General Info About Ohlins Dampers - Motorsports Spares International
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1. Fig 8 i e number thickness diameter the characteristics of the damping action can be changed This should only be done by an authorized Ohlins service workshop DAO oO oO Compression damping When movement of the vehicle causes compression of the shock absorber the fluid flows through the needle valve combined compression and rebound valve in the piston rod If the velocity of the compression movement is high i e in the case of rapid compression this will not be sufficient and consequently the shims underneath the piston will open to allow for a greater rate of flow The fluid that is displaced by the volume of the piston rod is forced into the external reservoir via a separate compression valve The separating piston is displaced thus increasing the gas pressure Rebound damping When the spring forces the shock absorber to extend again the fluid flows back through the needle valve The fluid flowing into the chamber is forced by the pressure of the gas back into the shock absorber via a separate one way valve If the piston velocity is high the shims on top of the piston will also open to allow the fluid to flow through Stop washer Shim stack Compression A Warning Before driving your vehicle make sure that the basic settings made by hlins are intact By using the adjustment possibilities you can test by trial and error and learn how they work Always begin2. 5 The oil flow is controlled by the base plate before it reaches the dividing piston The fluid is pressurized by nitrogen N The pressurisation prevents cavitation of the fluid and the shock absorbing action is therefore more even The external reservoir also contributes to better cooling of the fluid giving longer service life for the fluid as well as the components N Separating Piston Fluid Ohlins shock absorbers with external rebound adjustment have an integrated temperature compensation As the temperature increases and the fluid flows more easily the flow is controlled accordingly The shock absorbing effect is therefore independent of the temperature The more advanced models permit individual adjustment of compression and rebound damping hlins shock absorbers provide the possibility of adjustment making them adaptable to most vehicles drivers and ranges of use All of the shock absorbers with springs have adjustable preload of the spring action Fluid is forced through needle valves at a low rate of flow Fig 6 and through a number of orifices in the piston Fig 7 at a high rate of flow The flow through these orifices is regulated by shims thin steel washers that at high pressure are deflected to open for the fluid On most models the needle valve can be adjusted from the outside By altering the size of the shim stack
3. Basic_Information Ohlins Shock Absorber Owner s Manual hlins Racing AB The Story It was the 1970 s a young man named Kenth hlin spent most of his spare time pursuing his favourite sport motocross A careful observer Kenth s attention was continually drawn to one specific detail motocross bikes had more engine power than their suspension could handle It was not long before Kenth realised that better performance could be achieved by improved wheel suspension Ohlins Racing was established in 1976 and just two years later the company won its first World Championship title Despite being in the business for 30 years the search for perfection and new functions is still the main focus of the company Congratulations You are now the owner of an Ohlins Shock Absorber More than one hundred World Championships and other major world titles are definitive proof that Ohlins shock absorbers offer outstanding performance and reliability Every product has gone through rigorous testing and engineers have spent thousands of hours doing their very best to use every possible experience from our 30 years within the racing sport The product that you now have in your possession is pure racing breed that is built to withstand By installing this shock absorber on your vehicle you have made a clear statement you are a serious rider with a focus on getting the maximal handling ability and
4. by taking a test ride with all adjustments at their basic setting Choose a short run with varying character long and sharp bends hard and soft bumps Stay on this run and adjust only one setting at a time Start with Rebound Damping If the vehicle feels unstable loose and rather bouncy increase the rebound damping Turn the adjuster knob 4 clicks steps clockwise Test run again and adjust two clicks counter clockwise if it feels too hard and bumpy If the vehicle feels hard and bumpy especially over a series of bumps reduce the rebound damping Turn the adjuster knob counter clockwise 4 clicks take a test run and if necessary adjust 2 clicks clockwise Compression Damping If the vehicle feels soft has a low riding position and a tendency to bottom easily in long dips increase the compression damping Turn the adjuster 4 steps take a test run If necessary adjust 2 clicks counter clockwise If the vehicle feels harsh and has hard resilience for example over changes in the road paving reduce the compression damping Turn the adjuster 4 clicks counter clockwise Take a test run and if necessary adjust two clicks clockwise Note Make sure that the springs are properly preloaded before you make any other adjustments A simple rule Increased spring preload should be followed by an increase of rebound damping Note If you can not feel the clicks steps the shock absorber must be inspected by an authori
5. d for additional service please contact an authorized hlins workshop Cleaning Clean the shock absorber externally with a soft detergent Use compressed air Be careful that all dirt is removed Lift the bump rubber and clean the area below Keep the shock absorber clean and spray it with oil WD40 CRC 5 56 or equivalent after washing Wipe off excessive oil with a cloth m Caution Never spray water directly into the adjuster knobs and or the ball joints Inspection 1 Check ball joints for possible excessive play or stiction 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body for external damage 4 Check the reservoir for external damage that can restrict the floating piston from moving freely 5 Check for excessive wear of rubber components 6 Check the attachment points of the shock absorber to the vehicle Recommended Service Intervals Racing Every 10 hours of operation Maximum 20 hours of operation without service and oil change Regular street use Every 30 000 km Disposal Discarded Ohlins products should be handed over to an authorized Ohlins workshop or distributor for proper disposal Note The Ohlins shock absorber should only be filled with the Ohlins High Performance Shock Absorber Fluid Contact your Ohlins dealer for advise A Warning Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required w
6. f the product and should therefore accompany the product throughout its life cycle Safety Symbols In this manual mounting instructions and other technical documents important information concerning safety is distinguished by the following symbols A The Safety Alert Symbol means Warning Your safety is involved A Warning The Warning Symbol means Failure to follow warning instructions can result in severe or fatal injury to anyone working with inspecting or using the shock absorber or to bystanders m Caution The Caution Symbol means Special precautions must be taken to avoid damage to the shock absorber Note The Note Symbol indicates information that is important regarding procedures hlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited Printed in Sweden Most of hlins suspensions are a high pressure monotube type The fluid is put under gas pressure and the gas and the fluid are kept apart by a separating piston The piston is usually fitted in an external reservoir connected by a hose Fig 4 or fixed directly on top of the shock absorber Fig 3 In some models everything is fitted inside the main shock absorber Fig 2 A few shock absorbers are of emulsion type oil and gas mixed inside the shock absorber Fig 1 In some models an internal gas reservoir is separated from the tube by a base plate Fig
7. mental for the function of the suspension If the preload is incorrectly set other adjustments of the shock absorber will not help to get the intended performance from the suspension Spring Preload the difference between A and B A Free spring length B Installed spring length shock absorber fully extended A B Spring Preload How to Set the Spring Preload 1 Mechanical Adjuster Use a C spanner Loosen the lock nut 1A Move the lower spring platform 1B to the desired position Turn clockwise to increase the preload turn counter clockwise to decrease it 2 Hydraulic Adjuster Turn the Hydraulic Adjuster knob to set the spring preload Turn clockwise to increase the preload and turn counter clockwise to decrease 3 Integrated Hydraulic Adjuster Turn the hexagon screw on the hydraulic adjuster to set the spring preload Turn clockwise to increase turn counter clockwise to decrease Compression and Rebound Damping Compression damping controls the energy absorption when the shock absorber is compressed thus controls how easy the shock absorber compresses when the wheel is being loaded or hits a bump Rebound damping controls the energy absorption when the shock absorber is being extended and controls how fast the shock absorber returns to its normal position after being compressed Adjust compression and rebound damping by turning the adjusters The adjusters have a normal right hand thread T
8. o reset Turn the adjuster clockwise to fully closed position position zero 0 Then turn counter clockwise to open and count the clicks until you reach the recommended number of clicks See recommended Set up data in the Mounting Instructions for the shock absorber Contact an Ohlins distributor if you have any questions regarding correct spring set up Mm Caution Do not use force delicate sealing surfaces can be damaged Shock Absorber Length On some hlins shock absorber models you can adjust the length By adjusting the length of the shock absorber the geometry can be changed How to Adjust the Length 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 One 1 turn is 1 mm of shock absorber length Please make sure to measure the ride height before and after adjusting the length Tightening torque 40 Nm A Warning Remember to lock the lock nut after adjusting the length A 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 Note After adjusting the length check the headlight angle Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any nee
9. outstanding feedback from your vehicle Along comes the fact that your shock absorber will be a long lasting friend delivering the very best of comfort and performance every time you go for a ride Go explore Note The shock absorber is a very important part of the vehicle and will therefore affect the stability of the vehicle Read and make sure that you understand the information in this manual and the mounting instructions before you use this product If you have any questions regarding installation or maintenance please contact your nearest Ohlins dealer Ohlins Racing AB can not be held responsible for any damage to the shock absorber vehicle other property or injury to persons if the instructions for installing and maintenance are not followed exactly A Warning This product was developed and designed exclusively for a specific vehicle model and should only be installed on the intended vehicle model in its original condition as delivered from the vehicle manufacturer This product contains pressurized nitrogen gas N Do not open service or modify this product without proper education authorized Ohlins dealer distributor and proper tools A After installing this product take a test ride at low speed to make sure that your vehicle has maintained its stability Note When working on this product always consult your Vehicle Service Manual This Manual should be considered as a part o
10. ww ohlins se art No 07255 01_0 Issued 2008 10 20 2008 Ohlins Racing AB Your Ohlins retailer hlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands Vasby Fax 46 0 8 590 025 80 Sweden www ohlins com
11. zed Ohlins Service Centre The problem can be caused by incorrect or lack of gas pressure Stability All vehicles are designed with a suspension geometry including wheel movement and angles Changing components will affect this therefore it is essential that the rear and the front end match each other Changing to Ohlins suspension gives the best performance only when the front and the rear suspensions interact properly Read the manual carefully and contact your nearest Ohlins dealer if you have any questions regarding this shock absorber Spring action Incorrect spring action can affect the stability of the vehicle in a negative way It can lead to some over or understeering and consequently affect the stability of the vehicle It is important to use the correct spring for your shock absorber If you have any questions regarding the spring on your shock absorber please contact your nearest Ohlins dealer The adjustment possibilities on the Ohlins shock absorbers enable fine tuning You can optimize the shock absorber to suit your own vehicle s weight and equipment your individual way of driving and the condition of the road To improve the stability it is very important that you understand how the shock absorber works Spring Preload When adjusting the spring preload you move the spring seat This will decrease or increase the initial spring force which will lower or raise the ride height The spring preload is funda
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