Ohlins Shock Service
 

A mate sent his shock up, after the seal blew its load and sent oil all over the shop. He asked for a few pics along the way, so I figured I'd do a little thread incase anyone else was interested in the internals.

Safety note: Trying to work on a shock while still gassed up/charged with N2 is dangerous. Always ensure all pressure has been released prior to disassembly.

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I like to use the bleed port when dumping the contents of an Ohlins. Makes it easy to pump the oil out and less messy when removing the shaft and piston.

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Circlip removed
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Nut removed from shaft. Shims, piston, spacers all removed. Seal head slides off next.
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Above, I also removed the compression adjuster to allow for easier cleaning/flushing of the res and body. Everythings cleaned now.

Will be replacing the bump stop (which shows some deterioration), piston band (teflon coating looks a little rough around the edges), and the seal head as a whole. Leak was due to some Teflon from the seal head bushing getting caught up against the seal lip. Bushing itself shows a little wear down one side where it's loaded when in use.

Getting parts on order. Will update later once replacements arrive.

Nice job Jake, Thanks

thanks for the extra effort mate, really interesting to see how it all works..... i will have to have a go one day, cept you'll probably have to put it together for me...

Do. See that right, you have your own nitrogen generator? Or what is this small compressor for?


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Elvis. In the back ground is my vacuum pump. I do have a N2 cylinder and associate regulators and gauges here as well though.

You can hand bleed them up as well which is what most people will do. For this I may take a little longer and hand bleed it and then connect it up for a couple cycles to see how much more air I can purge.

Ah ok!
We build in our factory nitrogen generators which look similar than you vacuum pump. Nice work you are doing there.


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Nice post !

So after the retaining ring is removed from the inside of the shock body (as shown), the shaft/seal-head assy should slide out without too much effort? I have made it all the way to that point and the the seal head won't move past the land that the retaining ring resided. I really appreciate the walkthrough!

Edit: Got it out the next day.