Rally-Raid RRP 563 User manual

Fitting Instructions for RRP 563 1
Fitting Instructions for RRP Tractive Hydraulic Preload Adjuster
Husqvarna 701-RRP 563
DO NOT ATTEMPT TO COMMENCE THIS WORK WITHOUT A MECHANICAL SPRING
COMPRESSOR, OR CONSULT A SUSPENSION SPECIALIST
NOTE: BEFORE COMMENCING WORK ON THE CONVERSION, TAKE TIME TO READ THE INSTRUCTIONS
CAREFULLY. ALL WORK CAN BE CARRIED OUT BY A COMPETENT MECHANIC, BUT IF YOU ARE UNSURE
PLEASE CONTACT US OR A MECHANICAL PROFESSIONAL
Put the motorcycle on a stand so that the rear wheel is off the ground. Make sure the vehicle is
secured so that it will not fall over.
1. Remove seat by pulling back front corner of seat,
both sides, to unlatch pegs. Pull cord under left
side panel to release seat catch, and pull seat off
by sliding back and up.

Fitting Instructions for RRP 563 2
2. Remove both M6 screws at front of rear fender
spoiler, then undo both torx screws under spoiler.
Remove filler cap using key, then pull off spoiler by
moving backwards.

Fitting Instructions for RRP 563 3
3. Undo left panel torx screw, then pull panel out
from rear and detach snap connector to frame at
front, remove panel fully.
4. Prise open undercut catch on inside rear of right
panel, this can be very difficult as shown.

Fitting Instructions for RRP 563 4
5. Then undo the push tag in the front of panel
hidden behind frame, remove panel fully
6. Undo both M10 bolts attaching silencer mount to
rear tank.
7. Using air drive gun and torx bit, remove left screw,
then grease thread and replace, but do not tighten
hard. Remove torx screw on opposite side, then go
back and remove first torx screw. This may be
difficult, as the hollow tube in the tank may try to
spin

Fitting Instructions for RRP 563 5
8. Lift rear tank enough to access quick-disconnect
fuel connector and disconnect fuel line between
main tank and injector, then fully rotate tank up
high enough to access rear shock. Secure to bars
with strap, as shown.

Fitting Instructions for RRP 563 6
9. Remove lower shock bolt with torx bit, then
remove upper shock bolt with torx bit. Rotate
shock backwards and remove from frame, it may
need to raise the tank slightly more to gain enough
space to remove shock.

Fitting Instructions for RRP 563 7
10. On right-hand side of frame, remove M6 screw
holding plastic housing. Push housing forward to
allow preload adjuster to be inserted later.
11. Unpack new Preload Adjuster and rotate adjuster
knob anti-clockwise to check it is fully undone, this
means that the preload piston on the main
assembly should be sticking forward
approximately 2mm.
2017 Models Only

Fitting Instructions for RRP 563 8
12. Undo locking screw on red plastic collar and rotate
the threaded collar anti-clockwise, using a hand
tool, right up to the top, so that the OEM spring
can be slid up the shock tube, then the 2 split
collars can be removed from the stepped collar,
and both plastic & metal washers at the bottom of
the shock can be removed, then the spring and red
collar can be removed fully from shock.

Fitting Instructions for RRP 563 9
13. Clean any grease and road dirt from disassembled
shock with warm soapy water, and dry thoroughly
before attempting to assemble new Preload
Adjuster and new spring onto shock.
14. Load black locking ring onto shock body first,
ensuring stepped smaller diameter is facing the
top. Ensure M5 threaded hole is facing to the rear
of the shock and insert the small black rubber plug
into the threaded hole, followed by the M5x8
locking grub screw, do not tighten.

Fitting Instructions for RRP 563 10
15. Slide new Preload Adjuster onto shock body, and
engage pin on Preload Body into half-round recess
in upper locking ring. Slide 1mm thick stainless
steel washer up onto shock body so that it fits up
against aluminium adjuster piston on Preload
Adjuster, then slide on new spring supplied.

Fitting Instructions for RRP 563 11
16. Using a spring compressor, compress spring
sufficiently so that the OEM black plastic washer
and steel washer, then the OEM stepped collar can
be loaded onto the shock, leaving enough room to
fit the 2 split collars around the lower shock
mount. If it is difficult to fit shock and Remote PA
into spring press, it is possible to rotate Remote PA
to aid insertion, as it is possible to rotate the PA
unit even when the spring is fitted, as long as the
M5 grub screw is not tight.
17. Carefully release the spring compressor pressure
so that the 2 split collars locate into the recess in
stepped collar, and then release spring pressure
fully and remove compressor tool. Re-align grub
screw in black locking ring with rear of shock if
necessary. Tighten M5 locking screw gently (1Nm),
preferably using Loctite on threads of locking
screw to prevent loosening.

Fitting Instructions for RRP 563 12
NOTE: IT IS VERY IMPORTANT THAT THE SPLIT LOCKING COLLARS ARE LOCATED FLUSH IN THE RECESS OF THE
STEPPED COLLAR SO THAT THE SHOCK CANNOT COME APART DURING RIDING.
18. Insert complete shock assembly and preload
adjuster back into bike, putting the adjuster
knob in first, and threading it around to the
right of the bike and out through the frame as
shown.
19. Insert top shock bolt back through the frame
from the left and through the shock, do not fully
tighten. Grease the body of the bolt before
fitting.

Fitting Instructions for RRP 563 13
20. Replace lower shock bolt back through shock
and linkage, from the right side, do not tighten
fully. It is sometimes easier to lift the swing arm
up and down slightly to aid alignment. Grease
the body of the bolt before fitting.
Tighten both bolts fully to specifications in OEM
manual.
21. Assemble bracket supplied onto adjuster knob
as shown, using 2 spacers and M6 button head
screws, use Loctite on threads. Insert M6x25
screw through bracket, with remaining spacer
between bracket and frame, then mount
adjuster knob assembly into unused OEM
housing hole. Position knob and tighten screw
securely.

Fitting Instructions for RRP 563 14
22. Push tank assembly back down into position, then
insert the M8 screw from left side, through
exhaust mount, into tube do not tighten fully.
Repeat on left side, then tighten both screws fully.
23. Refit silencer mount, do not use Loctite on threads,
only PTFE tape. Tighten both M10 screws then fully
tighten lower tank mount bolt.
24. Replace side panels and rear fender spoiler. Refit
seat.