have to be tightened by hand without extending tool 02428 04 02428 08 ...
Страница 9: ...length 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 the fork legs to the motorcycle Tightening torques top fork crown 20 Nm and bottom fork crown 10 Nm L 460 mm Compression adjuster Dismantling 9 Loosen the screws that hold the fork legs in the upper ...
Страница 10: ...nd 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 Install the tool in the outer leg Rotate the tool to press out the bushings If tool 1702 04 is not avaliable push the inner steel leg to the bottom and then pull it back quickly so that the fork is toppin...
Страница 11: ...l 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 and damage replace if necessary Assemble the damper rod 15 Remove the compression valve assembly from the fork bottom using a 17 mm socket Fasten the valve assembly with soft jaws in a vice Remove all...
Страница 12: ...g separated by the sleeve on the inner steel leg 18 Apply some Öhlins 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 scraper CAUTION Make sure the circlip is fitted correctly into the groove in the outer leg 17 Fasten the outer leg in a vice with soft jaws Install the inner leg and mount the sleeve and the lower bushin...
Страница 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 assembly into the cylinder tube Use Loctite 542 on the cylinder tube cap Tighten with tool 1797 01 Tightening torque 60 Nm Pump the damper rod up and down a few times to check that there is no air left Me...
Страница 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 80 130 mm CAUTION Use only Öhlins high performance front fork fluid No 5 1311 01 Tighten torque Fork top crown bolt 20 Nm Fork bottom crown bolt 10 Nm Compression valve 60 Nm Base valve Cylinder tube cap...
Страница 15: ...4 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 01 2 Circlip 1 14 02411 02 2 Scraper 1 15 02339 01 2 Cylinder tube 1 16 02429 02 2 Bushing 1 17 02426 11 2 Fork leg inner 1 18 00438 16 2 O ring 1 19 02310 25 1 Fork bottom Ya RH 1 20 02310 26 1 Fork ...
Страница 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 M12x0 75 2 14 02430 01 2 Spring guide 2 15 01499 02 2 Circlip 2 16 02399 48 2 Cylinder tube cap 2 17 00110 03 4 Bushing 2 18 02340 01 2 Washer 2 19 02393 01 2 Shaft 2 20 02418 01 2 Spring guide 2 21 02...
Страница 17: ...16 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 04 4 Ball 3 39 01248 01 2 Spring 3 40 00438 02 2 O ring 3 41 02413 01 2 Base valve 3 42 04107 02 2 Spring 3 43 00438 52 2 O ring 3 44 02414 01 2 Poppet valve 3 45 00184 14 4 leg Shims 3 46 02415 01 1...
Страница 18: ...first 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 after a bump Front wheel grip insufficient in bumpy curves Not enough rebound damping or too much spring pre load Increase the rebound damping Decrease the spring pre load Front end ploughs understeers S...
Страница 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 Öhlins red grease 146 01 on the steel tubes and work it in by pushing the fork up and down Every 20 hours Dismantle the fork and check all parts for wear and damage replace if necessary NOTE Discarded Öhlins products should be handled over to a...
Страница 20: ...20 07295 23 Issued 05 01 28 Teknisk Illustration 1500 ex 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 info www ohlins com ...
