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 574, issued 2006 01 30
Mounting Instructions
Öhlins shock absorber kit YA 576
for Yamaha YFZ 450 - front
© 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.
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.
Shock absorber 36PRXQW YA 576 (1 pair)
Spring clip for springs 46 00116-03 (2)
C-spanner twin 00710-01 (2)
Sticker “ÖHLINS” 00197-01 (2)
Sticker “Memo notes” 01180-01 (1)
Öhlins Owners manual ATV shocks
NOTE!
No springs included. See Spring recom-
mendations in this manual. Consult your
Öhlins dealer for advice.
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
-
-
+
+
Compression damping adjuster
Adjustments are made on top of the
reservoir.
Low speed adjuster: Slotted centre
screw.
High speed adjuster: Hexagon screw.
Rebound damping adjuster
Adjust by turning the adjuster wheel
above the end eye.
Spring pre-load adjuster
Adjust by moving the upper spring seat
circlip to another groove.
Short spring stroke adjuster
The total spring characteristics can be
adjusted by moving the spring platform
nuts on the fl oating sleeve. The spring
platform position decides when the stroke
for the short spring is blocked. At this point,
the total spring stiffness will increase on
compression stroke.
Use the C-spanner provided in this kit.
Turn the spring platform nut (4a) clock-
wise to set the short spring stroke. Lock
the setting with the lock nut (4b).
Low speed
compression
adjustment
High speed
compression
adjustment
Adjustments
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.
CAUTION!
Do not use too much force, delicate sealing
surfaces can be damaged. Handtighten only.
1
2
3
4
4
3
2
1
Read more about the shock absorber and
the different adjustments in your Öhlins
Owners Manual.
4a
4b
25
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.
!
Step 1 - Installing the springs
NOTE!
Before installing the shock absorbers on
the vehicle you need to install the correct
springs. See spring recommendations in
this manual.
Circlip 00131-01
Washer 00115-01
Short spring
Spring platform
00154-02
Circlip 00428-01
Long spring
Spring clip
00116-03
Two springs
The shock absorbers have two springs work-
ing in series. When both springs are moving,
the total spring stiffness is lower than for
each spring separately, which provides
extra progressive and adjustable spring
characteristics.
Between the springs an adjustable slid-
ing platform adjusts the short spring stroke.
Altering the stroke is a very effective way
of adjusting the spring stiffness without
changing the springs.
Sleeve 03281-01
Groove no.1
Spring position 1
1
Remove the Circlips, Washer, Sleeve, Spring
platforms and Support sleeve.
2
Install the short spring, the long spring and
all the other parts according to the fi gure. Set
spring positions 1 and 2 according to the fi g-
ures below.
See Setup Data in this manual for the recom-
mended position of the Circlip 00131-01.
Circlip
00131-01
Spring position 2
See Setup Data in this manual for the recom-
mended position of the upper Spring platform
00154-02.
Spring platform
00154-02
General facts
Shock absorber length 450 mm
Stroke 124 mm
Recommended settings
Compression damping
Low speed 15 clicks
High speed 2 turns
Rebound Damping Adj 20 clicks
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 “
Spring positions
Spring position 1 10th groove
Spring position 2 38 mm
Total spring pre-load 7 mm
Setup Data
Rider's weight
A
-arm: Long travel Leager +
2
75kg/ 165 lbs Long spring 0480-16
Spring rate Prog 25-33.5 N/mm
Short spring 4060-40
Spring rate 40 N/mm
85kg/ 187 lbs Long spring 0180-72
Spring rate Prog 27.5-39
Short spring 4060-40
Spring rate 40 N/mm
95kg/ 209 lbs Long spring 0180-23
Spring rate 31 N/mm
Short spring 4060-40
Spring rate 40 N/mm
Spring recommendation
Support sleeve
00417-01
x mm
Use the
C-spanner
provided in
this kit!
Use
appropriate
tool!
Circlip 00428-01
3 4
1
Raise the front end of the vehicle so that the
original shock absorbers are in a neutral posi-
tion.
2
Remove the original shock absorbers.
3
Install the Öhlins shock absorbers in the same
positions as the original units. Fasten the upper
attachment fi rst. The piggy back reservoirs
should be at the top and facing outwards.
4
Fasten the lower attachment. Raise or lower the
wheels slightly to make the attachment fi t.
5
Tighten the attachment screws to the correct
torque. Consult your ATV Owners manual.
6
Check sag and ride height according to the Öh-
lins owners manual. See also Set-up data for this
specifi c shock absorber kit on the next page.
NOTE!
Make sure that all screws are tightened to the
correct torque and that nothing fouls or re-
stricts movement of the shock absorber when
the suspension is being fully compressed or
extended.
Step 2 - Installing the Öhlins shock absorbers
1
3
!
Before installing the shock absorbers, make
sure the correct springs are installed.
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.
4
!
Mounting Instructions
Front suspension
F1 ATV on a stand with the
suspension fully extended = ...............
F2 ATV on the ground without rider = ............
F3 ATV on the ground with rider = ............
Free sag F1 - F2 = .................
Ride height F1 - F3 = .................
F1
F2
F3
R1
R2
R3
On a stand Without rider With rider on
On a stand Without rider With rider on
Check sag and ride height
Rear suspension
R1 Bike on a stand with the
suspension fully extended = ...............
R2 Bike on the ground without rider = ............
R3 Bike on the ground with rider = ............
Free sag R1 - R2 = ...............
Ride height R1 - R3 = ...............
Read more about sag and ride height in
your Öhlins Owner’s manual.
Free sag
(F1-F2)
Ride height
(F1-F3)
Date
Front
Rear
Free sag
(R1-R2)
Ride height
(R1-R3)
Date
Notes
/