Owners Manual
Contents
1. Be careful that all dirt and debris is removed Lift the bump rubber and clean the area below Keep the shock absorbers clean and always spray them with oil QS 14 WD40 or CRC 5 56 or similar after washing the vehicle CAUTION Never use detergents that can damage the surfaces of the shock absorber IA thinner and brake cleaner will dry the surfaces too much WARNING Never alter the gas pressure Special purpose charging equipment and access to nitrogen is required The gas pressure should normally never be altered Inspection points After every competition Inspection points 1 Check brackets 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 7 Check the hose for leakage and damage NOTE Make certain that your shock absorber are always filled with hlins High performance shock ab sorber oil Every 300 500 km Mc Pherson struts only A Remove the cartridge from the front outer tube by removing the bottom nut B Clean all parts with a soft detergent C Lubricate the the inner tube and the scraper with a layer of hlins red grease part No 146 01 100 grams or 146 02 400 grams The space between the bushings in the outer tu2. is in direct contact with the outer tubing It gives more consistent damping regardless of the shock absorber s work ing temperature and it makes the shock absorber last longer The external shock absorber reservoir connected directly to the shock absorber body or by a hose is in fact an extension of the main body which contributes to the improved cooling The reservoir contains the floating piston and the gas that pressu rises the damping oil Function At low shaft speeds the damping oil is forced through an adjustable bleed valve in the main piston shaft The valve affects mainly rebound damping and has With the bleed valve on you adjust compression thereby only influencing Effect of compression adjuster m increased number of clicks 0 Damping force N O Piston speed m s 0 5 only a small effect on compression damping see fig 1 graph 1 above The adjuster is connected to the valve via an aluminium shaft that runs inside the piston shaft When the temperature in the shock increases the aluminium shaft extends thereby closing the bleed valve gradually This diminishes the influence of the oil viscosity changes due to temperature keeping the flow through the valve virtually the same regardless of temperature With the second adjustable bleed valve on the top of the reservoir you can adjust the compression damping Some models have separate high and low speed compression clamping The valv
3. is located at the end eye of the piston shaft Fig 8 The temperature compensation system of the rebound adjuster reduces the number of clicks due to the elongation of the aluminium shaft as described earlier when the shock absorber is hot Therefore always make changes from the previous click position without first closing the adjuster To count the number of clicks you are using first let the shock cool down to ambient temperature 6 High and low speed compression damping adjusters Low speed High speed NOTE Using to much force when closing the adjuster will destroy important sealing surfaces When possible use no tool simply your fingers All the adjusters have a normal right hand thread Click position zero 0 is when the adjusters are turned clockwise to fully closed WARNING There is no stop telling when the adjusters are fully open It is possible to unscrew the strut rebound adjuster if more than the recommended usable clicks are used Please see Setting up your car 7 Rebound adjuster on Mc Pherson strut Added damping force Reduced damping force 8 Rebound adjuster on piston shaft O Setting up your car Installing new shock absorbers may alter ride height wheel angles etc on your car Therefore it is wise to do a complete resetting of the car after you have installed the hlins shock absorbers Perform the following steps and always make notes before usin
4. see External adjusters and Recom mended settings NOTE Higher click numbers give less damping force Camber bushings available Bushing type 5194 Bushing type 5794 Part no Marking Eccentricity Part no Eccentricity grooves in mm in mm 05194 00 0 0 05794 00 3 00 05194 05 1 0 5 05794 01 2 44 05194 10 2 1 0 05794 02 1 88 05194 15 3 1 5 05794 03 1 32 05194 20 4 2 0 05794 04 0 76 05194 25 5 2 5 05794 05 0 20 05194 80 No hole the customer can drill the hole to tailor camber exactly When making adjustments keep notes make adjustments one at a time and in small steps The adjusters should normally not be adjusted in steps of more than 2 clicks at a time and not outside the usable click range When you think you have made an improvement go back to what you started with and double check to be sure Pay attention to changes in conditions like tires or temperatures etc In general compression damping changes should be used to influence the car s stability and response while rebound damping changes should be used to influence comfort and traction When you need more damping force you should mainly try to increase compression damping and use as little rebound damping as possible This usually means that you gain comfort and handling performance Lift the bump rubber and clean the area below Inspection and maintenance Clean the shock absorbers externally with a soft detergent Use compressed air
5. 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 SATE ana eaa E RE 2 B a a AEAEE E E E ET E ETE E 3 When you are driving cccceeccceceesssseeeeeeeeeeeees 4 External adjusters ccccccsseceeseeeeeseseseeeeees 5 Setting Up YOUR COP cenvcrcsunncsninieconsiimnnendsccanmanion 5 Camber DUSHUING wccenncncicsiaerierstoncsswiincnunertnneceiaes 6 Making adjustments cccccceeceeeeeeeeeeeeeeeeees 6 Maintenance INSPECTION ccssecceeeeeeeeees 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
6. through just the valve in the piston shaft The pressure on the compression side increases and opens the shim stack covering the compression orifices in the piston Fig 1 flow 2 Also oil displaced by the piston shaft can not be forced fast enough through just the valve in the reservoir The pressure increases and a shim stack parallel to the valve opens Fig 2 flow 1 and 2 The floating piston is forced to move compressing the gas by the displacement of the piston shaft Re D A i 3 Rebound flow in shock absorber A p 4 Rebound flow in externa reservoir When the shock absorber extends the floating piston forces the oil through the one way valve back into the shock absorber body Fig 3 flow 1 and 2 The pressure difference over the piston is still high and the flow can not be forced fast enough through just the valve in the piston shaft The shim stack covering the rebound orifices in the piston opens and the oil returns Fig 4 flow 1 5 Adjustment of compression damping External adjusters The Ohlins shock absorbers have a low speed compression adjustment knob located on top of the reservoir Fig 5 Some models even have a high and low speed compression adjustment Fig 6 A low speed rebound adjuster is located in the bottom end of the Ohlins McPherson strut Adjustments are made with a3 mm Allen key fig 7 On the Ohlins shock absorber the rebound adjustment knob
7. Owners Manual Ohlins shock absorbers Car Rally amp Track Including Setting up the car Trouble shooting ADVANCED SUSPENSION TECHNOLOGY Introduction All of Ohlins advanced suspension products are adepted to the specific brand and model This means that length travel springaction and damping 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 NATN ININ CEL 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 characteristics are tested individually just for the vehicle that you have decided to fit with Ohlins sus pension Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension or vehicle or injury to persons if
8. be should be filled with a layer of hlins red grease up to the bushing surface D Assemble the strut and tighten all nuts Once a year i Change shock absorber oil Use only Ohlins shock absorber oil Contact your hlins dealer NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal More info www ohlins com ADVANCED SUSPENSION TECHNOLOGY 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 all Read this years Newsletters Softail for Harley Davidson The First Volvo S60R with CES hlins Teams amp Riders 2003 The ultimate suspension site Find out everything about your suspension Download 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 07440 01 Teknisk Illustration OM Car Rally amp Track Issued 05 04 19
9. e restricts the flow to the reservoir but not from it thereby only influencing the compression damping see fig 2 graph 2 above At higher shaft speeds the damping forces are primarily controlled by the main piston and its compression and rebound shim stacks By changing the numbers diameter and thickness of the shims in the stack and by using different jets in the valves your Ohlins shock absorbers are tailor made for just your car 3 1 Compression flow in shock absorber body When you are driving On a smooth surface When you are driving on asmooth surface and the shock absorbers are compressed slowly low shaft speed the damping oil is forced only through the adjuster valve in the piston shaft Fig 1 flow 3 The oil displaced by the piston shaft is forced through the independent compression damping adjuster out into the external reservoir Fig 2 flow 3 The floating piston in the reservoir is forced to move compressing the gas behind it further When the shock absorber extends the pressure behind the floating piston will force the oil through a one way valve and back into the shock absorber body Fig 4 flow 1 and 2 The oil beneath the piston returns through the adjuster valve in the piston shaft Fig 3 flow 3 2 Compression flow in external reservoir Hitting a bump When you are hitting a bump the shock absorbers are compressed fast high shaft speed The oil can not be forced fast enough
10. g the shock absorber 1 Check ride height front and rear Adjust if necessary 2 Check corner weight front and rear if scales are available Adjust if necessary 3 Check all wheel angles front and rear Adjust if necessary 9 Camber bushings Bushing type 5194 Camber bushings Unlike most standard McPherson struts the Ohlins struts feature camber bushings that enable you to alter the wheel camber The different bushings are marked bushing type 5194 with grooves bushing type 5794 with a punched number on the side last figure of the Part No Depending on how you mount the bushings with the eccentric hole facing the wheel or away from the wheel different camber angles will be obtained Recommended settings The shock absorbers in your kit are adjusted to the Ohlins recommended setting for your car see Mounting instructions We advise you to use this as your start setting Groove Hole away from the wheel Hole facing the wheel Punched number 0 5 Making adjustments Suspension settings are dependent on your car s weight your driving style road conditions etc If you are not happy with our recommended settings here are a few guidelines and ground rules how to make adjustments To make improvements it is important to understand the function of the shock absorbers and through testing learn how they affect the handling of your Car Always start with the Ohlins recommended settings
11. if you have any questions with regard to the contents of the manual Effect of rebound adjuster m increased number of clicks 0 Damping force N O0 Piston speed m s 0 5 Design Ohlins car shock absorbers are based on Ohlins successful application of the high pressure monotube concept In short that means that the damping oil is put under gas pressure and separated from the gas by a floating piston The separating piston is positioned in an external reservoir Fig 1 To obtain a progressive damping system PDS the most advanced shock absorber has two pis tons One of the pistons is active throughout the 1 Shock absorber with external gas reservoir 2 Damping curves 1 2 At low shaft speeds the damping oil is forced through an adjustable bleed valve in the piston shaft The valve affects mainly rebound damping and has only a small effect on compression damping the top of the reservoir damping The valve restricts the flow to the reservoir not from it the compression damping entire lenght of the stroke while the second pis ton begins to work in the event of powerful com pression of the shock absorber The high pressure monotube concept has many advantages It prevents the risk of cavitation that can wear out internal components and cause incon sistent damping It eliminates aeration of the damp ing oil which also causes inconsistent damping It improves the cooling because the oil
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