Owners Manual
Contents
1. 2 External reservoir with hose connection Fluid 3 External piggyback reservoir Main 4 Internal gas reservoir piston with base plate 5 Emulsion shock absorber 6 McPherson shock absorber Fluid 1 Internal dividing piston Tuning the suspension Road holding qualities All vehicles are designed with a suspension geometry that includes wheel movemnets and angles The changing of components can affect this and it is therefore essential that both the rear and the front ends match each other Changing to Ohlins suspension gives optimum performance only when both the front and the rear suspen sion interact properly Everything must harmonize Incorrect spring action can affect the road holding abilities in a negative way This in turn can givea tendency for oversteering or understeering which could seriously affect the road holding charac teristics of the vehicle Its important that the springs are checked for correct lenght and stiffness when Ohlins shock absorbers are mounted 2 External gas reservoir hose connected Main piston Fluid 3 External gas Design Most Ohlins 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 gas and the separating piston are often fitted in separate fluid reservoir connected by hose or fixed direct on top of the shock absorber piggyback there are also2. pression damping Fig 1 Flow through Fig 2 Flow regulated needle valve by shims Rebound shims stack Compression shims stack Function The function in principle is that fluid is forced through needle valves at a low rate of flow Fig 1 and through a number of apertures in the piston at a high rate of flow Fig 2 The flow through these apertures is regulated by shims thin steel washers that at high pressure are deflected to open for the fluid On some models the needle valves can be set individually By altering the size of the shims stack ie number thickness diameter Fig 3 the charac teristics of the damping action can be varied this shall only be done by Ohlins authorized service workshops Compression damping When movement of the vehicle causes compres sion in the shock absorber the fluid flows through the needle valve combined compression and return valve in the piston rod If velocity of the piston is high ie in the case of rapid compres sion this will not be sufficient and consequently 4 Piston with aperture Compression flow Rebound flow the shims underneath the piston will open to allow a greater rate of flow The fluid that is displaced by the volume of the piston rod is forced into the external fluid chamber via a separate compres sion valve Even this valve is fitted with shims that open at high piston velocity The separating pis ton is displaced thus increasing the
3. gas pressure Rebound damping When the spring presses the shock absorber out again the fluid flows back through the needle valve in the piston rod The fluid flowing into the chamber is forced by the pressure of the gas back into the shock absorber via a separate non return valve If velocity of the piston is high the shims on top of the piston will also open to allow the fluid to flow though Base plate In some mdels an internal gas reservoir is seperated from the tube by a base plate The control of the oil flow is regulated by the base plate before it reaches the dividing piston Fig 3 Shim stack Stop washer Shims stack Piston Settings Basic settings Always ensure that the basic setting made by the Ohlins dealer is correct It is adapted to the specific make and model the shock absorber s is are designed for Setting the spring preload Preload on the spring springs is very important because it affects the height of the vehicle and the wheel angles Consequently road holding characteristics can be changed even negatively Adjusters are mechanical or hydraulical Me chanical adjustment is made with the rings on the shock absorber Hold the upper ring and ad just the lower one to the desired position then lock with the upper ring 4 Mechanical adjustment NOTE On shock absorbers that have mechanical type adjustment the position of the adjusting preload rings can be adjusted Se
4. NOTE When making new adjustments it is easiest to go back to zero and then count forward to the new setting The adjusting knobs should not be turned in too hard Avoid tools when attempt ing to adjust the shock absorber The adjust ment should be made when the shock absorber is cold 7 Compression adjustment 8 Adjustment of shock absorbers lenght Setting the shock absorber length Sensitivity of the steering can be adjusted by altering the length of the shock absorber with out affecting other characteristics The length is adjusted using two nuts down and the treaded clevis at the end of the piston rod Fig 8 The shock absorber can be adjusted up to 12 mm The length may never be altered more than to where the groove that is cut in the thread be comes just visible Adjusting the shock absorber length Each complete turn of the shock absorber gives one millimetre The length may never be altered more than to where the groove that is cut in the thread becomes just visible under the lower nut of the level brachet Make small steps and test run 9 Rebound adjustment Setting your vehicle By utilizing the adjustment possibilities you can test by trial and error and learn how they affect your vehicle Always begin by test driving with all adjust ments at their basic setting Choose a short run of varying character ie long and sharp bends hard and soft bumps Keep to the same run and adjust only one set
5. Owners Manual Ohlins shock absorber basic information Including Tuning the suspension Function im Maki lt BD mnn S Setting your vehicle ADVANCED SUSPENSION TECHNOLOGY Introduction All of Ohlins advanced suspension products are adepted to the brand and model This means that length travel springaction and damping character A WARNING 1 Installing a suspension that is not approved by the vehicle manufacturer may affect the stability of your vehicle Ohlins Safety signals Important information concerning safety is distinguished in this manual by the following notations The Safety alert symbol means Caution Your safety is involved WARNING Failure to follow warning instructions could result in severe or fatal injury to anyone working with inspecting or using 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 of importance with regard to 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 istics are tested individually just for the vehicle that you have decided to fit with Ohlins suspension Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension or vehi
6. cases where everything is fitted inside the main shock absorber internal gas reservoir some shock absorbers have a large diameter internal fluid reservoir and a base plate with damping qualities There is even a small number of emulsion shock ab sorbers that do not have a separating piston Pressurization of the fluid is made with nitrogen The pressurization prevents cavitation of the fluid and the shock absorbing action is therefore more even The external fluid chambers also contribute to better cooling of the fluid giving longer service life for both the fluid and components Ohlins shock absorbers have integrated temperature compensation As the temperature increases and the fluid flows more easily the flow reservoir piggyback 4 Internal gas reservoir 5 Emulsion with base plate shock absorber 6 McPherson shock absorber is controlled accordingly The shock absorbing effect is therefore independent of the temperature Ohlins shock absorbers provide the possibility for adjustment making them adaptable to most vehicles drivers and ranges of use All of the shock absorbers equipped with springs have adjustable preloading of the spring action either mechanically or hydraulically The more advanced models permit individual adjustment of compression damping and rebound damping and also certain adjustment of the length of the shock absorber The most advanced mod els can be equipped with high and low speed com
7. cle or injury to persons if the instructions for fitting and maintenance are not followed exactly Similarly the warranty will become null and void if the instructions are not adhered to Contents E a E 2 TUNING the suspension cccceeeseeeeeeeeeeeeeeeeees 3 PS SU GA eann ERER RE ea 3 CG e a cs E E E E PT TE 4 SAS lt E E T E E 4 Setting your vehicle ssssssssssnsseessssnsennnnnneenne 6 Inspection and maintenance ceeeeeeeeeees 7 Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension Contact an Ohlins dealer or other qualified person for advice 2 Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this suspension kit If you have any questions regarding proper installation procedures contact an Ohlins dealer or other qualified person 3 The vehicle service manual must be referred to when installing the Ohlins suspension NOTE Ohlins products are subject to continual improve ment and development Consequently although these instructions include the most up to date information available at the time of printing there may be minor differences between your suspen sion and this manual Please consult your Ohlins dealer if you have any questions with regard to the contents of the manual Design principles Gas 1 Internal gas reservoir Dividing piston
8. pressure Special purpose charging equipment and access to nitrogen is required The gas pressure should normally never be altered NOTE Make certain that your shock absorbers are al ways filled with hlins High Performance Shock Absorber Oil Remember Regular maintenance oil change and inspection contribute to the prevention of functional distur bances Recommended service intervals Road Once a year or every 20 000 30 000 km NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal More info www ohlins com Precision Makes the Difference If You are looking for the ultimate in performance this is the right site Surf around and find out what the ultimate in suspension is The ultimate suspension site Find out everything about your suspension Down load mounting instructions manuals and brochures And a lot more ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands Vasby Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your Ohlins dealer 07255 01 Issued 05 0113 500 ex
9. ting at a time NOTE Always begin with the basic settings recommended by the Ohlin dealer Always make notes adjust in small steps and make only one adjustment at a time Adjustments should be made with two steps clicks at a time Adjustments should not be more than four steps from the basic setting Reduced damping force 10 Adjustment of compression damping Added damping force Start with the rebound damping If the vehicle feels unstable loose and rather bouncy then the rebound damping should be in creased Fig 9 Begin by turning the adjusting knob 4 steps clicks clockwise Test run again and adjust two steps back if it felt too hard and bumpy If the vehicle is hard and bumpy especially over a series of bumps then the rebound damping should be reduced Turn counterclockwise 4 steps test run and make any necessary correc tion to 2 steps Compression damping If the vehicle feels soft has low riding position and a tendency to bottom easily in long dips then the compression damping should be increased Fig 10 Screw clockwise 4 steps and test run again If this was too much then turn back two steps anticlockwise High speed Low speed If the vehicle feels harsh and has hard resilience eg over changes in the road paving then the compression damping must be reduced Screw anticlockwise 4 steps Test run and make any necessary correction to two steps When you have sufficient feel of the
10. tting the damping The adjusting possibilities of Ohlins shock absorbers facilitate fine setting You can optimize adjustments to suit your own vehicles weight and equipment your individual way of driving and the condition of the road To be able to improve the road holding qualities it is of the utmost impor tance that you fully understand the functioning of the shock absorbers Then you can learn by trial and error how they affect the vehicle NOTE Ensure that the springs are properly preloaded before attempting to make any adjustments A simple rule is that increased preload of the spring should be followed by an increase of rebound damping by two steps Integrated adjuster 5 Hydraulic pre load adjuster Hose connected hydraulic pre load adjuster 6 Rebound adjustment Depending on the model there are adjustments for rebound damping and compression damp ing Damping is set with the knobs they have a normal right hand thread By turning clock wise they increase the damping action and an ticlockwise they reduce it The knobs have defi nite positions with a noticeable click so it is easy to count to the right setting Rebound damping action affects the char acteristics of the vehicle most The setting knob is at the bottom on the piston rod Fig 6 It can be adjusted in about 40 steps The compres sion damping knob is on the top of the cylinder Fig 7 This can be adjusted in about 25 steps
11. vehicle then you can make further fine adjustments It is feeling and experience that counts NOTE If no click is felt the shock absorber must be inspected by an authorized service workshop It could be due to incorrect or lack of gas pressure When you feel that you have achieved an improvement go back to where you started and check once more Be observant of other relevant factors such as tyres temperature etc Test run to make sure whether further fine adjustment should be made Lift the bump rubber and clean the area below Inspection and maintenance Keep the shock absorbers clean and always spray them with oil QS 14 WR40 or CRC 5 56 after washing the vehicle Inspection points 1 Check ball joints for possible excessive play 2 Check the piston shaft for leakage and damage 3 Check the shock absorber body and for external damages 4 Check the external reservoir for damages that can restrict the floating piston from moving freely 5 Excessive wear of rubber components 6 Fastening to the vehicle Check the hose equipped models for leaks in hose and inlet plugs Inspection points Preventive maintenance and regular inspection reduces the risk of functional disturbance If there is any need for additional service please get in touch with an authorized Ohlins service work shop There they have the necessary tools and know how for whatever you need WARNING Never alter the gas
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