Ohlins HO 404 User manual

Mounting instructions
HO 404 - RC 45
Kit contents
Shock absorber Type 46 HRC HO 404 1
Sticker 00192-01 2
Hook spanner 00710-02 1
Mounting rubber 00230-03 2
Tie-rap 00231-01 2
Hose clamp 00643-02 2
Owners manual 1
Set-up data
Total lenght 295,5 mm
Stroke 55 mm
Preload spring 8 mm
Rebound adj. 10
Compression adj. 8
Notes
HO 404, Issued 01 01 10
Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone [phone], fax [phone].
E-mail: [email protected]
Web: www.ohlins.com
Traction, handling,
comfort and safety
WARNING!
The shock absorber is provided with a
separate type reservoir filled with high pressure
nitrogen gas. To prevent danger of explosion,
study and make certain that you fully
understand the following information before
handling the shock absorber. The manufacturer
cannot be held responsible for damage to
property or personal injury that may result from
improper handling.
1. Never tamper with or attempt to
disassemble the cylinder or the reservoir.
2. Never expose the shock absorber to an
open flame or other excessive heat. The
shock absorber may othervise explode due
to too high pressure.
3. Be careful not to damage any part of the
gas reservoir. A damaged gas reservoir will
impair the damping performance or cause
malfunction.
4. Take care not to scratch the contact
surface of the piston rod of the cylinder; oil
could othervise leak out.
5. Never attempt to remove the plug at the
bottom of the nitrogen gas reservoir. Any
attempt to remove the plug implies serious
danger.
6. When scrapping the shock absorber,
follow the instructions for disposal.

Before you start
WARNING!
Installing a shock absorber, that is not
approved by the vehicle manufacturer, may
affect the stability of your vehicle. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage whatsoever
that may occur after fitting the shock
absorber. Contact an Öhlins dealer or other
qualified person for advice.
Öhlins Racing AB can not be held respon-
sible for any damage whatsoever to shock
absorber 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!
Please study and make certain that you fully
understand all the mounting instructions and
the owner´s manuals before handling this
shock absorber kit. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer or other qualified
person.
WARNING!
The vehicle service manual must be referred
to when installing the Öhlins shock absorber.
NOTE!
Öhlins products are subject to continual
improvement and development. Conse-
quently, although these instructions include
the most up-to-date information available at
the time of printing, there may be minor
differences between your suspension and
this manual. Please consult your Öhlins
dealer if you have any questions with regard
to the contents of the manual.
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 precautions
must be taken to avoid damage to the
suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
Kit contents
Before installing the shock absorber, please
check the contents of the kit, listed on the
front page of this instruction. If anything is
missing, contact your Öhlins dealer.
NOTE!
During storage and transportation, especially
at high ambient temperature, the oil and
grease used for assembling may run out in-
side the packing and damage the expanded
polystyrene packing material. This is not
unusual and is in no way detrimental to the
shock absorber.
© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
WARNING!
1. It´s advisable to have an Öhlins dealer or other
qualified person to fit your shock absorber.
2. Instructions in the vehicle service
manual are to be followed when changing
the shock absorber.
3. When working on a lifted vehicle it must
be securely supported to prevent it from
falling.
NOTE!
Make sure that all bolts are tightened to the
correct torque and that nothing fouls or
restricts movement of the shock absorber
when the suspension is being fully
compressed or extended.
Mounting instructions
1
Put the motorcycle on a stand so the rear
wheel is clear of the ground. Make sure it´s
steadily fixed so it will not fall over.
2
Remove the seat unit.
3
Remove the rear mudgard.
4
Remove the lower shock absorber bolt.
5
Remove the upper shock absorber bolt and
remove the shock absorber upwards and
rearwards.
6
Mounting the Öhlins shock absorber:
Fit the shock absorber from the top and
downwards with the reservoir on the right
side. Mount the upper shock absorber bolt.
Mount the reservoir using mounting rubbers
and hose clamp.
7
Mount the lower shock absorber bolt.
8
Mount the rear mudgard.
9
Mount the seat unit.
10
Continue your work according to Owners
manual.