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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 659, issued 2005 12 01
Mounting Instructions
Öhlins shock absorber kit YA 659
for Yamaha EUR: RX 1 ER SP/ GT,
US: Apex RTX/ ER/ GT - 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.
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 YA659 (1)
C-spanner 00710-02 (1)
Tie wrap 00231-01 (10)
Sticker Öhlins EC 03701-01 (2)
Sticker Öhlins 00192-01 (2)
Sticker memo notes 01180-01 (1)
Owner’s manual (1)
NOTE!
The following items are not included and need
to be purchased from a Yamaha dealer:
Sub-lead wire 8GD-82509-00 (1)
Grommet 90480-23001 (1)
Blind rivet 90267-47195 (1)
Clamps 90465-06376-00 (1)
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.
Öhlins products are subject to continuous
improvement and development. Conse-
quently, although these instructions include
the most up-to-date information available
at the time of printing, there may be minor
differences between your shock absorber
and this manual. Please consult your Öhlins
dealer if you have any questions regarding
the contents of this manual.
Spring pre-load adjustment:
Adjust the spring pre-load by turning the rings
on the cylinder house. Use a C-spanner.
Rebound damping adjustment:
Adjuster wheel on the piston shaft above the
end bracket.
Rebound
adjustment
Spring pre-load
adjustment
Adjustments
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NOTE!
When delivered the Öhlins shock absorber is
dialed to recommended settings for the spe-
cifi c brand and make of the snowmobile. If you
have changed the setting, reset according to
the following:
The adjusters have a normal right hand thread.
Turn clockwise to fully closed. Turn counter
clockwise to open and count the clicks until you
reach the recommended number.
CAUTION!
Do not use too much force, delicate sealing sur-
faces can be damaged. Do use fi ngers only.
+
-
Compression damping adjustment:
When you have installed the Öhlins shock
absorber according to this manual, a shock
absorber should appear on the display, when
the ignition key is turned on.
Press MODE on the speedometer unit
The display will change between showing grip
warmer level indicator and compression
damping level indicator.
Press MODE to activate compression damp-
ing level indicator:
Press “HI” on the left adjustment switch and
the compression damping level will increase.
Press “LO” and the compression damping level
will decrease.
There are 16 levels of compression damping.
Each bar on the display equals two damping
steps.
H
MODE
Compression damping
level indicator
HI
LO
Speedometer unit
Left adjustment
switch
Left side of the
handlebar
NOTE!
When the top or bottom segment of a level
indicator is reached, it fl ashes once.
When the engine is started, the rear suspension
compression damping levels are set to the levels
saved when the engine was stopped.
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 in-
side 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 instruc-
tions could result in severe or fatal
injury to anyone working with, inspect-
ing 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.
!
!
1 6
Raise the rear end of the snowmobile slightly,
until the drive track barely lifts off the ground. On
the running board, place a mark in line with the
rear axle. Measure the distance from the marking
on the running board to the ground (D1).
With a rider on the snowmobile, measure the
distance from the same mark on the running
board to the ground (D2).
Recommended rear ride height:
D1 - D2 = approximately 65 mm / 2.5 “
Adjust the ride height by changing spring pre-
load (see instructions below).
D1
D2
Recommended Rear Ride height
Shock absorber length 517.5 mm
Shock absorber stroke 151 mm
Spring rate 70 N/mm
Free spring length 290 mm
Spring pre-load 9 mm
Rebound damping adj. 20 clicks
Setup data
In line with the
rear axle
1
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.
Mounting instructions - step 1 - Removing the original shock absorber
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 begin, please consult your
Yamaha Work Shop Manual for dismantling
procedures.
Remove the two lower bolts of
the limiter strap.
1
3
Raise the rear end of the snowmobile so the
track is off the ground. Make sure the vehicle
is securely supported and will not fall over.
2
Loosen the two lower bolts of the limiter strap.
!
4
Turn the Remote Adjuster (RA) to Hardest.
6
Reinstall the plastic guide.
7
Loosen the front and rear attachment of the
original shock absorber and remove it from
the skid.
5
Remove the adjuster cable. To reach the cable,
loosen the two screws holding the plastic guide,
immediately behind the adjuster housing. Re-
move the cable from the adjuster housing (see
fi gure below).
NOTE!
Turn the adjuster to hardest damping force
before removing the adjuster cable.
8
Remove the collar from the original shock ab-
sorber. You will need it for the Öhlins shock
absorber.
collar
View from inside
adjuster cable
plastic guide
adjuster housing
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Remove the
two screws
25
1
Pull the sub-lead wire behind the radiator.
2
Loosen and gently fold out the radiator, without
disconnecting any hoses. Attach the sub-lead
wire to the chain housing with tie wraps around
the upper and the lower brackets. Attach the
wire so that it runs against the tunnel wall. See
fi gure below.
1
2
Mounting instructions - step 4 - Attach the EC-wire on the outside
3
5
grommet
4
Mounting instructions - step 2 - Install the Öhlins shock absorber
1
Connect the sub-lead wire to the EC wire on the
Öhlins shock absorber.
2
Attach the EC wire to the shock absorber with
a tie wrap.
Sub-lead wire
Part no. 8-GD-82509-00
EC wire
CAUTION!
Ensure the EC wire is thoroughly attached to
the shock absorber. This will reduce the fatigue
on the wire.
tie wrap
EC wire
Place the wire on this side of
the cylinder head.
NOTE!
Leave this area
clear!
Sub-lead
wire
Bend the
wire here
NOTE!
Lead the wire between the end
eye and the solenoid
3
Lead the wire behind the shift lever.
4
Attach the wire with a tie wrap.
5
Remove the connector plug and, plug in the
sub-lead wire to the connector.
5
Remove the
connector
plug
Plug in the
sub-lead wire
end eye
solenoid
2
tie wrap
chain housing
tie wrap
lower bracket
upper bracket
3 4
Mounting instructions - step 3 - Attach the EC wire to the swing arm
1
Attach the sub-lead wire to the swing arm with
the tie wraps provided in this kit. Start with the
two grommets on the wire (see fi gure).
NOTE!
It is important to attach the wire in the given
order. Start with the grommets and then attach
the wire along the swing arm as described.
2
Continue attaching the sub-lead wire with tie
wraps to the swing arm as indicated on the
fi gure.
3
Attach the grommet (part no. 90480-23001) to
the hole in the skid tunnel wall.
4
Lead the wire through the grommet out of the
tunnel.
CAUTION!
Make sure the threads on the limiter strap screws
are not facing toward the shock absorber, they
may cause damage to it. If the threads are
facing toward the shock absorber, change
their position so the threads are facing in the
opposite direction.
CAUTION!
If you need to change the position of the screws,
change position only of one screw at a time so
the limiter strap will keep holding the skid in
compressed position.
The threads away from the
shock absorber head
Limiter
strap
Shock
absorber head
1
2
sub-lead wire
Limiter strap
3
Shock
absorber
Swing arm
3
Attach the Öhlins shock absorber, using the
bolts from the original shock absorber. Reservoir
directed upwards and toward the front.
Also, use the collar from the original shock
absorber for the front attachment.
Reservoir
Limiter
strap
4
5
3
tie wraps
Skid tunnel wall
seen from inside the tunnel
Swing arm
5
Fold the clamp
Clamp, part no. 90465-06376-00
5
Attach the wire to the tunnel wall (steps 6 and 7
below). Use a clamp (Part no. 90465-06376-00),
folded as shown in the fi gure.
6
Drill a 5 mm (0.2 “) hole at the position indicated
in the fi gure below.
7
Attach the clamp with a blind rivet (part no.
90267-47195).
8
Reattach the limiter strap in its original posi-
tion.
NOTE!
See page 1, step 1: how to handle the limiter
strap in a safe way.
6
7
Steps 5 - 7
blind rivet
Skid tunnel wall
view from above
10 - 15 mm
0.4 - 0.6 “
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