© Öhlins Racing AB. All rights reserved. Any re-
printing or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
Printed in Sweden.
Mounting Instructions SU638_2 Issued 2007 03 23
These instructions and other documents
can be downloaded from
www.ohlins.com
Mounting Instructions
Kit Contents:
Part no. Pcs.
Shock absorber SU638 1
Tie rap 00231-01 1
Screw MC6S 8x50 01046-25 1
Öhlins Sticker 00192-01 2
Memo Notes Sticker 01180-01 1
Owner’s Manual 07242-01 1
Before installing this shock absorber,
check the contents of the kit listed
below. If anything is missing, please
contact your nearest Öhlins dealer.
SHOCK ABSORBER SU638
for Suzuki GSXR1000
During storage and transportation,
especially at high ambient tempera-
ture, some of the oil and grease used
for assembling may leak and stain
the packaging. This is in no way det-
rimental to the product, wipe off the
excessive oil/grease with a cloth.
Before installing this product, read the Öhlins Owner’s Manual!
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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
WITH SET-UP DATA
Shock absorber length 316
+1
mm
Stroke 63 mm
Spring 21040-36
(105 N/mm)
Free spring length 160
0
mm
Set-up Data
Spring preload 12,5 mm
Compression 12 clicks
Rebound damping 12 clicks
-3
-3
ADJUSTMENTS
4
4
NOTE!
When delivered the Öhlins shock
absorber is dialed to the recommended
settings for the specifi c vehicle model.
If you have changed the setting, reset
according to the following:
The adjuster has a right hand thread.
Turn the adjuster clockwise to fully
closed (pos. zero [0]). Turn counter clock-
wise to open and count the clicks until
you reach the recommended number
(see Set-up Data).
CAUTION!
Do not use force, delicate sealing sur-
faces can be damaged. Handtighten only.
Length Adjustment
We advise to remove the shock absorber
from the vehicle before adjusting the
length. Use two 24 mm wrenches. Hold
the upper nut with one hand and at the
same time loosen the lock nut (lower nut).
Turn the end eye/bracket to the desired
length. Tightening torque 40 Nm.
WARNING!
Remember to lock the lock nut after
adjusting the length.
WARNING!
The adjustable end eye/bracket must
not be threaded out more than that
the groove is fully visible beneath the
lock nut. This is maximum length. After
adjusting, make sure that the lock nut is
tightened.
HOW TO INSTALL
1
Put the motorcycle on a workstand so that the
rear wheel barely touches the ground.
WARNING!
Make sure the vehicle is securely supported so
that it will not tip.
2
Remove the right side exhaust guard.
3
Remove the upper screw of the link (A). Re-
move the front screw (B), and loosen the rear
screw of the link arm (C).
4
Push the link and the link arm backwards so
that you can remove the rear screw of the link
arm (C).
WARNING!
It is advisable to have an Öhlins dealer install the
shock absorber.
5
Remove the upper screw of the original shock
absorber. Remove the shock absorber and
the link, remove the whole unit above the rear
wheel.
NOTE!
Recommendation! Before installing the Öhlins
shock absorber:
• clean the vehicle thoroughly
• adjust the length of the shock absorber (check
the headlight angle after adjusting the length!)
6
Attach the Öhlins shock absorber to the link.
Install the Öhlins shock absorber and the link
in the same way as the original unit. Use the
original screws.
NOTE!
Lower the motorcycle so that the shock absorber
is sligthly compressed, before tightening the
screws.
7
Install the hydraulic preload adjuster to the foot
rest bracket according to the fi gure. Use the
screw provided in this kit, use the original nut.
Fasten the hose to the frame with the tie-rap
provided in this kit.
1
Remove (C)
3
View from the left
CAUTION!
The brake hose must not be stretched. It can
be damaged. Support the swing arm once the
lower screw of the shock absorber is removed.
Remove (A)
Remove (B)
4
2
8
Reinstall the right side exhaust guard. Make
sure that all removed parts are installed in the
same way as they were before the installation.
WARNING!
Make sure that all screws are tightened to the
correct torque and that nothing fouls or restricts
movement of the shock absorber when the sus-
pension is fully compressed or extended.
Silencer
Rear foot rest
bracket
7
Replace this
screw
Tie-rap
ADJUSTMENTS
1
2
Spring Preload
Turn the hydraulic adjuster knob to set
the spring preload. Turn clockwise to
increase the preload and turn counter
clockwise to decrease.
Compression Damping
Adjust by turning the gold knob labelled
“COMP” on the cylinder head. Or, use
a 14 mm socket T-bar and turn the
hexagon nut on the adjuster knob. Turn
clockwise to increase damping, turn
counter clockwise to decrease.
Rebound Damping
Adjust by turning the black knob labelled
“REB” on the cylinder head. Or, use a 14
mm socket T-bar and turn the hexagon
nut on the adjuster knob. Turn clockwise
to increase damping, turn counter clock-
wise to decrease.
Continue on the next page
C
O
M
P
R
E
B
C
O
M
P
R
E
B
1
C
O
M
P
R
E
B
2
3
2
3
Before riding, always ensure that the basic set-
tings made by Öhlins are intact.
3
-
1
-
2
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