Ohlins SD444 Mounting Instruction

Brand: Ohlins

Model: SD444

Category: Car kits

Type: Mounting Instruction

Mounting Instructions

Öhlins Steering Damper Bracket Kit SD 444

for KTM SX, EXC

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

Upper handlebar clamp

(adjustment

shaft)

Tower

Link arm

Front bracker

Rear bracket

Öhlins steering damper bracket

kit fitted to the motorcycle

Steering damper bracket kit

This Öhlins steering damper kit for MX, Enduro

and SuperMotard is especially designed to fit the

brand and model you are running. The kit con-

sists of steering stem brackets, a tower , upper

handlebar clamps and a steering damper link

arm. Everything is to be fitted together with the

Öhlins steering damper SD415 (two-way damp-

ing) or SD425 (compression damping only).

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

SD 444. Issued 04 07 06

Install the one-piece upper handlebar mount pro-

vided. Tighten the bolts evenly to allow fine ad-

justment later.

Tighten the tower bolts to 6.5 Nm and the han-

dlebar clamps to 22-25 Nm or according to the

Owners Manual of the motorcycle.

CAUTION!

Make certain that the steering stops are working

properly. If the damper acts as a stopper it can

be damaged.

NOTE!

Make sure that all bolts are tightened to the cor-

rect torgue and that nothing fouls or restricts the

handlebar when beeing turned to each side.

When testing, the damper adjuster must be in

soft damping position).

CAUTION!

It is of vital importance that the centre of the steer-

ing damper mounting bolts are aligned with the

centre of the steering stem. If the lower handle-

bar brackets are reversible the brackets must be

positioned according to this.

Install the damper to the new handlebar mount.

Use the two Allen bolts provided. Tighten to 8 –

10 Nm.

NOTE!

If the damper does not fit between the main bar

and the crossbar, bow or bend the crossbar slightly

to allow clearance. Minimum 40 mm is required.

With the damper fitted and the handlebar bolts

evenly seated, position the tower tower so the

steering pin top extracts at least 0.5 mm above

the damper link arm. It is even possible to adjust

the damper position by using the four bolts hold-

ing the handlebar clamps. If the front bolts are

tightened and the rear bolts are slackened the

distance to the tower is decreased and vice versa.

CAUTION!

When installed the tower pin must reach 0.5 mm

above the upper surface of the link arm. This is

especially important when the lower handlebar

clamps are rubber mounted and the handlebar

is allowed to flex downwards. If the link arm

touches the frame the damper can be damaged.

≥0.5 mm

KTM motorcycles only:

Loosen and remove the upper triple clamp and

change the steering head cap (washer) with the

cap provided.

Refit the triple clamp and change the steering

stem lock screw with the screw (M6S 8x35) pro-

vided.

Continue your work according to instruction #2

and so on.

Steering stem

lock screw

5404-05

Washer

4564-01

Before installation

Öhlins Racing AB can not be held responsible for

any damage whatsoever to steering damper or

vehicle, or injury to persons, if the instructions for

fitting and maintenance are not followed exactly.

Similarly, the warranty will become null and void

if the instructions are not adhered to.

WARNING!

1. Installing a steering damper, 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 whatsoever

that may occur after fitting the steering

damper. Contact an Öhlins dealer or other

qualified person for advice.

2. Please study and make certain that you

fully understand all the mounting instructions

and the owners manuals before handling this

steering damper kit. If you have any ques-

tions regarding proper installation proce-

dures, contact an Öhlins dealer or other quali-

fied person.

3. The vehicle service manual must be referred

to when installing the Öhlins steering damper.

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.

CAUTION!

Caution indicates that special pre-

cautions must be taken to avoid dam-

age to the suspension.

NOTE!

This indicates information that is of

importance with regard to procedures.

Öhlins products are subject to continual improve-

ment and development. Consequently, although

these instructions include the most up-to-date

information available at the time of printing, there

may be minor differences between your suspen-

sion and this manual. Please consult your Öhlins

dealer if you have any questions with regard to

the contents of the manual.

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

steering damper.

WARNING!

When installing the The Öhlins tower the motor-

cycle workshop manual must be at hand.

WARNING!

Certain modifications can be necessary to install

the tower. It is vital that the mounting instructions

are carefully followed.

Kit contents

Before installing the steering damper, please

check the contents of the kit. If anything is

missing, contact your Öhlins dealer.

Description Pcs. Part No.

Tower 1 04562-02

Bracket 1 04561-03

Screw MC6S 6x22 2 01046-05

Screw MC6S 5x16 4 01046-18

Screw K6S M8x35 1 05404-05

Adjustment shaft (pin) 1 04563-01

Link arm 1 04032-01

Handlebar clamp 1 04352-03

Washer 1 04564-01

Sticker Öhlins 2 00197-01

Mounting instructions

Steering damper link arm

The link arm is to be attached to the steering

damper wing assembly. Use socket tool 4956-

01 or a 10 mm socket to prevent the stem from

moving upwards and socket tool 4955-01 or a

15 mm socket to press the link arm onto the

damper wing stem.

Mounting instructions

Steering damper bracket kit

Remove the original upper handlebar mounting

clamps and the number plate (and front light on

enduro motorcycles).

NOTE!

KTM motorcycles must have the top cap of the

steering head changed, see instructions below.

Fit the tower to the rear steering head bracket.

Use Loctite 222 or similar to the bolts before tight-

ening. Tighten to a torque of 6.5 Nm. Applt Loctite

222 to the pin and install it into the tower.

Tower 4562-02

Pin (adjustment shaft) 4563-01

Steering

head

brackets

4561-03

CAUTION!

It is of vital importance that the link arm is not

pressed onto the steering damper without a

holder up. Delicate sealing surfaces can be dam-

aged.

Fix the link arm into a vice and and fit the nut.

Use Loctite 222 or similar and tighten to a torque

of 15 Nm.

Tool

4956-01

Steering

damper

SD 415

SD 425

Link arm

4032-01

Tool

4955-01

Nut

Fit the tower to the steering head by use of the

front and the rear brackets. Do not tighten yet.

Ohlins SD444 Mounting Instruction

Brand: Ohlins

Model: SD444

Category: Car kits

Type: Mounting Instruction

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Ohlins SD444 Mounting Instruction

Ohlins SD444 Mounting Instruction

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