Workshop Manual
Contents
1. 8 4 Insert the separating piston using the Disassembly tool end cap 00720 04 Be careful not to trap any air 8 5 Push down until you have reached the bottom and zero your caliper on the measurement from the edge of the external reservoir tube to handle of end cap tool 8 6 Pull the separating piston up 2 mm 19 Wrap the piston band with the Piston install o ring 00338 40 8 8 Insert the inner tube 8 9 Fill the cylinder tube and inner tube with damper fluid up to the top of the inner tube 20 8 10 Carefully insert the piston into the inner tube The installed o ring should slide off towards the end eye 8 11 Without pulling the piston out of the inner tube stretch the install o ring over the seal head bump rubber and end eye Or you may cut the o ring to remove it Tip If you have performed a rebuild and left off the seal head and end eye you can remove the o ring much easier Once the o ring has been removed install the seal head See chapter 4 Replace Seal Head 8 12 Place the main piston at fully extended without removing the piston from the inner tube and fill the cylinder tube with damper fluid 8 13 Slide the seal head down the shaft and into the cylinder tube without allowing the piston to move in the inner tube The seal head should squeeze fluid out 21 8 14 Tighten the seal head to a torque of 20 Nm Be sure to have the torque wre2. ring Note There are different versions of separating piston seal Some versions use an o ring and some use an x ring 6 2 Assemble 6 2 1 Apply grease to the new separating piston seal and install m 6 2 2 Apply grease to the new reservoir end cap o ring and install 6 2 3 Install Separating piston and Reservoir end cap See chapter 8 Oil Fill Procedure 7 1 Disassemble 7 1 1 Release gas pressure see chapter 1 Pressure 7 1 2 Put the damper in a vise with the valve train axis pointing vertica 7 1 3 Note the clicker settings Adjust the high speed adjuster to the half way position 7 1 5 Remove the circlip A dental pick and razor blade are helpful when doing this MMM det Note To start this procedure the valves separating piston shaft assembly and inner tube should be removed from the damper See prior sections for these instructions 8 1 Put the damper in the vise with the valve train port axis pointing vertical and fill with damper fluid until the valve ports are completely full 8 2 Screw in the adjusters just until you can no longer see the o ring so as to not preload the valve springs der Note Fluid should squirt out of the adjuster bleed hole 8 3 Turn the damper up in the vise with the cylinder tube axis pointing vertical and fill until the external reservoir tube is full 18
3. 55 11101 4244 rsrsnsetintitiririnnnnnnns nnns nnnsnsnsne nene nee eene 13 n e EE 14 7 CHANGE VALVE SGPECIEICATION 15 4 lt 1 016855610016 coves lt lt 1 34450 15 TZ ASSOMDIC 17 8 OIL FILL PROCEDURE 18 Pos Part No Description Note 1 000050 09 Shaft vise 2 00720 04 Disassembly tool end cap 3 U00050 18 Seal head pin spanner 4 01840 02 Filling machine 5 01781 01 Gas filling device kit 5 U00050 16 Gas fill needle 6 00338 40 Piston install o ring 7 U00050 10 Seal head install sleeve 8 Assembly grease 9 Razor blade 10 Dental pick 11 Vise 12 Rag 13 Adjustable wrench 14 Heat gun 15 Oil reservoir container 16 Loctite 270 17 Torque wrench wk Screwdriver Torx T20 1 1 Depressurize 1 1 1 Note the adjuster settings 1 1 2 Put the damper in a vise with the cylinder tube axis pointing vertically 1 1 3 Remove the screw and o ring at the bottom of the external reservoir Use a Torx T20 screwdriver A Warning For safety reasons use Gas fill needle U00050 16 Gas filling device kit 01781 01 with special care Read the instructions provided with the tool A Warning Be careful when working with a Needle 1 1 4 Insert the Gas fill needle U00050 16 Note the ga
4. UI lt N ES Ben o LL Oo E D N Ben o LL Ben 5 Ben D Q i O d lt x O E 7 Workshop Manual General Warnings Note The shock absorber is an important part of the vehicle and will affect the stability Note Read and ensure you understand the information in this manual and other technical documents provided by hlins before using the product 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 Note hlins Racing AB can not be held responsible for any damage to the shock absorber vehicle other property or injury to per sons if the instructions for mounting usage and maintenance are not followed exactly A Warning After installing the Ohlins product take a test ride at low speed to ensure your vehicle has maintained stability A Warning If the suspension makes an abnormal noise or the function is ir regular 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 the product has been operated and maintained in accordance with recommend
5. ations in this manual If you have any questions regarding usage ser vice inspection and or maintenance please contact Ohlins amp Note When working with the Ohlins product always read the Vehicle Service Manual 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 Ohlins Racing AB All rights reserved Any reprinting or unauthorized use without the written permission of Ohlins Racing AB is prohibited 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 SAFETY PRECAUTTIONGS 2 EE ee ee leegen A E TE 5 WET EE 5 1 2 EE 7 2 REMOVE SHAFT ASSEMBLY 8 3 REPLACE END EYE ae 2 E E ERS 9 3 1 Disassemble a uu4 en dE ee Eden 9 KS le E 10 4 REPLACE SEAL HEAD nennen 11 4 1 RTE le unse 11 E e EE 11 8 REPLACE PISTON BAND gt 544 55 22 aaa 12 5 1 Disassemble nennen 12 BRAUN IN EE 12 6 REPLACE SEPARATING PISTON SEAL 13 6 1 10153
6. nch 90 to the pin spanner otherwise the actual torque applied will be different from that measured Tip If you performed a rebuild and left off the end eye you can install it now see chapter 3 Replace End Eye Note When installing the seal head the separating piston will move approximately 5 mm from the oil displaced from the seal head 8 15 Screw the high speed adjusters to the half way position and install the circlips 8 16 Install the external reservoir end cap and circlip Use Disassembly Tool End cap 00720 04 8 17 Pressurize see chapter 1 Pressure 22 This page is intentionally left blank 23 Ohlins Workshop Manual TTX25FormulaStudent SAE_0 Issued 2013 03 18 Ohlins Racing AB Your hlins retailer hlins 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 com
7. ove shaft assembly see chapter 2 4 1 2 Remove end eye see chapter 3 4 1 3 Carefully remove the seal head from the shaft Note If you are re using the seal head it is recommended that you replace the shaft seal 4 2 Assemble 4 2 1 Install the Seal head install sleeve U00050 10 on to the threads of the shaft and apply some grease 4 2 2 Carefully slide the seal head on to the shaft Tip If performing a rebuild wait to install seal head on the shaft until the piston and shaft assembly have been installed into the inner tube 4 2 3 Insert the piston and shaft assembly see chapter 8 11 5 1 Disassemble 5 1 1 Remove shaft assembly see chapter 2 5 1 2 Remove the old piston band and o ring Note Always be careful not to scratch the o ring groove when replacing the o ring 5 2 Assemble 5 2 1 Apply grease to the new o ring and piston band and install 5 2 2 Wrap the piston band with the Piston install o ring 00338 40 5 2 3 Install shaft assembly into the damper See chapter 8 Oil Fill Procedure k 12 6 1 Disassemble 6 1 1 Use Disassembly tool end cap 00720 04 to press down on the reservoir end cap 6 1 2 Remove the circlip and pull the reservoir end cap out 6 1 3 Use Disassembly tool end cap 00720 04 to pull the separating piston out 13 6 1 4 Remove the old separating piston seal and the reservoir end cap o
8. s pressure Ideal pressure is 5 Bar 1 1 5 Open the Gas fill needle valve to bleed pressure from reservoir Remove Gas fill needle 1 2 Pressurize A Warning Only use nitrogen gas N to pressurize the shock absorber Nitrogen is an inflammable gas that does not affect the materials in the gas reservoir 1 2 1 After your work is complete insert the Gas fill needle assembly and pressurize to 5 Bar 1 2 2 Remove the Gas fill needle and install the screw and o ring 2 Remove Shaft Assembly 2 1 Release gas pressure See chapter 1 Pressure 2 2 Unscrew the seal head using the Seal head pin spanner U00050 18 2 3 Carefully remove the shaft assembly from the cylinder tube 2 4 Drain the fluid from the damper 3 1 Disassemble 3 1 1 Clean the shaft of dirt and damper fluid Clamp the shaft using the Shaft vise U00050 09 3 1 2 Use a heat gun to loosen the Loctite from the shaft end eye threads 3 1 3 Use a 13 mm or open end wrench or an adjustable wrench on the flats of the end eye and unscrew 3 2 Assemble 3 2 1 Clean the Loctite from the threads on the shaft and end eye Tip If performing a rebuild wait to install the end eye until after the damper has been filled with damper fluid 3 2 2 Apply one small drop of Loctite 270 to the threads of the shaft 3 2 3 Install end eye to 10 Nm 10 4 1 Disassemble 4 1 1 Rem
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