Öhlins SD442 Bracket Mounting Instructions PDF

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Summary of Content for Öhlins SD442 Bracket Mounting Instructions PDF

Mounting Instructions hlins Steering Damper Bracket Kit SD 442 for Yamaha YZ 20042005 and YA WR 2005

hlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited. Printed in Sweden.

Upper handlebar clamp

Pin (adjustment shaft)

Tower Link arm

Front bracker

Rear bracket

hlins steering damper bracket kit fitted to the motorcycle

Steering damper bracket kit This hlins steering damper kit for MX, Enduro and SuperMotard is especially designed to fit the brand and model you are running. The kit con- sists of steering stem brackets, a tower , upper handlebar clamps and a steering damper link arm. Everything is to be fitted together with the hlins steering damper SD415 (two-way damp- ing) or SD425 (compression damping only).

hlins Racing AB, Box 722, S-194 27 Upplands Vsby, Sweden.

Phone +46 8 590 025 00. Fax +46 8 590 025 80. www.ohlins.com S

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4 Install the one-piece upper handlebar mount pro- vided. Tighten the bolts evenly to allow fine ad- justment later.

7 Tighten the tower bolts to 6.5 Nm and the han- dlebar clamps to 22-25 Nm or according to the Owners Manual of the motorcycle.

CAUTION! Make certain that the steering stops are working properly. If the damper acts as a stopper it can be damaged.

NOTE! Make sure that all bolts are tightened to the cor- rect torgue and that nothing fouls or restricts the handlebar when beeing turned to each side. When testing, the damper adjuster must be in soft damping position).

CAUTION! It is of vital importance that the centre of the steer- ing damper mounting bolts are aligned with the centre of the steering stem. If the lower handle- bar brackets are reversible the brackets must be positioned according to this.

5 Install the damper to the new handlebar mount. Use the two Allen bolts provided. Tighten to 8 10 Nm.

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.

6 With the damper fitted and the handlebar bolts evenly seated, position the tower tower so the steering pin top extracts at least 0.5 mm above the damper link arm. It is even possible to adjust the damper position by using the four bolts hold- ing the handlebar clamps. If the front bolts are tightened and the rear bolts are slackened the distance to the tower is decreased and vice versa.

CAUTION! When installed the tower pin must reach 0.5 mm above the upper surface of the link arm. This is especially important when the lower handlebar clamps are rubber mounted and the handlebar is allowed to flex downwards. If the link arm touches the frame the damper can be damaged.

0.5 mm

Before installation hlins Racing AB can not be held responsible for any damage whatsoever to steering damper 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.

WARNING! 1. Installing a steering damper, that is not approved by the vehicle manufacturer, may affect the stability of your vehicle. hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the steering damper. Contact an hlins 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 steering damper kit. If you have any ques- tions regarding proper installation proce- dures, contact an hlins dealer or other quali- fied person.

3. The vehicle service manual must be referred to when installing the hlins steering damper.

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.

hlins 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 hlins dealer if you have any questions with regard to the contents of the manual.

NOTE! During storage and transportation, especially at high ambient temperature, the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material. This is not unusual and is in no way detrimental to the steering damper.

WARNING! When installing the The hlins tower the motor- cycle workshop manual must be at hand.

WARNING! Certain modifications can be necessary to install the tower. It is vital that the mounting instructions are carefully followed.

Kit contents Before installing the steering damper, please check the contents of the kit. If anything is missing, contact your hlins dealer.

Description Pcs. Part No. Tower 1 04562-02 Bracket 1 04561-02 Screw MC6S 6x22 2 01046-05 Screw MC6S 5x16 4 01046-18 Adjustment shaft (pin) 1 04563-01 Link arm 1 04032-01 Handlebar clamp 1 04301-08 Sticker hlins 2 00197-01

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Mounting instructions Steering damper link arm

A The link arm is to be attached to the steering damper wing assembly. Use socket tool 4956- 01 or a 10 mm socket to prevent the stem from moving upwards and socket tool 4955-01 or a 15 mm socket to press the link arm onto the damper wing stem.

Mounting instructions Steering damper bracket kit

1 Remove the original upper handlebar mounting clamps and the number plate (and front light on enduro motorcycles).

NOTE! KTM motorcycles must have the top cap of the steering head changed, see instructions below.

2 Fit the tower to the rear steering head bracket. Use Loctite 222 or similar to the bolts before tight- ening. Tighten to a torque of 6.5 Nm. Applt Loctite 222 to the pin and install it into the tower.

Tower 4562-02

Pin (adjustment shaft) 4563-01

Steering head brackets 4561-03

CAUTION! It is of vital importance that the link arm is not pressed onto the steering damper without a holder up. Delicate sealing surfaces can be

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