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 678, issued 2005 12 05
Mounting Instructions
Öhlins shock absorber kit YA 678
for Yamaha RS Rage, Rear
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
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 678 (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 NJFX-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)
Owner’s manual (1)
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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 55 mm / 2.16 “
D1
D2
Recommended Rear Ride height
Shock absorber length 517.5 mm
Shock absorber stroke 151 mm
Rebound adjustment 20 clicks
Spring pre-load adjustment 5 mm
Free spring length 290 mm
Spring rate 60 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
29
3
Adjuster
housing
Adjuster
cable
3
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
6
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.
!
1
NOTE!
Before you start, please follow the dismantling
instructions in the Yamaha Work Shop manual.
1
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.
2
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.
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42
35
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 678 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 678 shock
absorber
Insufficient voltage to the control
unit
Measures: Check battery and alternator.
Check all connections.
4
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.
5
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
5
4
!
3
8
8
Mark the wire in three places as indicated on
the fi gure above. Use tape or paint.
9
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.
10
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
8
76.5 mm
Ø3.3 mm
3.5 mm
21.5 mm
8.5 mm
81.5 mm
Wire bracket
Wire bracket position
9
10
Reinforcement plate on
the left side of the tunnel
Drilled hole for
grommet Ø10 mm
4xØ3.3mm
18 mm
25
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
26
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
7
Remove the solenoid and wire from the Öhlins
shock absorber.
7 4
11
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.
12
Seal
Wire end
connectors
Quick connector
housing
Front
holder
Drilled hole in chassis
(Ø10 mm)
Grommet
Lock-up
pins
12
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
11
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
23
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.
24
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
24
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.
23
25
25
Connect the fused wire to the blue/white wire
with the Scotch lock provided. Connect the
ground wire to a screw in the chassis.
A
26
Tie wraps
Tie wraps
To shock
absorber
Ground wire
Blue/white wire
5 6
13
Refi t the skid frame, without the shock absorber,
into the snowmobile.
14
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.
15
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.
15
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
14
Mark no. 3
Retainer clip holding
solenoid
CAUTION!
Attach the wire to the shock
absorber reservoir with a tie wrap.
17
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.
18
Open the hood and loosen the speedometer
attachments.
19
The opening for the speedometer must be
extended on the right upper side to make room
for the EC-wires (see fi gure 19).
20
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.
21
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).
21
EC control unit
EC control unit position
Speedometer unit
36.5 mm
1.44”
42.5 mm
1.73”
EC-unit
20
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
19
Duct tape will
secure the screws
holding the EC-
unit
22
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.
16
Reattach the limiter strap in its original posi-
tion.
See page 2, step 4: how to handle the limiter
strap in a safe way.
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