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Mounting Instructionshlins shock absorber kit

AP 351 for Aprilia RSV-R 2004

hlins Racing AB. All rights reserved. Any reprinting or unauthorized use without thewritten permission of hlins Racing AB is prohibited. Printed in Sweden.

hlins shock absorber 46 PRCLSYour hlins shock absorber type 46 PRCLS

features the following adjusters:

Compression damping adjuster

Adjustments are made on top of the reservoir.

Rebound damping adjuster

Adjuster wheel on the piston shaft above the endbracket.

Spring preload adjuster

Adjustments are made by turning the knob onthe hydraulic adjuster. Clockwise for harderadjustment, counter clockwise too release thepreload.

Lenght adjuster

Adjustment is made by turning the end eye andtightening with the lock nut.

NOTE!

When delivered the hlins shock absorber isdialed to recommended settings for the specificbrand and make of the motorcycle. If you havechanged the settings, check like this:

The adjusters have a normal right hand thread. Turnthe damping adjusters clockwise to fully closed (pos.zero [0]). Turn counter clockwise to open and countthe clicks until you reach the recommended number

of clicks. See Setup data at last page.

CAUTION!

Do not use too much force, delicate sealing sur-faces can be damaged.

Spring

preload

adjuster

Rebound

damping

adjuster

Lenght

adjuster

hlins Racing AB, Box 722, S-194 27 Upplands Vsby, Sweden.Phone +46 8 590 025 00. Fax +46 8 590 025 80.

www.ohlins.com

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Setup data

Shock absorber length 313(+3.5/-2.5)mmShock absorber stroke 63mmSpring preload 15 mmRebound damping adjuster 20 clicksCompression damping adj. 12 clicks

Checking sag and ride height

Front suspensionF1. Bike on a stand with the

suspension ful ly extended = ... .. .. .. .. .

F2. Bike on the ground without rider = ............

F3.Bike on the ground with rider = ............

Free sag F1 - F2 = ............

Ride height F1 - F3 = ............

Rear suspension

R1.Bike on a stand with thesuspension ful ly extended = ... .. .. .. .. .

R2.Bike on the ground without rider = ........... .

R3.Bike on the ground with rider = ............

Free sag R1 - R2 = ............

Ride height R1 - R3 = ............

WARNING!If the shock absorber has an ad-justable end eye/bracket, thismust not be treaded out morethan that one groove is fully vis-ible beneath the lock nut. Makesure that the lock nut is tight-ened after adjustment.

Groove

Bike on a stand.

F1

R1

Bike on the ground.

F2

R2

Bike with rider on.

F3

R3

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Before installationhlins Racing AB can not be held responsible forany damage whatsoever to shock absorber orvehicle, or injury to persons, if the instructions forfitting and maintenance are not followed exactly.

Similarly, the warranty will become null and voidif the instructions are not adhered to.

WARNING!1. Installing a shock absorber, that is notapproved by the vehicle manufacturer, mayaect the stability of your vehicle. hlinsRacing AB cannot be held responsible forany personal injury or damage whatsoeverthat may occur after tting the shockabsorber. Contact an hlins dealer or otherqualied person for advice.

2. Please study and make certain that youfully understand all the mounting instructionsand the owners manuals before handling thisshock absorber kit. If you have any questionsregarding proper installation procedures,contact an hlins dealer or other qualiedperson.

3. The vehicle service manual must be referredto when installing the hlins shock absorber

Safety signalsImportant information concerning safety isdistinguished in this manual by thefollowing notations:

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injuryto anyone working with, inspecting orusing 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 ofimportance with regard to procedures.

hlins products are subject to continual improve-ment and development. Consequently, althoughthese instructions include the most up-to-dateinformation available at the time of printing, theremay be minor differences between your suspen-sion and this manual. Please consult your hlinsdealer if you have any questions with regard tothe contents of the manual.

NOTE!During storage and transportation, especiallyat high ambient temperature, the oil and

grease used for assembling may run outinside the packing and damage the expandedpolystyrene packing material. This is notunusual and is in no way detrimental to theshock absorber.

Kit contents

Before installing the shock absorber, pleasecheck the contents of the kit. If anything ismissing, contact your hlins dealer.

Description Pcs. Part No.

Shock absorber 46 PRXLS 1 AP 351Tie-rap 2 00231-01Sticker memo notes 1 01180-01

Sticker hlins 2 00192-01Owners manual 1

WARNING!

1. Its advisable to have an hlins dealer or otherqualified person to fit your shock absorber.2. Instructions in the vehicle service manual are

to be followed when changing the shockabsorber.3. When working on a lifted vehicle it must besecurely supported to prevent it from falling.

Mounting instructions

1

Put the motorcycle on a stand so the rear wheelis clear of the ground. Make sure its steadily fixedso it will not fall over.

NOTE!

Make sure that all bolts are tightened to the correcttorque and that nothing fouls or restricts movementof the shock absorber when the suspension isbeing fully compressed or extended.

2

Loosen first the lower and than the upper boltsof the original shock absorber and remove them.The absorber is removed by lifting it upwards andout at any side of the bike.

3

Fit the hlins shock absorber in reverse order.The piggyback towards the wheel. Fasten it byusing the two original bolts.

4

Attach the hydraulic preload adjuster to the wheelside of the right silencer bracket by using theoriginal bolt

5

Fit the hose on the backside of the silencerbracket on the right side of the motorcycle. Tieup the hose by putting the tie rap around thebracket behind the front upper bolt.

NOTE!

Make sure that all bolts are tightened to the cor-rect torque and that nothing fouls the shock ab-sorber when the suspension is being com-pressed. See: Motorcycle workshop manual.

Check with the Service Manual of the motorbike.

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Continue your work according to the OwnersManual, section Adjustments

This particular model has an adjustable end eye/bracket. The eye/bracket must not be treated outmore than that one groove is fully visible beneaththe lock nut. Make sure that the lock nut is tight-ened after adjustment

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