Owners Manual
Contents
1. Sweden Phone 46 8 590 025 00 Fax 46 8 590 025 80 Your Ohlins dealer 07450 01 Issued 05 03 172. been changed or modified the clearances and the stability of the vehicle can be affected Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension or vehicle 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 SLY a E 2 Tuning the suspension ccccsesseeeeeeeeeseeeeeees 3 De A ara AEAEE EAE 3 FUNC GO serao E e EA 4 EAE A E E E E E E E 4 Setting your vehicle ssssssssssssseesssseennnnnennennne 6 Inspection and maintenance cceceeeeeeees 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 y
3. can learn by trial and error how they affect the vehicle Depending on the model there are adjustments for damping forces rebound damping and com pression damping Damping is set with a knob with a normal right hand thread Fig 6 By turn ing clockwise they increase the damping action and counter clockwise they reduce it The knob has definite positions with a noticeable click so itis easy to count to the right setting On some models compression and rebound damping are set individually Fig 7 and 8 Added damping force Reduced damping force J 7 Individual 8 Individual compression rebound adjuster adjuster NOTE When making new adjustments it is easiest to go back to zero and then count forward to the new setting The adjusting knob should not be screwed in too hard Never use tools when at tempting to adjust the shock absorber The ad justment should be made when the shock ab sorber is cold CAUTION 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 9 Damping force Added damping force Reduced damping force 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 l
4. the chamber is forced by the pressure of the gas back into the shock absorber via a separate non re turn 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 C spanner 5 Mechanical adjustment Settings Basic settings Always ensure that the basic setting made by Ohlins is correct It is adapted to the specific make and model in its original state Setting the spring preload measuring adjustable models only 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 Setting the spring preload adjusting adjustable models only Adjust the preload with the rings on the shock absorber hold the upper ring and adjust the lower one to the desired position Then lock with the upper ring 6 Damping force adjusters When adjusting simply use your fingers avoid tools Adjuster mounted Adjuster mounted downwards upwards Setting the damping The adjusting possibilities of Ohlins shock ab sorbers 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
5. Owners Manual Ohlins shock absorber Car Road amp Track Including Tuning the suspension Function Setting your vehicle 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 istics are tested individually just for the vehicle that you have decided to fit with Ohlins suspension WARNING The specifications for the particular suspension shock absorber are developed in tests on a factory equipped vehicle If wheel dimensions springs and or other chassis parts have
6. d Ohlins service work shop There they have the necessary tools and know how for whatever you need A WARNING Never alter the gas pressure Special purpose charg ing equipment and access to nitrogen is required The gas pressure should normally never be altered Recommended inspection and maintenance intervals For normal use clean and inspect the shock absorbers once a year Once a year general Let an authorized Ohlins dealer change shock absorber oil NOTE Make certain that your shock absorbers are always filled with hlins High Performance Shock Absorber Oil NOTE Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal More info www ohlins com LoG EEEE T eae a Precision Makes the Difference te fid If You are looking for the ultimate in performance this is the right cite Surf around and find out what the ultimate in suspension is all sbout LE r9 is gt e ae A 5 a g R Read this years Newsletters Tren B ee gt Softail for Harley Davidson d lt The First Volvo S6OR with CES sf ROEHAIG Ohlins Teams amp Riders 2003 Se garann and more The ultimate suspension site Find out everything about your suspension Download mounting instructions manuals and brochures And a lot more m m OHLINS ADVANCED SUSPENSION TECHNOLOGY Ohlins Racing AB Box 722 S 194 27 Upplands Vasby
7. kness diameter the characteristics of the damping action can be varied this shall only be done by Ohlins authorized service work shops CAUTION Do not try to open the shock absorber yourself The warranty will be null and void if the shock absorber is not handled by an Ohlins authorized workshop 2 Flow regulated by shims Rebound shims stack Compression shims stack 3 Piston with shims Piston Apertures 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 the shims underneath the piston will open to al low a greater rate of flow The fluid that is dis placed by the volume of the piston rod is forced into the internal or external fluid reservoir The separating piston is displaced thus increasing the gas pressure In a damper equipped with an external reservoir the fluid flows via a separate compression valve Even this valve is fitted with shims that open at high piston velocity Shock absorbers equipped with a base plate have a similar flow 4 Flow through piston Stop washer 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
8. ong and sharp bends hard and soft bumps Keep to the same run and adjust only one setting at a time Setting the damping If the vehicle feels unstable loose and rather bouncy then the damping should be increased If the vehicle is hard and bumpy especially over a series of bumps then the damping should be reduced If the vehicle feels soft has low riding position and a tendency to bottom easily in long dips then the damping should be increased If the vehicle feels harsh and has hard resilience e g over changes in the road paving the damping must be reduced 6 Rebound damping Begin by turning the adjusting knob two 2 steps clicks Test run again and adjust one 1 step back if it affects the vehicle too much When you have sufficient feel of the vehicle then you can make further fine adjustments It is feeling and experience that counts NOTE Ensure that the springs are in good conditions and properly preloaded before attempting to make any adjustments NOTE Always begin with the basic settings recom mended by Ohlins Always make notes adjust in small steps and make only one adjustment at a time Adjustments should be made with max two steps clicks at a time Do not shut adjuster more than one click from fully closed Compression damping When you feel that you have achieved an im provement go back to where you started and check once more Be observant of other relevant factors such as ty
9. our suspen sion and this manual Please consult your Ohlins dealer if you have any questions regarding the contents of the manual Design principles Dividing piston Shock absorber piston Tuning the suspension Road holding qualities All vehicles are designed with a suspension ge ometry that includes wheel movements and an gles 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 can give a tendency for oversteering or understeering It is important that the springs are checked for correct length and stiffness when Ohlins suspension is mounted e X Base plate C restrictor g A 2 Design Most hlins suspensions are of the high pressure mono tube type The fluid is put under gas pressure The gas and the fluid are kept apart by a separating pis ton The separating piston is fitted inside the main shock absorber internal gas reservoir 1 orina separate fluid reservoir connected by hose 2 or fixed direct on top of the shock absorber piggy back 3 A few shock absorbers have a larger diameter separating piston combined with a base plate 4 Pressurization of the fluid is made with nit
10. res temperature etc Test run to make sure whether further fine adjustment should be made CAUTION When suspension components are exchanged it is of greatest importance that the wheel alignments are checked NOTE Save your original shock absorbers If your Ohlins shock absorber must be modified e g for racing purposes or serviced the original shock absorb ers may be of use again Inspection points Inspection and maintenance Clean the shock absorbers externally with a soft detergent Lift the dust cover and use com pressed air 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 CAUTION Never use detergents that can damage the sur faces of the shock absorber E g thinner and brake cleaner will dry the surfaces too much Inspection points 1 Check brackets or bushings for possible excessive play 2 Check the piston shaft for leakage and damage o Check the shock absorber and reservoir body for external damages Check the dust cover for damages Spring condition 4 5 6 Excessive wear of rubber components 7 Fastening to the vehicle 8 Check the hose for leakage and damage 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 authorise
11. ro gen The pressurization prevents cavitation of the fluid and the shock absorbing action is therefore more even The external fluid chambers also con tribute to better cooling of the fluid giving longer service life for both the fluid and the components Fig 1 External reservoir with hose connection Fig 2 External piggyback reservoir Fig 3 Internal gas reservoir Fig 4 Internal reservoir with base plate hlins shock absorbers have integrated tempera ture compensation As the temperature increases and the fluid flows more easily the flow is con trolled accordingly The shock absorbing effect is therefore independent of the temperature hlins shock absorbers provide the possibility for adjustment making them adaptable to most vehicles drivers and ranges of use Some of the shock absorbers equipped with springs have adjustable preloading of the spring action The more advanced models permit individual adjust ment of compression damping and rebound damping 1 Flow through needle valve Function The function in principle is that fluid is forced through a needle valve at a low rate of flow and through a number of apertures in the piston ata high rate of flow The flow through these aper tures 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 thic
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