Ohlins HUSABERG MX 2000 Manuel utilisateur

Owners Manual

Öhlins 48 mm front fork TM

MX/Enduro and Supermotard

Including:

Setting up

your bike

Fine-tuning

Service

the fork

General

handling set-up

Technical info

Spare parts

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.

Introduction

All of Öhlins advanced suspension products are

adapted to the brand and model. This means that

length, travel, spring, action and damping charac-

teristics, are tested individually just for your

motorcycle.

Before installation

Öhlins Racing AB can not be held responsible for

any damage whatsoever to front 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.

Any reprinting or unauthorized use

without the written permission of

Öhlins Racing AB is prohibited.

Printed in Sweden.

NOTE

Öhlins 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 Öhlins

dealer if you have any questions with regard to

the contents of the manual.

Contents

Safety signals ................................................ 2

Introduction ................................................... 2

Before installation .......................................... 2

Tuning the suspension ................................... 3

Design ........................................................... 3

Settings ......................................................... 4

Setting the spring preload ............................. 4

Fine tuning the bike ....................................... 5

Preload adjustment ....................................... 7

Changing springs .......................................... 9

Technical information ................................... 10

Spare parts .................................................. 11

General handling set-up .............................. 14

Maintenance ................................................ 15

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 48 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.

The compression adjuster is

located at the bottom of the

fork leg.

The rebound adjuster

is located at the top of

the fork leg.

Spring pre-load is adjusted

with different spring supports.

Optional springs are available.

Settings

Basic settings

Always ensure that the basic setting made by

Öhlins is correct. It is adapted to the make and

model (in its original state) and for a rider of

average weight.

WARNING

Incorrect spring action can produce a fork angle

that is too steep or too flat.This in turn will give a

tendency for oversteering or understeering, which

could seriously affect the handling characteristics

of the motorcycle.

The original setting of the front fork, when delivered

from Öhlins, should always be a base when the

settings are changed by use of the adjustment

devices.

Recommendations

The difference should not deviate from the

following sizes, if no other recommended settings

are given in the Mounting Instructions:

Free sag: (R1-R2), (F1-F2)

Rear: MX/Enduro/Supermotard 30±5 mm

Front: MX/Enduro/Supermotard 30±5 mm

Ride height: (R1-R3), (F1-F3)

Rear: MX 100±5 mm

Enduro/Supermotard 30% of the

total stroke

Front: MX/Enduro/Supermotard 80±5 mm

Setting the spring pre-load

Measuring

Pre-load on the spring/springs is very important,

because it affects the height of the motorcycle and

the fork angle. Consequently, handling characteristics

can be changed, even negatively. Proceed as follows

(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, eg. from the

lower edge of the rear mudguard or

from a point marked by a piece of tape,

immediately above the rear wheel axle,

to the wheel axle (R1).

•Make a similar measurement on the front axle,

e.g. from the bottom of the upper fork crown

to the front wheel axle (F1).

•Allow the motorcycle (without rider) to

apply load on the springs and repeat the

measuring procedure (R2, F2).

•Then take the same measurements with

the rider and equipment on the

motorcycle (R3, F3). It is important that the rider

has a correct riding posture, so that the

weight is balanced on the front and rear

wheel in the same way as when riding.

Bike on a stand.

Bike on the ground.

Bike with rider on.

Fine-tuning the bike

Learning how to use the adjusters will take time

but you quickly appreciate them once you know

the tricks. Even the specialists sometimes need

a specialist!

With the adjusters you optimize the suspen-

sion for your riding style and the track you are

competing on.

The same basic guidelines go for both the front

fork and the rear shock absorber.

Too much compression damping will give you a

harsh ride as your bike “jumps“ along the track.

With too much rebound damping your bike will

have difficulties with several bumps in a row. The

suspension will not extend fast enough between

bumps, your bike will ride lower and lower and

eventually the suspension will bottom!

External adjusters

On the Öhlins front fork the adjusters are bleed

valves, completely separated from each other.

The compression bleed valve controls the flow

in the cartridge tube during the compression

stroke, the rebound bleed valve controls the flow

during the rebound stroke.

CAUTION!

Using too much force when closing the adjusters

will destroy important sealing surfaces.

learn how they effect the handling of your bike.

Make sure that you have the correct 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 adjusters should normally not be adjusted

in steps of more than 2 clicks at a time and not

outside the usable click range.

When you think you have made an improvement,

go back to what you started with and double

check to be sure. Pay attention to changes in

conditions like tires, temperatures etc.

NOTE!

See Mounting Instructions for recommended

settings.

Both the adjusters have a normal right-hand

thread.

Click position zero (0) is when the adjusters are

turned clockwise to fully closed.

The adjustment range, from fully closed until

maximum open valve (counter clockwise), is 20

clicks.

In order not to click in the wrong direction; always

first close the adjuster, then dial-in the new setting.

Making adjustments

To make improvements using the adjusters, it is

important to understand the function of the front

fork and the shock absorber and through testing

In general, compression damping changes should

be used to influence the bike’s stability and re-

sponse, while rebound damping changes should

be used to influence comfort and traction.

When you need more damping force, you should

mainly try to increase compression damping and

use as little rebound damping as possible.

This usually means that you gain comfort and

performance in handling.

Oil level adjustment

As the air trapped between the oil and the top

nut acts as an air-spring, a change in oil level will

effect the damping forces. Not in the early stage

of fork travel, but a great deal in the later stage.

A general description of how the oil level/air-

spring effects the damping forces are shown in

Fig.4.

The air-spring gives the Öhlins USD fork a pro-

gressive spring rate, preventing it from bottoming

out hard.

By using different 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!

The oil level must be the same in both front fork legs.

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 level is lowered

The air-spring in the later half of travel is soft,

and thus the front fork soft.

CAUTION!

Adjust the oil level with the fork leg fully com-

pressed and no pre-load washer or spring installed.

NOTE!

See Mounting Instructions for recommended oil

level.

The oil level is measured from the top of the outer

leg, with the top nut off (Fig.6).

Changes in oil level should be made in small

steps. We recommend a change of 5 mm at a

time and not outside the range of 80-130 mm.

Oil level

Oil level is measured

from the top of the

outer leg, with the top

nut off, the fork fully

compressed and no

pre-load washer or

spring installed.

Oil level

Air spring

A change in oil level

will effect the damp-

ing forces, not in the

early stage of fork

travel but a great

deal in the later

stage.

Force

Stroke

Oil level 100 mm

Oil level 110 mm

Oil level 120 mm

Oil level 130 mm

❿

Pre-load adjustment

Put the bike on a stand and loosen the screws in

the top fork crown that hold the fork legs.

NOTE!

On most MX-bikes you have take of the handle

bar off before you can unscrew the top cap.

Remove the adjustment wheel and the springs

and balls of the adjuster.

Unscrew the top cap, use tool (1860-01 or

1761-02).

Put a box under the front wheel so that the

springs are visible.

Remove the top cap from the damper rod extender.

Use a 17mm wrench, and tool (1860-01 or

1761-02).

Adjustment

wheel

Balls and

springs Tool (1860-01)

Top cap

17 mm

wrench

Damper

rod assy

Damper rod

extender

Tool (1761-02)

Remove the original spring support.

Install a new spring support to achieve the right

static sag.

Fit the spring support and the top cap. Tighten

the top cap and lock nut to a torque of 20 Nm.

CAUTION!

The piston shaft must bottom in the top cap

before the lock nut is tightened.

Original

spring

support

Adjustment

wheel

Top cap

Spring support

Refit the adjustment wheel.

Tighten the bolt in the top fork crown to 20 Nm.

NOTE!

The top nut only have to be tightened by hand

without extending tool.

New spring

support

Changing springs

Follow instructions 1-4 on previous page and

remove the spring. Do not install the spring

support spacer.

Install the new spring.

NOTE!

Check the free length of the spring. Original 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

NOTE!

Closing the compression and the rebound valves

will keep the damper rod extended making it

easier to install the new spring.

Check the oil level according to page 6 and 10.

Pull out the damper rod as far as possible and

then close the compression and the rebound

valve (clockwise).

Technical specifications

Fork lengths and diameters

Front fork

ØA ØB

53.9 mm 59.3 mm

Length (L)

MX/Enduro Supermotard

935 mm 904 mm

Rebound and compression adjustment

Refer to mounting instruction for set-up data.

Maximum open rebound and compression valve:

20 clicks.

Free Spring Length:

MX/Enduro: 467 mm (service limit 460 mm).

Supermotard: 436 mm (service limit 429 mm).

Spring pre-load:

Maximum allowed adjustment

range 4-8 mm (with optional spring support).

Spring rate (depending on models):

MX/Enduro Supermotard

2428-39: 3.9 N/mm 2490-41: 4.1 N/mm

2428-41: 4.1 N/mm 2490-43: 4.3 N/mm

2428-43: 4.3 N/mm 2490-45: 4.5 N/mm

2428-45: 4.5 N/mm 2490-47: 4.7 N/mm

2428-47: 4.7 N/mm 2490-49: 4.9 N/mm

2490-51: 5.1 N/mm

Settings:

Compressing adj. 12±2 clicks

Rebound adj. 12±2 clicks

ØA

ØB

300

200

Oil level:

Adjustment range: 80-130 mm.

CAUTION!

Use only Öhlins high performance front fork fluid

No. 5 (1305-01).

Tighten torque:

Fork top crown bolt: 20 Nm

Fork bottom crown bolt: 10 Nm

Compression valve: 65 Nm (Base valve).

Cylinder tube cap (cartridgetube): 65 Nm

Compression valve, 8 mm nut 8 Nm.

Rebound valve, 8 mm nut 8 Nm.

Grease:

Öhlins Front Fork grease 00146-01

(Red grease).

Service Intervals:

Every 20 hours.

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