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 1
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. Introduction All of Öhlins advanced suspension products are adapted to the brand and model.
1. The compression adjuster is located at the bottom of the fork leg. 2. The rebound adjuster is located at the top of the fork leg. Tuning the suspension Design 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.
F1 F2 F3 R1 R2 Bike on a stand. R3 Bike on the ground. Settings Setting the spring pre-load 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. 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.
Compression stroke Flow in compression valve Rebound stroke Flow in rebound valve 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 suspension 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.
Oil level 110 mm Oil level 120 mm Oil level 130 mm Oil level Oil level 100 mm 500 450 400 F 350 o r 300 c e 250 Force Air spring 4. 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. k 200 g f 150 Oil level 5. 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.
Tool (1873-01) Adjustment wheel Balls and springs Tool (1860-01) 17 mm wrench 17 mm wrench Top cap Damper rod extender 24 mm wrench Damper rod assy Pre-load adjustment 1 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. 2 Unscrew the top cap, use a 17 mm wrench and tool (1860-01) or tool (1873-01) and a 1/2” socket wrench.
Spring support Adjustment wheel Optional spacers 02428-08 02428-04 Top cap Spring support 4 Remove the spring support. Install a optional spacer to achieve the right static sag. 5 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. Refit the adjustment wheel. Tighten the bolt in the top fork crown to 20 Nm and the lower triple clamp to 10 Nm.
Front fork L ≥ 460 mm Compression adjuster Vice with soft jaws Changing springs 6 Follow instructions 1-4 on previous page and remove the spring. Do not install the spring support spacer. Dismantling 8 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. 7 NOTE! Closing the compression and the rebound valves will keep the damper rod extended making it easier to install the new spring.
Outer tube Tool 1797-03 Outer tube Inner leg Damper rod assy Tool 1702-04 Sleeve Bushing Seal Cylinder tube Inner leg Fixed bushing 10 Perform steps 1-2 on page 7. Loosen the cylinder tube cap, on top of the cylinder tube, with tool 1797-03. Lift up the damper rod assembly and drain the oil. Pull up the scraper with a screwdriver, release and remove the circlip. 11 CAUTION! The fork legs have one fixed bushing and one sliding bushing. Be very careful when disassembling the fork legs.
Sleeve Bushing Seal Rebound valve assembly 13 Remove the seal and bushing and check them for wear and damage. Replace if necessary. 14 Fasten the damper rod assembly in a vice with soft jaws. Use tool 0727-02. CAUTION ! CAUTION! When removing the oil seal and bushing use a small plastic bag to cover the bushing attachment groove and edges of the inner tube, to avoid damage to the seals. Fasten the damper rod assembly in a vice. Be carful not to tighten too hard. The piston rod is very delicate.
Inner leg Circlip Inner leg Scraper Tool 1799-04 Seal Washer Scraper Tool 1799-04 Circlip Bushing Sleeve Sleeve Seal Bushing Outer leg Bushing Assembling 16 Apply a thin layer of Öhlins red grease (146-01) on the scraper ring and on the sealing surface of the fork seal. 17 Fasten the outer leg in a vice with soft jaws. Install the inner leg and mount the sleeve and the lower bushing. Use tool (1799-04). 18 Apply some Öhlins red grease on the seals.
Damper rod assy Cylinder tube cap 17 mm wrench Top cap Damper rod extender 60 Nm Compression valve assy 19 Fasten the fork leg, at the fork bottom, in a vice with soft jaws. Install the compression valve assembly in the fork bottom. Tightening torque 60 Nm. Apply some front fork oil on the outer surface of the inner leg, and push the outer leg up and down a few times. First, fill up the cartridge tube, then raise up the outer leg about 250 mm and add the remaining oil.
Technical specifications 70 Fork length and stroke Length (L): 938 mm Stroke: 300 mm Oil level: When delivered from factory: 105 mm Adjustment range: 80-130 mm. 200 Rebound and compression adjustment Refer to mounting instruction for set-up data. Maximum open rebound and compression valve: 20 clicks. Use only Öhlins high performance front fork fluid No. 5 (1311-01). 300 L Free Spring Length: 467 mm (service limit 460 mm). Spring preload: Maximum allowed adjustment range 3-13 mm (with washers).
1 1 11 12 13 14 2 Spare parts Pos. 1:2 1:3 1:4 3 1:5 4 5 1:6 1:7 1:8 1:9 1:10 1:11 1:12 1:13 1:14 1:15 1:16 1:17 1:18 1:19 1:20 1:21 10 6 15 16 7 17 8 9 Part No. 02400-01 02403-01 02436-04 02436-08 02428-41 02428-43 02428-45 02428-47 02425-03 02409-01 02427-02 02431-01 02332-05 02412-01 02410-02 02015-01 02411-02 02339-01 02429-02 02426-11 00438-16 02310-25 02310-26 02314-02 Pcs.
2 19 1 2 3 4 5 8 9 10 11 12 13 20 17 21 6 7 Spare parts Pos. 2:1 2:2 2:3 2:4 2:5 2:6 2:7 2:8 2:9 2:10 2:11 2:12 2:13 2:14 2:15 2:16 2:17 2:18 2:19 2:20 2:21 14 15 16 17 18 16 Part No. 00828-01 00820-02 01473-06 00338-79 02405-01 00884-01 00833-01 01050-01 00338-59 02397-48 00438-61 02366-13 02402-01 02430-01 01499-02 02399-48 00110-03 02340-01 02393-01 02418-01 02063-13 Pcs.
Rebound adjuster 3 21 22 23 24 Spare parts Pos. 3:21 3:22 3:23 3:24 3:25 3:26 3:27 3:27 3:28 3:29 3:30 3:31 25 26 27 28 29 30 31 32 33 34 3:32 3:33 3:34 3:35 3:36 3:37 3:38 3:39 3:40 3:41 3:42 3:43 3:44 3:45 3:46 3:47 3:48 3:49 3:50 3:51 Part No.
General handling set-up Front suspension. Front end falls into the curves (oversteering) especially in sand. Steep front fork angle. Front end too low in comparison to rear end. Front fork travel is not used to its full capacity. Harsh feeling, front wheel grip is not satisfactory in bumpy turns. Suspension too hard. Feels harsh over small bumps, but using full wheel travel. Too much spring pre-load or too much compression damping. • Increase the front fork compression damping.
Maintenance Telescopic front forks depend on a smooth, friction free action. Make sure your forks are regularly serviced. Do not use strong solvents, such as brake cleaner, to clean the front forks. This will dry out the seals and the steel tubes and cause friction 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.
More info 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: 20 07295-23, Issued 05 01 28. Teknisk Illustration. 1500 ex. www.ohlins.
