Mounting Instructions
Öhlins Steering Damper Bracket Kit SD 442
for Yamaha YZ 2004–2005 and YA WR 2005
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the
written permission of Öhlins Racing AB is prohibited. Printed in Sweden.
Upper handlebar clamp
Pin
(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 442. Issued 04 09 30
4
Install the one-piece upper handlebar mount pro-
vided. Tighten the bolts evenly to allow fine ad-
justment later.
7
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.
5
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.
6
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
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 04561-02
Screw MC6S 6x22 2 01046-05
Screw MC6S 5x16 4 01046-18
Adjustment shaft (pin) 1 04563-01
Link arm 1 04032-01
Handlebar clamp 1 04301-08
Sticker Öhlins 2 00197-01
3
Mounting instructions
Steering damper link arm
A
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
1
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.
2
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.
B
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.
2
Tool
4956-01
Steering
damper
SD 415
SD 425
Link arm
4032-01
Tool
4955-01
Nut
3
Fit the tower to the steering head by use of the
front and the rear brackets. Do not tighten yet.
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