ohlins shock rebuild...
 

hello,

i've been searching for info on my ohlins shock but can't find the right info i need.
i need the amount and weight (viscosity) of the shock oil that goes in.
i started to disassemble it and drained the oil allready but can't tear it apart.
took out the circlips under the metal dust cap and tried popping it out but no luck so far...

mine's a 2000 EC 300.

thanks, Hannes.
belgium.

ill give my my mechanic a call and get back to you, he should know.

I have a PDF of the rebuild manual and I'm sure it has the specs, I will send it to you tomorrow if you still need it (send me a PM either yes or no). It is on my work computer and I'm home now.

thanks in advance for everyone who helped me out! :-)

haven't succeeded yet in dissasabling the shock :(
got the snap ring out of the main shaft but can't pull the rod out.it gets stuck right to the position where the snap ring was...

in the manual it says to use an injection needle to loosen the nitrogen gas from the piggy bag, i suppose this means i would have to replace the rubber valve then?

i have to be doing something wrong, but what...:confused:

any input?

thanks, hannes.

Did you have success rebuilding the shock Hannes ?

Standard ohlins on an '06 #GG 6811. I've got mine apart to do an oil change and nitrogen recharge. I used a 23 gauge (0.61mm) hypodermic needle to discharge the nitrogen, as I understand it, the rubber bung 'heals' itself and can be punctured multiple times. It takes some effort to pull out the pistons. There was no apparent damage to the o rings or piston rings.

Any recommendations to air bleeding procedure when refilling the oil for this type of shock with a floating piston in the reservoir ? Or oil recommendations (I'm in England, so might not have access to brands available in other parts of the world) I can get the nitrogen recharged at the local mx shop for a nominal fee.

I can't quite understand how to determine the correct oil quantity / level at reassembly.

Not done a shock service before, so any help or advice very welcome. Good to learn by doing.

I'm hoping Jakobi will chime in here as he is way more experienced than I but I just serviced my Ttx shock. I built a vacuum bleeder as they are the best way to fill the shock and from what I understand the best hand bleed will probably still have a bit of air in it. Does your shock have a torn screw at the top of it? If so, that is where the bleed adapter fits. Object is to have shock body completely full with reservoir full to piston (on mine) depth and no air in it. You may have a bladder in the 2000 shock though but goal is the same.

Worth noting is the amount of air in the shock fluid straight out of the bottle. I 'de-gassed' my fluid and was amazed at how long it took to become bubble-free.

Mechanically there isn't a lot holding the shock together.

Safety first - never try to disassemble without discharging the nitrogren completely (you'd have a hard time doing it, but if you suceed it wouldn't be pretty).

The base of the N2 res uses a rubber pad/seal. A hyperdermic needle is required to discharge it, and again (with correct tooling/adapters) to regas is.

You can search how to use a bleed bottle which will is how people hand bleed the ktm pds shocks, or you can go a simple hand bleed which should work fine too. First time around expect to spend a fair whack on some tools, and bulk time learning. From what I see a standard service is pretty cheap. Just things to consider.

Decided to take it to a suspension specialist this time, so I can get the bike back together. From what I can gather, a vacuum bleeder and correct nitrogen regulator are important tools to do the job right, so now I can take my time figuring out a home brew version.

From an economic point of view, I suspect that even with 3 bikes to maintain, there probably isn't much benefit to doing the work myself. Even so, it's good to learn new things.

This is a rebuild of a Yamaha shock by an Ohlins dealer, see 2.38 for the nitrogen removal process.


http://www.youtube.com/watch?v=RQRxBSpG-Ng