Owner`s Manual/ Workshop Manual
Contents
1. 10 2 10 Remove the Separating piston positioning tools 10 2 11 Pressurize the shock absorber See chapter 1 Pressure 33 10 3 Remove Oil 10 3 1 Release gas pressure See chapter 1 Pressure Leave the Needle unit and Quick connect hose mounted 10 3 2 Put the shock absorber in a vice 00773 01 with tool 01878 01 Place the shock absorber with the Oil filling screw pointing up 10 3 3 Remove the Oil filling screw on the Cylinder head Use a Torx T25 screwdriver Make sure to keep the O ring in place on the Cylinder head 10 3 4 Mount 1mm thick Shim stacks or Washers around the two pins of the Separating piston po sitioning tool To help setting the Separating pis ton in the correct position 10 3 5 Mount the Separating piston positioning tool part no 01876 XX Push it in slowly until the Shim stack Washers are in contact with the Reservoir end cap Oil will now flow out through the screw hole 10 3 6 Keep the pressure on the tool and mount the Screw to prevent air from entering 10 3 7 Remove the Separating piston positioning tool 10 3 8 Pressurize the shock absorber See chapter 1 Pressure 34 Ohlins Owner s Workshop Manual TTR Part No 07452 01_0 Issued 2011 07 07 2011 Ohlins Racing AB Your Ohlins retailer Ohlins Racing AB Box 722 Phone 46 0 8 590 025 00 SE 194 27 Upplands V sby Fax 46 0 8 590 025 80 Sweden www ohlins com2. 5 2 10 Tighten the Outer tube to the Cylinder head Tightening torque 9ONm To assemble the Shock absorber go to Chapter 4 2 8 Replace Piston Rod 24 6 1 Disassemble 6 1 1 Release gas pressure See chapter 1 Pressure 6 1 2 If any remove the Spacers in the top eye Use two screwdrivers 6 1 3 Mount the shock absorber in a vice with soft jaws Clamp at the flat sides of the Cylinder head 6 1 4 Use an adjustable wrench Loosen the Top eye by turning counter clockwise Ensure that the span ner covers both sides of the Bearing hole 6 1 5 Continue to screw the Top eye counter clockwise by hand 3 5 turns The Top eye will thread out of the shock absorber while the Reservoir end cap stays M Caution Do not unthread the Top eye so much that it comes off the Reservoir end cap 6 1 6 Push the Reservoir end cap down by hand The Top eye will follow the Reservoir end cap into the shock absorber 6 1 7 Insert an allen key into the small hole on the Cyl inder head Remove the Circlip 6 1 8 Pull the Top eye and the Reservoir end cap out of the Cylinder head 6 1 9 Remove the Top eye from the Reservoir end cap 25 6 2 Assemble 6 2 1 Put a thin layer of assembly lubricant on the new Top eye put it where the Separating piston moves 6 2 2 Add some assembly lubricant on the new Top eye thread 6 2 3 Thread the new Top e
3. 7 Turn the Top eye clockwise by hand until it stops Note If it is not possible to turn it by hand use an adjustable wrench and carefully turn the Top eye 2 8 Use a Peg spanner Turn the Reservoir end cap counter clockwise until the Top eye points in a 90 angle from desired position Turning the End cap counter clockwise ensures that the Reservoir end cap and the Top eye turn together 2 9 Use an adjustable wrench and turn the Top eye 90 to the desired position Ensure that the span ner covers both sides of the Bearing hole 2 10 Pressurize the shock absorber See chapter 1 Pressure 16 A 3 1 Disassemble 3 1 1 Release gas pressure See chapter 1 Pressure 3 1 2 Pull the Piston rod to fully extended position 3 1 3 Mount the shock absorber in a vice with soft jaws 3 1 4 To remove the Spring seats use tool 03199 01 3 1 5 Loosen the Lock nut at the End eye Use Oh lins 21mm wrench part no 01772 03 3 1 6 Put the shock absorber in a horizontal position Unscrew the End eye Note If the Piston rod rotates with the End eye clamp the Piston rod in a vice 3 1 7 Remove the Lock nut and External spacers if any 3 1 8 Put the shock absorber upside down in a vice with soft jaws Clamp gently at the flat sides of the Cylinder head 3 1 9 Compress the shock absorber slightly to prevent the internal piston rod from leaving the sea
4. Loctite does not fall into the shock absorber To remove the Separating plate go to Chapter 7 5 2 2 Add some assembly lubricant inside the end of the new Inner tube 5 2 3 Push the new Inner tube on the Separating plate Make sure that the side with assembly lubricant is facing the Separating plate 5 2 4 Put 3 drops of Loctite 243 on the new Outer tube thread Apply a thin layer of assembly lubricant on the surface meeting the Cylinder head O ring Ap ply some assembly lubricant inside the other end of the Outer tube thread and the surface that will meet the End cap O ring 23 D 8 5 2 5 Screw the new Outer tube in place by hand 5 2 6 Mount the Piston rod and End cap assembly in the shock absorber Use Mounting sleeve part no 01861 XX 5 2 7 Screw in the Cylinder End cap enough to support the Outer tube when tightening the Outer tube in the Cylinder head Recommended position for the End cap 1 2mm above the Outer tube end M Caution Never have the end cap flush with the Outer tube when the Outer tube is installed on the Cylinder head The high torque used to install the Outer tube can damage the Cylinder end cap if it has been threaded in too much 5 2 8 Mount Sleeve part no 00737 05 on the Outer tube Put the top of the Sleeve at the same height as the end of the Outer tube 5 2 9 Mount the Spanner on the Sleeve Place it in the same area as the Cylinder end cap
5. Piston rod in a vice with soft jaws m Caution Do not clamp the external Piston rod closer than 25mm from the Piston position 4 2 2 Add some assembly lubricant on the Piston rod Install the End cap carefully from the Piston side 4 2 3 Add Internal spacers if needed 4 2 4 Put the Piston on the new internal Piston rod 4 2 5 Add a few drops of Loctite on the thread of the Internal Piston rod and screw the two Rods to gether Use a torque wrench Tightening torque 22Nm 4 2 6 Put the Cylinder head in a vice Cylinder tube up 4 2 7 Mount the Piston rod assembly in the Cylinder tube Use hlins mounting sleeve 01861 XX 4 2 8 Screw the End cap on the Tube and tighten Use Peg spanner part no 01761 01 Tightening torque 50Nm 4 2 9 Mount the External spacers on the Piston rod Thread the Lock nut to the end of the thread 4 2 10 Mount the End eye on the Piston rod Thread it until you feel a stop 4 2 11 Remove the Cylinder head from the vice Turn the shock absorber so that the Cylinder head is point ing up Clamp the End eye in the vice 4 2 12 Tighten the Lock nut on the End eye Use Ohlins 21mm wrench part no 01772 03 Tightening torque 25Nm gt Go to Chapter 8 Fill Oil and 1 Pressure 21 5 1 Disassemble 5 1 1 Release gas pressure See chapter 1 Pressure 5 1 2 Put the shock absorber in a vice with soft jaws with the Piston rod pointing up Clamp at the flat sides
6. air The Syringe is ready to use 01880 01 Note The Plunger rubber will swell from shock absorber oil This process that takes some time can be annoying so always remove the Piston from the casing after use If the Rubber seal is removed from the Piston and carefully cleaned it can be reused but the low price of this Piston makes a frequent change the best solution The Separating piston moves 2 mm per ml of oil 32 wm MU 10 2 Add Oil 10 2 1 Release gas pressure See chapter 1 Pressure Leave the Needle unit and Quick connect hose mounted 10 2 2 Put the shock absorber in a vice 00773 01 with tool 01878 01 Place the shock absorber with the Oil filling screw pointing up 10 2 3 Remove the Oil filling screw on the Cylinder head Use a Torx T25 screwdriver Make sure to keep the O ring in place on the Cylinder head 10 2 4 Mount Oil syringe part no 01881 01 See chap ter 10 1 Prepare Oil Syringe 10 2 5 Mount Separating piston positioning tool part no 01876 XX 10 2 6 Mount the Separating piston positioning spacer part no 01877 5X and the Positioning pin part no 24602 01 10 2 7 Insert oil with the Syringe into the Reservoir until the Piston of the Syring gets solid The Separating piston has now bottomed out towards the pres sure indicators positioned by the Separating pis ton positioning tools 10 2 8 Remove the Syringe 10 2 9 Mount the Oil filling screw
7. pushing it into the hole after adding some assembly lubricant to the surface of the Membrane 7 2 1 Mount the Back up ring in the Cylinder head hole 7 2 2 Apply a thin layer of assembly lubricant on the X ring Place it on top of the Back up ring 7 2 3 If removed press the Bushing into the Separat ing plate m Caution Be careful with the Sealing surface of the Separating plate Ensure the Bushing is correctly aligned in the hole 7 2 4 Put some assembly lubricant on the O ring on the Separating plate Put the Inner tube on the Sepa rating plate by hand 7 2 5 Mount the Separating plate and Inner tube as sembly Ensure the Separating plate is centred in the Cylinder head hole 7 2 6 Clock the Separating plate to the correct position Put the screw hole in the plate in line with the hole of the Cylinder head 7 2 7 Put one drop Loctite on the Screw and tighten Tightening torque 3Nm 28 7 2 8 To mount Spherical bearings e f possible round the edges on one of the sides of the new Bearing Mount on of the Circlips in the groove oppo site side with the small chamfer Use a pair of small circlip pliers Clean the Outer ring of the Bearing and the hole of the Eye Add 1 2 drops Loctite in a thin layer to the Bearing Mount the Bearing Use Manual arbor press Mount the other Circlip Note Use Ohlins Vacuum Filling Machine See Owner s Manual 07221 01 for correct p
8. to zero Turn counter clockwise to obtain less damping force Turn clockwise to obtain increased damp ing force Note Normally you will only need to turn until you hear a noticeable click or less 4 Lock the 1mm hex screws by only slightly tight ening each screw at a time in a cross pattern not to make the Inserts skewed into the Adjustment housing VALVE AND VALVE SEAT G67 06183 47 06183 57 06183 67 06185 50 06185 70 DAT 5 7 6 7 2 6 3 6 4 6 06198 47 06198 57 06198 67 06197 50 06197 70 Part No D mm 06195 10 1 0 06196 20 06195 15 1 5 06196 30 06195 20 2 0 06196 40 06196 50 Recommended Tools when Revalving Tool Part no Clamp tool 01878 01 Adjuster house tool 01898 01 Ohlins High Performance fluid 01304 XX Torque wrench Small pliers Note Every time you revalve the oil level and the amount of air in the shock absorber will be slightly increased Therefore we recommend that after approximately five 5 revalvings Check the Oil Level and Vacuum Fill see Chapter 9 10 in the Workshop Section 1 Put the shock absorber in a vice Use clamp tool 01878 01 2 Depressurize the shock absorber See chapter 1 Pressure 3 Use tool 01898 01 and a torque wrench Press the tool down in a straight line so that the pins on the tool are aligned with the holes in the Adjust me
9. too long it may damage the Separating piston 1 1 5 Make sure that the Needle is not damaged Re place if you find burrs around the tip Carefully grab the Needle between two fingers and gently move your fingers along the needle to look for damage A Warning Be careful when checking the needle 13 coupling 01778 01 Replace 01779 01 coupling 01778 01 1 2 Depressurize 1 2 1 Remove the Screw and Washer covering the Membrane at the Reservoir end cap Use a Torx T20 screwdriver A Warning Be careful when working with the Needle 1 2 2 Apply some assembly lubricant on the Needle tip Insert the tip into the Rubber membrane in the Reservoir end cap Thread the Needle housing into the Reservoir end cap 1 2 3 Attach the Quick connect hose with the Gauge to the shock absorber 1 2 4 Note the current gas pressure Note The Gauge will show approx 1 bar less the total gas volume will be greater when the gauge is attached This means that you need to add 1 bar to your noted gas pressure to get the correct value 1 2 5 Remove the Gauge to depressurize the shock ab sorber 1 2 6 Remove the Needle 14 1 3 Pressurize A Warning Only use nitrogen gas N2 to pressurize the shock absorber Nitrogen is an inflammable gas that does not affect the materials in the gas reservoir 1 3 1 Remove the Needle cover A Insert Gas needle housing assembly in the f
10. 9 01 Positioning pin 24602 01 Adjustable wrench Allen key 3mm Allen key 6mm Circlip pliers Heat gun Loctite Nitrogen gas N2 Torx T20 and T25 Screwdriver Torque wrench Vice with soft jaws Wrench 10 11 and 14mm 1 1 Prepare Gas Filling Device Note Ifyou have a TTX46MT shock absorber combined with the TTR shock absorber the gas filling device must to be modified before use Replace needle housing part no 01779 01 included in the standard gas filling device part no 01781 01 with needle housing part no 01779 02 Needle housing 01779 02 can be used on most Ohlins products If you are working on a TTX46MT you do not need to modify the gas filling device 1 1 1 Remove the old Needle housing from the Quick coupling Use an 11 mm and 14 mm wrench 1 1 2 Remove the current Needle from the Housing by gently pushing it out Note Push the needle against a surface that will not damage the needle tip some wood or plastic is recommended 1 1 3 Put the Needle into the new Needle housing and screw it back on the Quick coupling Use a 10 mm and 11 mm wrench M Caution Use a low tightening torque approximately 5 Nm 1 1 4 Check the length of the Needle The visible length should be 14 20 mm measured to the tip of the needle m Caution If the Needle is too short it may not reach all the way through the Rubber membrane If it is
11. Shock Absorber for High Level Racing TTR Owner s Manual Workshop Manual IL was the 19705 a young man named Kenth Ohlin 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 three hundred World Championships and other major Q Q D Safety Precautions Service amp Maintenance Design and Functioning External Adjusters Zeroing Valve Overview Revalve Workshop Section Oo oO A fWW I 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 By installing this shock absorber on your vehicle you have made a clear statement you are a serious driver with a focus on g
12. ap you will not be able to know the actual oil level There must be some air between the tool and the End cap Therefore the lower limit is set to gt 0 If the tool is in contact with the end cap add oil When the tool is hitting the reservoir end cap the separating piston can still move 1 mm more inside the damper before it bottoms against the cylinder head When the separating piston posi tioning spacer part no 01877 5X is installed and oil is pressed into the damper for example in the vacuum filling machine the distance between the tool and the end cap will be approximately 1 mm If the shock absorber is properly filled with oil you will not notice any movement of the separating piston when the damper is getting pressurised If the separating piston moves further in there is air in the oil 10 1 Prepare Oil Syringe 10 1 1 Pull out the Plunger with the rubber seal from the Plastic casing 10 1 2 Put some assembly lubricant or shock absorber oil on the Rubber seal and install it into the Steel casing part no 01880 01 10 1 3 Fill oil into a cup you can use the Ohlins bottle cap and put the tip of the Syringe under the sur face of the oil and suck oil into the Syringe by pulling the Plunger outwards Note There is no stop so pay attention to the position of the Plunger so that you do not pull it out of the 8 casing 10 1 4 Turn the Syringe up and push the Plunger in just enough to evacuate the
13. er with the Filling screw 8 13 Pressurize the shock absorber See chap ter 1 Pressure 8 14 Remove the Quick connect hose at the Needle housing and unscrew the Needle housing 8 15 Remove the Separating piston positioning tools Twist the 01877 5X spacer tool and pull out Note If you find it hard to remove the separating positioining tools if the shock absorber is pressurized remove the separating piston positioning tools after removing the gas needle unit then reinstall the needle unit and pressurize the damper 30 a 9 1 Mount the Separating piston positioning tool part no 01876 XX in the Reservoir end cap Push down the pressure indicators with the two pins of the tool If the tool is pushed back the shock absorber is pressurized 9 2 Push the tool so that it is parallel to the End cap and measure the distance between the tool and the end cap Recommended distance gt 0 2mm at room tem perature As the temperature rises the distance will in crease At operating temperature the distance should not extend more than 4 5mm when using short reservoir end cap part no 06121 01 Note If long reservoir end cap part no 06121 02 is used recommeded distance gt mm 31 Note If the Separating piston is not parallel to the Cylin der head up to 3mm when installing the Separat ing piston positioning tool If the tool is in contact with the Reservoir end c
14. etting the maximal handling ability and 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 drive Go explore Note The shock absorber is an important part of the vehicle and will affect the stability Note Read and make sure that you understand the information in this manual before you use this product If you have any questions regarding installation or maintenance please contact an Ohlins dealer A Warning 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 maintenance are not followed exactly A Warning 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 Warning After installing this product take a test drive at low speed to make sure that your vehicle has maintained its stability A Warning If the suspension makes an abnormal noise or the function is irregular or if you notice any leakage from the product stop the vehicle immediately and return the product to an Ohlins Service Centre A Warning The product warranty shall only apply if this product has been operated and main
15. g the damper clean and dry any leakage will be easy to de tect If oil is leaking from the X ring seal re peatedly replace X ring and inspect the piston rod for imperfections on the surface e Inspect the dampers for external wear or dam age e Check the spherical bearings regularly for ex cessive play On installations where the spring is not of coil over type a gap is more critical as the bearings will see loads in both directions Recommended Service Intervals e After 30hours or 6000Km e After 15hours or 3000Km if working temper ature exceeds 110 C If the shock absorber reaches a temperature of 140 C or more it needs immediate service Recommended service change replace e oil o rings x rings e piston band e bushings m Caution If you have any questions regarding service and maintenance please contact hlins DESIGN AND FUNCTIONING hlins now releases the TTR damper a 4 way fully independent adjustable damper based on well proven technology that has been behind winning success for many years in high end factory racing in IndyCar Le Mans and DTM This high end racing damper is now available for teams seeking optimal performance and on track success Features include a precise valving system both high and low speed can be zeroed externally to ensure an accurate matching between dampers while at the same time maintaining reference clicks The TIR damper combines top performance with
16. h internal 3mm hex inside the silver casing Number of positions approx 40 8 clicks turn Click position 0 Fully counter clockwise at minimum force spring min preloaded CANS Zeroing result See the examples below for results after calibrat ing Low Speed and High Speed Valve To calibrate according to the example below see Low Speed Zeroing and High Speed Zeroing on the following two pages Note When calibrating we recommend to calibrate Low Speed and High Speed in the same order as performed below The Low Speed Bleed affects the High Speed Valve Low Speed Zeroing Q Actua curve Re Se poe Se gee NS ERE Se ES KS Se ae SS er ee ee ae en Se ee eS pre ee Soe Sie ere ae ne Calibrate High Speed Valve CPE PEAREN E AEE a FR E TAE Beten A E EE E S PE EE E EAS a a ee ge EE ret ee eke me Be area erate epee ee a me rm fo fe emi int pl a a ah Sk a ep te eh lt i i iL a m ee ee Adjustment tool 01899 01 Screwdriver 1mm hex screwdriver 1 3mm hex screwdriver 3mm hex screwdriver Low Speed Zeroing Choose one of your shock absorb ers that is closest to the Valving Reference Program VRP as a ref erence 1 Chec
17. ill hole 1 3 2 Mount Quick connect hose and Gauge to the Needle housing 1 3 3 Pressurize the shock absorber to 5 bar 75psi 1 3 4 Remove Quick connect hose from the Needle housing to release gas pressure in the gauge Warning Never remove the Needle housing from the fill hole with pressurized Gauge still connected A pressurized needle can be hazardous If ni trogen is injected into the body there is a risk for personal injury or death 1 3 5 Remove the Gas needle housing assembly from the fill hole Mount the Needle cover Note Make sure there is no leakage nitrogen gas Apply some soap water on the end cap and Rubber membrane and check for bubbles 1 3 6 A Warning Mount the Washer and Screw in the fill hole 15 2 1 Release gas pressure See chapter 1 Pressure 2 2 Mount the shock absorber in a vice with soft jaws clamp at the flat sides of the Cylinder head 2 3 If any remove the Spacers in the top eye Use two screwdrivers 2 4 Use an adjustable wrench Loosen the Top eye by turning counter clockwise Ensure that the span ner covers both sides of the Bearing hole 2 5 Mount the Peg spanner part no 01761 03 on the Reservoir end cap Note that the pins go into the pressure indicator holes 2 6 Rotate the Reservoir end cap in any direction just enough to ensure that the Top eye follows the End cap If it does not loosen the Top eye a little more 2
18. k in the dyno the number of clicks needed to close or open the adjuster to match your reference 2 Turn the adjuster to fully open by turning counter clockwise until stop 3 Note that there are two lock screws one on each side of the adjuster Unlock these 3 1 Turn the adjuster half a turn clockwise so that you can unlock turn the screw that was fac ing in Use a 1 8mm hex screwdriver 3 2 Turn the adjuster counter clockwise until stop Loosen the screw facing out 4 1 click LI Use a screwdriver and turn the slotted centre screw Turn the number of clicks that was de fined in step 1 Note that one groove or the dis tance between two peaks equals one click Turn clockwise to obtain increased force Turn counter clockwise to obtain less force 5 Push the knob towards the cylinder head and at the same time lock the screw facing out 6 Turn the adjuster half a turn clockwise Push the knob and lock the screw that was facing in 7 Turn the adjuster to fully open by turning counter clockwise until stop 8 Set the adjuster to the desired number of clicks Run the shock absorber once again in the dyno to confirm your set up High Speed Zeroing Note When zeroing first zero low speed and then high speed 1 Loosen the 1mm hex screws Note that there are two on each side of the two Adjustment housings 2 Use a 3mm hex screwdriver to fixate the Adjust ment screw 3 Use tool 01899 01 3A
19. l in the cylinder head If the top eye leaves the seal oil will leak out into the top eye cavity before it comes out through the holes of the top eye 3 1 10 Loosen the Cylinder end cap Use a Peg spanner part no 01761 01 GP 17 3 1 11 Remove the shock absorber from the vice Turn it upside down Pull out the Piston rod assembly and drain all oil from the shock absorber 3 1 12 Put the shock absorber body in an upright posi tion so that it is standing on the end of the Tube to prevent oil from entering the Top eye 3 1 13 Put some assembly lubricant on the End eye thread of the Piston rod Rotate the Cylinder end cap when sliding it up the Piston rod so that it does not get stuck m Caution Pull the Cylinder end cap carefully over the thread so that it does not get damaged 3 1 14 If needed replace Internal spacers To replace Piston rod Go to Chapter 4 Replace Piston Rod To Assemble and Fill Go to Chapter 3 2 Assemble 18 I A 8 p Jam 3 2 Assemble 3 2 1 If needed add Internal spacers 3 2 2 Carefully mount the Cylinder end cap on the Pis ton rod assembly m Caution Pull the Cylinder end cap carefully not to damage the End cap seal 3 2 3 Put the shock absorber in the vice with the Cyl inder tube up 3 2 4 Mount tool 01861 XX in the Cylinder tube 3 2 5 Push the Piston rod as
20. ning torque 10Nm 11 Circlip Support shim eae washer Check valve shim ZA Kae IS EI Valve seat Contents Chapter Tools 1 Pressure 1 1 Prepare Gas Filling Device 1 2 Depressurize 1 3 Pressurize 2 Reclock Top Eye 3 Add Replace Spacers 3 1 Disassemble 3 2 Assemble 4 Replace Piston Rod 4 1 Disassemble 4 2 Assemble 5 Replace Cylinder Tube 5 1 Disassemble 5 2 Assemble 6 Replace Top Eye 6 1 Disassemble 6 2 Assemble 7 Replace Seals Bushings Bearings and or Membrane 7 1 Disassemble 7 2 Assemble 8 Fill Oil 9 Check Oil Level 10 Adjust Oil Level 10 1 Prepare Oil Syringe 10 2 Add Oil 10 3 Remove Oil Page 12 13 14 15 16 17 19 20 21 22 23 25 26 27 28 29 31 32 33 34 JOP Recommended Tools Tool Part No Assembly lubricant Red grease 00146 01 Soft jaws 00727 02 Soft jaws 00727 03 Sleeve 00737 05 Spanner 00738 01 Vice 00773 01 hlins High Performance Fluid 01304 XX Peg spanner 01761 01 Peg spanner 01761 03 hlins 21mm wrench 01772 03 Gas Needle Housing 01779 02 Gas Filling Device 01781 01 M5 Adapter 01820 01 hlins Vacuum Filling Machine 01840 01 hlins Vac Filling Machine Manual 07221 01 Mounting Sleeve 01861 XX Separating piston positioning tool 01876 XX Separating piston positioning spacer 01877 5X Clamp tool 01878 01 Syringe kit 01881 01 Adjuster House Tool 01898 01 Spring PL Tool 0319
21. nt housing Remove the Adjustment housing gt To Replace Valve Spring Go to 4 1 gt To Replace Valve Valve seat and Shuttle Guide Go to 4 2 4 1 Replace Valve Spring 4 1 1 Use small pliers and remove the Valve spring 4 1 2 Replace the Spring 4 1 3 Pour oil up to the edge of the valve cavity Note Only use Ohlins High Performance fluid 4 1 4 Mount the Adjustment housing Use tool 01898 01 and a torque wrench Tightening torque 10Nm 10 4 2 Replace Valve and Valve seat 4 2 1 Use small pliers and remove the Valve spring 4 2 2 Use small pliers and remove the Valve Pour out some of the oil that may come with the Valve 4 2 3 Remove the Shuttle guide and Valve seat 4 2 4 Remove the Check valve shim Wave washer Support shim and the Circlip from the Valve seat 4 2 5 Put the Check valve shim Wave washer Support shim and the Circlip on the new Valve seat Note Note the Wave washer position 4 2 6 Put the new Valve seat on the Shuttle guide Note the position of the Shuttle guide legs Make sure that the Valve seat snaps on to the Shuttle guide 4 2 7 Put the Shuttle guide Valve and Spring back into the Cylinder head 4 2 8 Pour oil up to the edge of the cavity see fig ure 4 1 3 Note Only use Ohlins High Performance fluid 4 2 9 Mount the Adjustment housing Use tool 01898 01 and a torque wrench see figure 4 1 4 Tighte
22. of the Cylinder head 5 1 3 Remove the Cylinder end cap Use a Peg spanner part no 01761 01 5 1 4 Remove the shock absorber from the vice Turn it upside down Pull out the Piston rod and drain all oil 5 1 5 Put the Cylinder head with the Cylinder tube unit in the vice Clamp at the Cylinder head 5 1 6 Mount the Piston rod and End cap assembly tem porarily into the shock absorber Use Mounting sleeve part no 01861 XX 5 1 7 Screw the End cap into the Tube until you feel a stop Then loosen just so that the End cap easily can be removed by hand later on 5 1 8 Mount Sleeve part no 00737 05 on the Outer tube Put the top of the Sleeve at the same height as the end of the Outer tube 5 1 9 Mount Spanner part no 00738 01 on the Sleeve make sure it grips the area around the Cylinder end cap 5 1 10 Loosen the Outer tube from the Cylinder head Note If the Outer tube does not come off heat the Cylinder head with a heat gun Protect the Adjuster from the heat not to damage the o rings in the valve units 22 5 1 11 Remove the Sleeve and the Spanner 5 1 12 Unscrew the Cylinder end cap Pull out the Piston rod assembly 5 1 13 Unscrew the Outer tube and remove it 5 1 14 Remove the Inner tube by hand 5 1 15 If necessary replace Inner and or Outer tube 5 2 Assemble 5 2 1 Clean the Cylinder head thread from Loctite m Caution Make sure old
23. rocedure 8 1 Release gas pressure See chapter 1 Pressure 8 2 Open the Low speed adjusters completely 8 3 e If the shock absorber is still filled with oil Drain all oil by removing the O ring Oil filling screw Use a Torx T25 screwdriver Push the Piston rod back and forth to drain all oil Mount the O ring back after draining If the shock absorber is empty Remove the Oil filling screw on the Cylinder head Use a Torx T25 screwdriver Make sure to keep the O ring in place on the Cylinder head 8 5 Use M5 adapter part no 01820 01 and mount it where the Oil filling screw was 8 6 Mount Separating piston positioning tool part no 01876 XX 8 7 Mount the Separating piston positioning spacer part no 01877 5X 8 8 Mount the Positioning pin part no 24602 01 Note the different diameters on the pin as well as on the Separating piston positioning spacer 29 8 9 Mount the Gas needle unit and the Quick connect hose to keep atmosphere pressure inside the Reservoir during the filling procedure 8 10 Connect the Adapter to the Vacuum filling ma chine See Owner s Manual 07221 01 for correct procedure m Caution Lower the Air pressure of the machine to 2 5 0 5 bar when filling TTX dampers Note Make sure spacer part no 01877 5X stays in place during the filling procedure 8 11 Disconnect the shock absorber from the Vacuum filling machine 8 12 Replace the M5 adapt
24. sembly into the Cylinder tube until the Piston seal enters the Inner tube Remove the Mounting sleeve Push the Piston rod assembly all the way and engage the thread to the End cap 3 2 6 Screw the End cap on the Tube Tightening torque 50Nm 3 2 7 Mount the External spacers on the Piston rod Thread the Lock nut to the inner end of the thread 3 2 8 Mount the End eye on the Piston rod Thread it until you feel a stop 3 2 9 Turn the shock absorber to an upright position Clamp the End eye in a vice 3 2 10 Tighten the Lock nut to the End eye Use hlins 21mm wrench part no 01772 03 Tightening torque 25Nm gt Go to Chapter 8 Fill Oil and Chapter 1 Pressure 19 4 1 Disassemble 4 1 1 Follow chapter 3 Add Replace Spacers steps 3 1 1 3 1 12 4 1 2 Clamp the Piston rod in a vice with soft jaws Note Clean the rod carefully to keep the Piston rod from rotating Spray some degreaser on the Piston rod to make it stick to the jaws Avoid getting degreaser into the Piston rod seal 4 1 3 Use a 6mm allen key and loosen the thread in the Internal piston rod 4 1 4 Use a heat gun Heat the external Rod Protect the Piston from the heat Separate the rods and remove the Piston 4 1 5 Remove Internal spacers if any 4 1 6 Remove the Cylinder end cap from the Piston rod 4 1 7 Remove the Piston rod from the vice 20 4 2 Assemble 4 2 1 Clamp the new external
25. tained in accordance with recommendations in this manual If you have any questions regarding usage service inspection and maintenance please contact Ohlins Safety Symbols In this manual mounting instructions and other technical documents important infor mation 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 Note When working on this product always consult your Vehicle Service Manual Note This Manual shall be considered a part of the product and shall therefore accompany the product throughout its life cycle Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited Printed in Sweden CE AND MA N NANCE After every use e Measure the position of the separating piston See Chapter 9 Check Oil Level in the Work shop Section Look for oil leakage By keepin
26. user friendly handling for instance change valving in close to one minute The damper also comes with valving simulation software drastically reducing time from idea to ready damper and helps making accurate adjustments at the track Features e 4 way fully independent adjustable damper e Solid piston e Well proven valve technology e Through rod design to minimize hysteresis e Large adjustment range e Top performance combined with easy handling e Change valving in close to 1 minute e Comes with valving simulation software e Precise valving system both low and high speed can be zeroed externally Low Speed Compression Damping Adjuster LSC Adjuster type Bleed adjuster Identification Gold coloured knob Number of positions Approx 55 10 clicks turn Click position 0 Fully counter clockwise at minimum force orifice open Low Speed Rebound Damping Adjuster LSR Adjuster type Bleed adjuster Identification Silver coloured knob Number of positions Approx 55 10 clicks turn Click position 0 Fully counter clockwise at minimum force orifice open High Speed Compression Adjuster HSC Adjuster type Poppet valve Identification Screw with internal 3mm hex inside the gold casing Number of positions approx 40 8 clicks turn Click position 0 Fully counter clockwise at minimum force spring min preloaded High Speed Rebound Adjuster HSR Adjuster type Poppet valve Identification Screw wit
27. ye a couple of turns into the Reservoir end cap 6 2 4 Mount the Top eye and Reservoir end cap unit into the Cylinder head 6 2 5 Mount the Circlip Note Ensure that the Circlip opening is not where the hole that is used to remove it 6 2 6 Set the clocking of the Top eye See chapter Re clock Top Eye 6 2 7 Drain oil from the holes of the Top eye gt Go to Chapter 8 Fill Oil and 1 Pressure 26 m pD A gt hs IM N 7 1 Disassemble 7 1 1 Remove the End eye Lock nut and Piston rod according to chapter Replace Cylinder Tube 5 1 1 5 1 12 7 1 2 Let the shock absorber stand for a while with the Cylinder head up so that the oil from the inside of the Inner tube flows down 7 1 3 Remove the Screw of the Separating plate Use a 3mm allen key 7 1 4 Lift up the Inner tube by hand Ensure that the Separating plate follows 7 1 5 Remove the Separating plate by pushing it out by hand 7 1 6 To replace Bushing Press the Bushing out of the Separating plate Use appropriate tool 7 1 7 Remove the X ring and Back up ring from the Cylinder head hole Use appropriate tool 27 7 2 Assemble Note Always put assembly lubricant on new O rings before assembly Also put a thin layer of assembly lubricant on the surfaces that will slide against the O rings during installation Note Mount the Membrane of the Reservoir end cap by
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