Before Installing
Öhlins Racing AB cannot be held respon-
sible 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.
Kit Contents
Before installing the shock absorber, check
the contents of the kit. If anything is miss-
ing, please contact your Öhlins dealer.
Art.No. (Pcs)
Shock absorber 46PRX YA 684 (1)
C-spanner 00710-02 (1)
Öhlins Sticker 00197-01 (2)
Memo Notes Sticker 01180-01 (1)
Öhlins Owner’s Manual (1)
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
Mounting Instructions YA 684 - Issued 2006 06 01
© Öhlins Racing AB. All rights r
eserved. Any reprinting or
unauthorized use without the written permission of Öhlins
Racing AB is prohibited. Printed in Sweden.
Mounting Instructions
Öhlins shock absorber kit YA 684
for Yamaha YFZ 450 - rear
In this manual
Safety precautions
Mounting instructions
Setup Data
Adjustments
ADJUSTMENTS
Spring pre-load
Use the C-spanner provided in this kit.
Turn the spring platform nut (1a) clock-
wise to increase the spring preload. Turn
counter clockwise to decrease it. Lock the
setting with the lock nut (1b).
Compression damping:
Adjustments are made on top of the
reservoir.
Low speed: Slotted centre screw.
High speed: Hexagon screw.
Rebound damping:
Adjust by turning the wheel on the piston
shaft above the end bracket.
Low speed
compression
adjustment
High speed
compression
adjustment
-
-
+
+
NOTE!
When delivered the Öhlins shock absorber
is dialed to recommended settings for the
specifi c brand and make of the vehicle. 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. See Setup
data in this manual.
1
2
3
1
3
2
1b
1a
SET-UP DATA
General data
Shock absorber length 480 mm
Stroke 127 mm
Recommended settings
Compression damping
Low speed 15 clicks
High speed 1 turn
Rebound damping 25 clicks
Spring preload 15 mm
Recommended Free sag
Front 60 ± 5 mm
2½ ± ¼ “
Rear 30 ± 5 mm
1 ¼ ± ¼ “
Recommended Ride height
Front 80 ± 5 mm
3 ¼ ± ¼ “
Rear 105 ± 5 mm
4½ ± ¼ “
CAUTION!
Do not use force, delicate sealing surfaces
can be damaged. Handtighten only.
SAFETY PRECAUTIONS
Read this manual carefully!
Pay special attention to statements pro-
ceded by the following notations:
The Safety alert symbol means: Attention!
Your safety is involved!
Failure to follow these warning instructions
may result in severe or fatal injury to any-
one working with, inspecting or using this
shock absorber, or to bystanders.
Caution indicates that special precautions
must be taken to avoid damage to the
shock absorber.
Indicates information that is of importance
regarding mounting procedures.
!
WARNING
CAUTION!
NOTE!
WARNING!
1. Installing a shock absorber, that is not
approved by the vehicle manufacturer,
may affect the vehicle’s stability. Öhlins
Racing AB cannot be held responsible for
any personal injury or damage that may oc-
cur after fi tting the shock absorber.
2. The vehicle service manual must be
referred to when installing this shock
absorber.
3. Please study and make certain you fully
understand the mounting instructions and
the owner’s manual before handling this
shock absorber. If you have any questions
regarding proper installation procedures,
contact an Öhlins dealer.
!
!
NOTE!
During storage and transportation, espe-
cially 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.
NOTE!
Öhlins products are subject to continuous
improvement and development. Therefore,
although these instructions include the most
up-to-date information available at the time of
printing, there may be minor differences be-
tween your shock absorber and this manual.
Please consult your Öhlins dealer if you have
any questions regarding the contents of this
manual.
1
Your vehicle OEM
Owners Manual
MOUNTING INSTRUCTIONS
1
Remove the seat.
2
Raise the rear end of the vehicle so that the
original shock absorber is in an unloaded
position.
CAUTION!
Do not apply lifting force to the swing arm.
Make sure the vehicle is securely supported
so that it will not fall over.
3
Remove the original shock absorber.
NOTE!
Remove the lower bolt of the triangle link so
that the lower bolt of the shock absorber can
be removed.
4
Install the Öhlins shock absorber in the same
position as the original unit. Fasten the upper
attachment fi rst.
NOTE!
The piggy back reservoir should be at the top,
towards the rear and slightly to the right.
5
Fasten the lower attachment. Raise the
wheels slightly to make the attachment fi t.
Reattach the triangle link!
6
Tighten the attachment screws to the correct
torque. Consult your ATV Owners manual.
7
Check sag and ride height according to the
Öhlins Owner’s manual. See also Set-up data
for this specifi c shock absorber kit on the next
page.
NOTE!
Make sure that all bolts are tightened to
the correct torque and that nothing fouls or
restricts movement of the shock absorber
when the suspension is being fully com-
pressed or extended.
2
CAUTION!
WARNING!
1. It is advisable to have an Öhlins dealer 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
tipping over.
!
1
3
Remove
bolt
Fold out
the arm
Triangle link
!
4
3
5
reservoir
-
1
-
2
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