Ohlins YA653 Mounting Instruction

Brand: Ohlins

Model: YA653

Type: Mounting Instruction

Ohlins YA653 is an electronically controlled rear shock absorber kit for Yamaha snowmobiles. It features an adjustable spring pre-load, rebound damping, and compression damping. The compression damping can be controlled electronically, allowing you to adjust the damping force on the fly to suit your riding conditions. The shock also has a built-in solenoid that can be used to lock out the compression damping, providing a firmer ride for aggressive riding. The kit includes all the necessary mounting hardware and instructions.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.

Phone +46 8 590 025 00. Fax +46 8 590 025 80.

www.ohlins.com

YA 653, issued 2005 12 05

Mounting Instructions

Öhlins shock absorber kit YA 653

for Yamaha RX-1 /ER, RS Vector ER /GT, Rear

written permission of Öhlins Racing AB is prohibited. Printed in Sweden.

Please read before installing

Öhlins Racing AB cannot be held responsible

for any damage to shock absorber or vehicle,

or injury to persons, if the instructions for ﬁ tting

and main tenance are not followed exactly.

Similarly, the warranty will become null and

void if the instructions are not adhered to.

Spring pre-load adjuster:

Adjust the spring pre-load by turning the rings

on the shock absorber body. Use the C-spanner

provided in this kit.

Compression damping adjuster:

Adjust by setting the electronic adjustment

device. High number means hard compression

damping.

Rebound damping adjuster:

Turn the adjuster wheel on the piston shaft

above the end bracket.

NOTE!

When delivered the Öhlins shock absorber is

dialed to the recommended settings for the

speciﬁ c brand and make of the snowmobile. If

you have changed the setting, reset according

to the following:

The adjuster has a normal right hand tread. Turn

clockwise to fully closed. Turn counter clockwise

to open and count the clicks until you reach the

recommended number of clicks.

CAUTION!

Do not use too much force, delicate sealing

surfaces can be damaged. Use ﬁ ngers only.

Rebound

adjustment

Spring pre-load

adjustment

Adjustments

Electronic

Compression (EC)

damping adjuster,

solenoid

Kit Contents

Before installing the shock absorber, please

check the contents of the kit. If anything is

missing, please contact your Öhlins dealer.

Shock absorber 46PRC3 YA 653 (1)

C-spanner 00710-02 (1)

Tie wrap 00231-01 (20)

Control unit EC, for solenoid 03700-02 (1)

Scotch lock (1)

Quick connector:

Connector housing (1)

Front holder (1)

Screw MKFX-Z stainless 00828-03 (3)

Wire bracket 03714-01 (1)

Pop rivet 03715-01 (4)

Grommet 03716-01 (1)

Sticker Öhlins 00192-01 (2)

Sticker Öhlins EC 03701-01 (2)

Sticker Memo notes 01180-01 (1)

Öhlins Owner’s manual (1)

Increased

damping

NOTE!

Make sure that all bolts are tightened to the

correct torque and that nothing fouls or restricts

the movement of the shock absorber when

the suspension is being fully compressed or

extended.

WARNING!

1. 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 that may oc-

cur after ﬁ tting the shock absorber. Contact

an Öhlins dealer or other qualiﬁ ed person

for advice.

2. Please study and make certain that you fully

understand all the mounting instructions and

the owner’s manual before handling this shock

absorber kit. If you have any questions regard-

ing proper installation procedures, contact an

Öhlins dealer or other qualiﬁ ed person.

3. The vehicle service manual must be

referred to when installing the Öhlins shock

absorber.

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 shock absorber.

Safety Signals

Important information concerning safety is

distinguished in this manual by the following

notations:

The Safety alert symbol means:

Attention! Your safety is involved.

WARNING!

Failure to follow these warning instructions

could result in severe or fatal injury to

anyone working with, inspecting or using

the shock absorber, or to bystanders.

CAUTION!

Caution indicates that special pre cautions

must be taken to avoid damage to the

shock absorber.

NOTE!

Indicates information that is of importance

regarding mounting procedures.

NOTE!

Öhlins products are subject to continuous

improvement and development. Consequently,

although these instructions include the most up-

to-date information available at the time of print-

ing, 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.

1 10

Raise the rear end of the snowmobile slightly,

but only until the drive track barely lifts off the

ground. On the running board, place a mark

with a pen, in line with the rear axle. Measure

the distance from the mark on the running board

to the ground (D1).

With a rider on the snowmobile, measure the

distance from the same marking on the running

board to the ground (D2).

Recommended rear ride height:

D1 - D2 = approximately 65 mm / 2.5 “

Recommended Rear Ride height

Shock absorber length 517.5 mm

Shock absorber stroke 151 mm

Rebound adjustment 20 clicks

Spring pre-load adjustment 9 mm

Free spring length 290 mm

Spring rate 70 N/mm

Compression adjustment EC-

controlled

(EC basic setting: level 10 of 20)

Setup data

In line with the

rear axle

Left side cover

Adjuster

Limiter

strap

Öhlins shock absorber with

reservoir directed upwards

and to the front.

General ﬁ gure for the mounting instructions

Reinforcement

plate on the skid

frame tunnel

Adjuster

housing

Adjuster

cable

Remove the adjuster cable from the adjuster

housing. Release the track tension. Remove the

bolts and then the skid frame from the vehicle.

NOTE!

Before the adjuster cable is removed the adjuster

must be turned to hardest damping force.

Reposition the bolt to

face rearwards

Limiter

strap

Front

Correct ﬁ tting of

the bolts, washers

and nuts

Loosen the front and rear attachment bolts

and remove the original shock absorber from

the skid frame.

NOTE!

Change the position of one bolt at a time to

ensure you reﬁ t the bolts in the original holes

on the limiter straps.

Mounting Instructions

WARNING!

1. It is advisable to have an Öhlins dealer

or other qualiﬁ ed person install the shock

absorber.

2. Follow the instructions in the vehicle service

manual when changing the shock absorber.

3. When working on a raised vehicle, make

sure that it is securely supported to prevent

it from falling.

NOTE!

Before you start, please follow the dismantling

instructions in the Yamaha Work Shop manual.

Loosen, but do not yet remove, the two skid

frame attachment bolts on each side of the

snowmobile. Remove the left side cover above

the foot rest. See also, ﬁ gure on page 1.

NOTE!

The side cover is attached with four screws and

a rubber mount. One of the screws is located

under the seat.

Carefully tip the snowmobile on its side. To pre-

vent fuel leaks, clamp the fuel tank vent hose. It

is recommended that you use a handlebar stand

or equivalent to help hold the machine and thus

avoid damaging it.

You can instantly optimize adjustments to suit

your individual way of riding and the condition

of the trail.

The electronically controlled compression damp-

ing is set with the control panel of the electronic

unit.

NOTE!

Read more about basic setting procedures in

your Öhlins Owner’s manual.

EC – Electronic Control Settings

Pressing

the plus

(+) button

increases

damping

Pressing

the minus

(-) button

decreases

damping

Press the Öhlins button once for voltage reading.

Press again to turn the voltage reading off.

Read more about the EC unit in your Öhlins

Owner’s manual.

WARNING!

Do not alter the damping when riding. The

snowmobile must come to a stop before the

damping is set. To avoid dangerous situations,

do not take your eyes and attention off your

surroundings.

When the snowmobile is restarted the adjusters

will return to the earlier chosen positions. If the

power supply fails there is always a damping

force in the shock absorber, to allow for safe

riding.

CAUTION!

Make sure the tie wraps are not interfering with

any movable parts, when attaching the wires.

No power to the front damper

Does not apply for the YA 563 shock

absorber

No power to the rear damper

Measures: Make sure the damper is

connected. Check wires and connec-

tions for damages.

No power to the front and rear

dampers

Does not apply for the YA 563 shock

absorber

Insufficient voltage to the control

unit

Measures: Check battery and alternator.

Check all connections.

Compress the front part of the rear suspen-

sion so that the limiter strap is no longer

tight.

A tip: Put a large piece of wood under the

front part of the rear suspension to raise it, and

thereby loosen the tension of the limiter strap.

Remove the two lower bolts of the limiter

strap.

Remove the two lower bolts

of the limiter strap.

CAUTION!

Make sure that the threads on the limiter strap

bolts are not facing towards the shock absorber,

they may cause damage to it. If they are fac-

ing towards the shock absorber, change their

position so that the threads are facing in the

opposite direction.

The control unit

Damping

force

Electrical

voltage

Troubleshooting

Er1

Er 2

Er 3

Er 4 -

Er7

Mark the wire in three places as indicated on

the ﬁ gure above. Use tape or paint.

Using the wire bracket included in the kit, make

a cardboard template. Drill four 3.3 mm holes

according to the following:

From the inside, drill the two lower holes for the

bracket. Then, using the cardboard template,

drill the two upper holes from the outside. Ensur-

ing that the template is positioned in the same

manner as the bracket.

NOTE!

Using the bracket from the outside will result in

a mirrored image, which is incorrect.

Drill a 10 mm hole above the wire bracket to run

the wire through. Install the grommet, provided

in this kit, into the hole.

NOTE!

This drawing is NOT a 1:1 scale. It is only intend-

ed to give the correct measurement ﬁ gures.

545 mm / 21.4”

165 mm / 6.5”

90 mm / 3.54”

Mark no. 3 for positioning the wire in relation to

the tie wrap mounted on the shock absorber

Mark no. 2 for rubber

hose position

Rubber hose

Mark no. 1 for positioning the wire

in relation to the grommet mounted

in the chassis

76.5 mm

Ø3.3 mm

3.5 mm

21.5 mm

8.5 mm

81.5 mm

Wire bracket

Wire bracket position

Reinforcement plate on

the left side of the tunnel

Drilled hole for

grommet Ø10 mm

4xØ3.3mm

18 mm

Ground wire

Fuse 5A

Scotch lock

– to be connected

to power supply

(blue/white wire)

Fuse

Scotch lock

– connects

to blue/white

wire

Ground wire

Press

rearward

Tool box

Blue/white wire

Let excess wire length form a loop on the lower

side of the hood. Attach the remaining length

with tie wraps.

NOTE!

Loosen the forward attachment of the toolbox

and push the box rearwards for better access

to the blue/white wire.

CAUTION!

Make sure that the wires do not restrict the

suspension and steering, and that they are ﬁ rmly

attached to the snowmobile.

Quick connection

Electronic

Control Unit

Wire for negative

connection

Fuse 5A

Scotch lock

– to be

connected

to power the

supply

Electronic

adjuster

– solenoid

Overview of electronic control system including wiring and connections

solenoid

Remove the solenoid and wire from the Öhlins

shock absorber.

7 4

Run the wire through the grommet and position

mark number 1 right at the grommet. Attach the

wire with the aluminum wire bracket and the four

pop rivets, which should be installed from the

outside for a better appearance. Make sure that

the bracket holds the wire ﬁ rmly in place.

Seal

Wire end

connectors

Quick connector

housing

Front

holder

Drilled hole in chassis

(Ø10 mm)

Grommet

Lock-up

pins

Attach the wire ends to the quick connector.

Make sure that the lock-up pins match the stop

in the connector.

Wire bracket

Pop rivet

Reinforcement

plate on the left

side of the skid

frame tunnel

Mark no. 1 at

grommet

Wire bracket

4xØ3.3mm

Solenoid

Rubber

hose

NOTE!

The two wire end connectors may go in either

hole in the quick connector housing. It makes no

difference which wire goes in which hole.

Wire connections RX-1

Connection

to power

supply

Wires

from the

control

unit

Control unit

Connection to

power supply

(blue/white

wire)

Quick

connecter

Solenoid

Shock

absorber

Let the two (2) control unit connection wires run

forward, under the hood. Attach them to the in-

strument wire cluster. Fix the wires with tie wraps,

but only as far as pos. (A) in ﬁ gure 23. Follow the

wire cluster to the front of the snowmobile hood,

then turn the shock absorber wire to the left side

of the snowmobile, under the front attachment

of the toolbox with the fused wire and ground

wire to the right side. See illustrations above

and next page.

Connect the quick coupler to the wire connector

from the shock absorber. Then go forwards along

the sub frame and ﬁ x it with tie wraps.

Quick

connecter

to the shock

absorber

Tie wraps

Vent hose

Quick

connecter

Grommet

(in drilled

hole)

CAUTION!

Do not ﬁ x a tie wrap around the clear plastic

vent hose, running along the frame tube. The

vent hose should not be choked off.

Connect the fused wire to the blue/white wire

with the Scotch lock provided. Connect the

ground wire to a screw in the chassis.

Tie wraps

To shock

absorber

Ground wire

Blue/white wire

5 6

Reﬁ t the skid frame, without the shock absorber,

into the snowmobile.

Attach the rubber hose to the front swing arm

with four tie wraps.

NOTE!

The following operation should be carried out

when the wire is installed with the wire bracket

and the hole drilled in the chassis.

Install the Öhlins shock absorber with the reser-

voir directed upwards and to the front. Install in

the following order:

1. Rear bolt

2. Solenoid

3. Front bolt and sleeve

4. Retaining clip for solenoid

Use the original bolts and front collar.

CAUTION!

Attach the wire to the shock absorber reservoir

with a tie wrap. This will reduce the fatigue on

the wire.

Skid frame

Reservoir

Solenoid

Make sure the o-ring

is in correct position

before ﬁ tting the

solenoid

Make sure the rubber hose

stops about halfway between

the swing arm and the tunnel

wall

The wire should go on the left

hand and back hand side of

the tubing

107 mm

4.21”

The two tie wraps on the cross member must

be placed in such a way so that the slide bump

rubber will not destroy them.

Mark no. 2

Mark no. 3

Retainer clip holding

solenoid

CAUTION!

Attach the wire to the shock

absorber reservoir with a tie wrap.

Remove the head light cover, the head light and

the small side covers.

NOTE!

The light cover is attached with two (2) screws

on it´s upper side and three (3) from below. The

head light is attached with six (6) screws and the

side covers with one (1) screw each.

Open the hood and loosen the speedometer

attachments.

The opening for the speedometer must be

extended on the right upper side to make room

for the EC-wires (see ﬁ gure 19).

Drill three (3) Ø3.3 mm holes to attach the EC-

unit on the instrument panel. Make a template

out of cardboard, as in ﬁ gure 20, to get the holes

in the right place.

Attach the EC-unit to the left side of the speed-

ometer (ﬁ gure 21). Use the three M3 screws

(00828-03) provided to attach the EC-unit in the

instrument panel from the back. Pull the wires

behind the speedometer unit and through the

extended hole (from step 19 above).

EC control unit

EC control unit position

Speedometer unit

36.5 mm

1.44”

42.5 mm

1.73”

EC-unit

NOTE!

This drawing is NOT a 1:1 scale. It is only intend-

ed to give the correct measurement ﬁ gures.

10 mm

Enlargment of the speedometer

opening for the EC wires.

Speedometer

cluster

Duct tape will

secure the screws

holding the EC-

unit

Reﬁ t the speedometer, headlight and covers.

NOTE!

A tip: put a piece of duct tape on the backside

of the panel, to cover the screws of the control

unit. This will secure the screws and prevent

them from coming loose.

Reattach the limiter strap in its original posi-

tion.

See page 2, step 4: how to handle the limiter

strap in a safe way.

Ohlins YA653 Mounting Instruction

Ohlins YA653 Mounting Instruction

Ohlins YA653 Mounting Instruction

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