OHLINS S36D Twin Rear Suspension for W650

Introduction

This instruction manual provides essential information for the proper installation, adjustment, and maintenance of your OHLINS S36D Twin Rear Suspension for the Kawasaki W650 motorcycle. Please read this manual thoroughly before installation and use to ensure optimal performance and safety.

Please note that product images are for illustration purposes only. Actual product appearance may vary slightly due to manufacturer specification changes.

Safety Information

• Installation should be performed by a qualified mechanic or an individual with appropriate experience in motorcycle suspension systems.
• Always use appropriate tools and follow torque specifications for all fasteners.
• Ensure the motorcycle is securely supported on a stand before beginning any work.
• Important Note: Chain case modification is required for proper fitment of this suspension system on the Kawasaki W650. Failure to perform this modification may result in damage or unsafe operation.
• Regularly inspect the suspension for any signs of wear, damage, or leaks.
• Do not attempt to disassemble the shock absorber unit. It contains high-pressure gas and oil.

Package Contents

Verify that all components are present before beginning installation:

• OHLINS S36D Twin Rear Shock Absorbers (2 units)
• Mounting hardware (if included by manufacturer)
• This instruction manual

Image: Two OHLINS S36D Twin Rear Suspension units, featuring black springs and silver bodies, ready for installation.

Setup and Installation

The following steps outline the general procedure for installing the OHLINS S36D Twin Rear Suspension. Specific torque values and detailed steps may vary; always refer to your motorcycle's service manual for precise instructions.

1. Prepare the Motorcycle: Securely place the motorcycle on a suitable stand, ensuring the rear wheel is off the ground and the motorcycle is stable.
2. Remove Original Shocks: Carefully remove the original rear shock absorbers by unbolting the upper and lower mounting points. Retain any original hardware that may be reused.
3. Perform Chain Case Modification: As noted in the safety section, the chain case on the Kawasaki W650 requires modification to accommodate the OHLINS S36D shocks. This typically involves trimming or reshaping a portion of the chain case for clearance. This step is critical and must be completed before proceeding.
4. Install OHLINS Shocks: Mount the OHLINS S36D shocks, ensuring the upper and lower mounting eyes are correctly aligned. Install the bolts and tighten them to the torque specifications provided in your motorcycle's service manual.
5. Final Inspection: Once installed, check for proper clearance around all moving parts, especially the modified chain case area. Ensure all bolts are securely tightened.

Image: An angled view of the OHLINS S36D Twin Rear Suspension, highlighting the spring and body design.

Operating and Adjustment

The OHLINS S36D Twin Rear Suspension features a stepless screw-type preload adjustment. It does not include external adjustment for extension or compression damping.

Preload Adjustment

Preload adjustment allows you to set the initial compression of the spring, which affects the ride height and sag of the motorcycle. This is crucial for matching the suspension to the rider's weight and riding style.

1. Locate the Adjuster: The preload adjuster is typically a threaded collar located at the top or bottom of the spring.
2. Adjust Preload: Use the appropriate tool (often a C-spanner) to turn the threaded collar.
   • Turning the collar clockwise (compressing the spring) increases preload, raising the ride height and making the suspension firmer.
   • Turning the collar counter-clockwise (decompressing the spring) decreases preload, lowering the ride height and making the suspension softer.
3. Ensure Even Adjustment: Adjust both left and right shock absorbers equally to maintain balanced handling.
4. Check Sag: After adjustment, measure the static sag and rider sag to ensure they are within recommended values for your motorcycle and riding preferences. Consult your motorcycle's service manual or an OHLINS dealer for recommended sag settings.

Maintenance

Proper maintenance ensures the longevity and consistent performance of your OHLINS S36D Twin Rear Suspension.

• Regular Cleaning: Keep the shock absorbers clean from dirt, dust, and road grime. Use mild soap and water, then rinse thoroughly and dry. Avoid high-pressure washers directly on seals.
• Inspection: Periodically inspect the shocks for:
  • Oil leaks around the seals.
  • Damage to the spring, body, or mounting points.
  • Loose fasteners.
  • Corrosion.
• Professional Servicing: OHLINS shock absorbers are precision components. For internal servicing, re-valving, or seal replacement, always consult an authorized OHLINS service center. Do not attempt to disassemble the shock yourself.

Troubleshooting

If you experience issues with your OHLINS S36D Twin Rear Suspension, consider the following common problems and solutions:

Specifications

Warranty and Support

Specific warranty terms and conditions for OHLINS products vary by region and retailer. Please retain your proof of purchase and contact the authorized OHLINS dealer or the point of purchase for detailed warranty information and support services.

For technical assistance or professional servicing, it is recommended to contact an authorized OHLINS service center.