Ohlins SD534 Mounting Kit SD v2.1 KTM/Husaberg Mounting Instruction
Ă–hlins SD534 steering damper enhances stability and improves your vehicle's handling, especially off-road. Adjust the damping levels to suit your riding style and terrain with the easy-to-use controls. This damper is designed specifically for motocross and enduro disciplines and is compatible with KTM EXC/SX and Husaberg FE/TE models.
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aDjuSTMENTS
Warning!
Before riding, always make sure that the basic settings made by Öhlins are according to recommended
Set-up Data. Read about adjustments and setting up in the Öhlins Owner’s Manual before you make any adjustments. Contact an Öhlins dealer if you have any questions about setting up the steering damper.
Decrease damping level
-
Increase damping level
+
DL Valve
Decrease damping back to centre
Increase damping back to centre
SET-up DaTa
Recommended set-up
Motocross:
DL Valve
RTC Valve
Enduro:
DL Valve
RTC Valve
12 clicks
6 clicks
12 clicks
8 clicks
+
RTC Valve
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, minor updates may occur.
To find the latest information contact your Öhlins distributor.
Please consult your Öhlins dealer if you have any questions regarding the contents in this document.
Part no. MI_SD534_0
Issued 2013-03-13
© Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited.
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
Note!
Please note that during storage and transportation, especially at high ambient temperature, some of the oil and grease used for assembly may leak and stain the packaging. This is in no way detrimental to the product, wipe off the excessive oil/grease with a cloth.
Note!
To be used together with SD 502.
Before installing this product, check the contents of the kit. If anything is missing, please contact an Öhlins dealer.
Kit Contents
Bracket
Washer
Screw
Pin
Washer
Screw
Screw
Nut
X-ring
Screw
Screw
Sleeve
Sleeve
Tool
Screw
Bracket
Plug
Washer
Part No. Pcs.
15550-55
00153-04
00432-11
15549-01
00153-04
00382-25
00382-31
00437-05
01027-09
01046-01
01046-06
01444-02
02238-01
04970-01
05404-05
15505-14
15507-02
15527-03
Mount. Block Steer. Damp 15532-01
Seal Washer 15551-05
Nut M20x1,5
Spacer
15552-15
15555-02
Cover
Warning!
15558-03 1
Before installing this product, read the Öhlins Owner’s
Manual. The steering damper is an important part of your vehicle and will affect the stability.
1
1
1
1
1
1
1
1
1
6
2
1
1
1
1
1
1
1
1
1
1
2
SD 502 Mounting Kit for KTM EXC/SX, Husaberg FE/TE
SD 534
Mounting Instructions
HoW To INSTall
Warning!
It is advisable to have an Öhlins dealer install the steering damper.
Warning!
When working, make sure the vehicle is securely supported so that it will not tip.
Warning!
Also see your Vehicle Service Manual for correct removing/installation procedures.
1
Pre-assemble the steering damper. Place nut and washer (15552-11(D), 15527-03 (C)) according to figure. Use grease on both sides of the washer (C).
2
Mount the bracket (15505-13 (B)) with the six screws (00382-25 (A)). Use thread locking fluid and tighten to 4 Nm.
A
2
1
B
C
D
4
5
Tower
Pin
1 +2 /
-0.5
mm
Washer
3
Put the motorcycle on a workstand. Remove the front fork and triple clamps. Remove original upper steering stem nut and washer (you will not need these parts to install the Öhlins steering damper).
4
To prevent difficult removal and remounting, perform a premounting and measuring procedure; Place the fork in a vice and mount the provided bracket, triple clamps and steering damper.
5
Measure the distance between the top of the tower and the pin with a slide gauge. This is just a first rough estimation of the distance.
Caution!
The gap between the tower and the pin must be 1 +2 /
-0,5 mm. The tower shall never touch the lower part of the pin at any position between the steering stops. There shall always be a visible gap. If washers are added/removed, retighten the tower to 11 Nm and use thread locking fluid.
1
HoW To INSTall
17
Tighten the slit screw to 20 Nm.
Note!
If the original screw interferes with the damper, replace the original screw with screw (05404-05) provided in this kit.
18
Use a torque wrench and tool 04970 01 (provided in this kit). Tighten the upper steering stem nut temporarily to 55 Nm. This will press down the pins into the triple clamp.
Note!
All threads on the upper steering stem nut will not be used, that is correct as long as the nut is tightened properly.
Minimum 4 [four] full turns engagement.
Rec:
19
First loosen the upper steering stem nut, then the slit screw. Retighten the upper steering stem nut to 10 Nm. Tighten the slit screw to
20 Nm. Continue tightening the upper steering stem nut to 20 Nm.
20
Again, measure the distance between the top of the tower and the pin to ensure that the gap is within the tolerance (1+2/-0,5mm).
21
Make sure that the steering stops work properly. Tighten the upper triple clamp bolt to recommended tightening torque.
Caution!
The damper should not act as a steering stop since that can damage and possibly break the steering damper.
22
Reinstall all removed parts in reversed order.
23
Install the centre lid by pressing it into the hex opening. Use an M6 screw and a pair of pliers if you must remove the lid.
17
18
23
Tool 04970-01
90º
Centre lid
Upper steering stem nut
Caution!
Do not try to remove the lid with a screwdriver, the lid may break!
6
HoW To INSTall
Note!
There are 3 different procedures (a, b and c) for steps
13-16 depending on vehicle model. Make sure to follow the correct instructions.
Type c
HuSaBERG FE/TE 2010-2011
Caution!
It is of critical importance that the damper is mounted in a straight line according to the figure. The two small pins will be pressed down into the upper triple clamp when the upper steering stem nut provided is tightened.
13c
Mount the damper in a straight line and tighten slightly. Use an 8 mm drill by hand to indicate the position of the hole.
14c
Remove the damper and make a punch mark.
15c
Drill a 5 mm hole. Use a thread tap (M6x1) to make the thread.
Note!
We recommend to use a thread tap when making the hole. If you do not have a thread tap; drill a 6,5mm hole through the triple clamp.
16c
Mount the damper. Do not tighten yet . Use provided screw (01046-01), sleeve (01444-02) in the threaded hole.
Use thread locking fluid
Tightening torque 15 Nm
For 6,5 mm hole;
Mount the screw (01046-06), sleeve
(01444-02) above the triple clamp and sleeve
(02238-01) below the triple clamp. Nut
(00437-05)
Tightening torque 15 Nm
→ Go to step 17
13c
16c
5 mm threaded hole : screw
01046-01 sleeve
01444-02
90º
Pin
14c
Pin
6,5 mm hole: screw
01046-06 sleeve
01444-02 sleeve
02238-01 nut
00437-05
5
6
If the distance is too large, use washers between pin and bracket.
Note!
The pins at the bottom of the steering damper have not been pressed into the triple clamp, which makes the distance 1mm larger.
7
Remove the steering damper and triple clamp.
8
Remove the outer ring of the upper steering head bearing. Remove the original dust seal on the bearing, if any.
9
Replace the outer ring with the bracket provided. The bracket must be press fitted into the steering head, use proper tools.
Caution!
The bracket must be installed in a straight line. Follow the sight line on the bracket, see figure.
9
Bracket
HoW To INSTall
10
Apply some grease on the x-ring and install it (do not twist it) in to the groove on the seal washer.
Put grease and install the original steering head bearing and the seal washer provided Flat side of the seal washer facing up. The provided seal washer replaces the original dust seal, if any.
10
Seal washer
X-ring
Steering head bearing
Bracket
Pin
Note!
On models with adjustable offset you may need to adjust the pin offset position, use tread lock and tighten the screw to 15 Nm.
Adjust pin offset position
Warning!
If the throttle cables interfere with the steering damper it may restrict handlebar operation. Rubbing on the steering damper body can cause excessive wear on the throttle cables.
To prevent this, install cover (15558-03) and two screws (00382-31) (provided in the kit).
Tightening torque 4 Nm
Caution!
Do not remove any other screws than the two indicated.
Remove
Cover installed
Remove Screw 00382-31
2
HoW To INSTall
11
Put some grease inside the tower to avoid noise that otherwise can occur.
12
Reinstall the triple clamps and fork legs.
Tighten the bolts on the lower triple clamp to recommended tightening torque according to the Vehicle Service Manual.
Note!
If the handlebar interferes with the steering damper, use spacer 15555-02 (provided in this kit) between the bottom part of the handle bar clamps and the upper triple clamp.
12
Spacer
Upper triple clamp
Note!
There are 3 different procedures (a, b and c) for steps
13-16 depending on vehicle model. Make sure to follow the correct instructions.
Type a
KTM SX 2010-2012
Caution!
It is of critical importance that the damper is mounted in a straight line according to the figure. The two small pins will be pressed down into the upper triple clamp when the upper steering stem nut provided is tightened.
13a
Install block with screw and sleeve according to figure.
Use thread locking fluid
Tightening torque 15 Nm
14a
Mount the damper. Do not tighten yet .
→ Go to step 17
13a screw
01046-01 sleeve
01444-02 block
15532-01
3
90º
Pin
Pin
HoW To INSTall
Note!
There are 3 different procedures (a, b and c) for steps
13-16 depending on vehicle model. Make sure to follow the correct instructions.
Type b
KTM EXC 2008-2012 SX 2008-
2009
Caution!
It is of critical importance that the damper is mounted in a straight line according to the figure. The two small pins will be pressed down into the upper triple clamp when the upper steering stem nut provided is tightened.
13b
Mount the damper in a straight line and tighten slightly. Use an 8 mm drill to indicate the position of the hole by hand.
14b
Remove the damper and make a punch mark.
15b
Drill a 5 mm hole. Use a thread tap (M6x1) to make the thread.
Note!
We recommend to use a thread tap when making the hole. If you do not have a thread tap; drill a 6,5 mm hole through the triple clamp.
16b
Mount the damper. Do not tighten yet . Use provided screw (01046-06), sleeve (02238-01) in the threaded hole.
Use thread locking fluid
Tightening torque 15 Nm
For 6,5mm hole;
Mount screw (01046-06), sleeve (02238-01) and the nut (00437-05).
Tightening torque 15 Nm
→ Go to step 17
13b
16b
5 mm threaded hole : screw
01046-06 sleeve
02238-01
90º
Pin
14b
Pin
6,5 mm hole: screw
01046-06 sleeve
02238-01 nut
00437-05
4

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