Ohlins DH38 Instruction manual

Workshop Manual - Rebuild air spring cartridge

2
© Öhlins Racing AB. All rights reserved.
Any reprinting or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
General Warnings
Note!1
When working with the Öhlins product, always read the Vehicle Service Manual.
Note!1
The shock absorber/front fork/steering damper is an important part of the vehicle
and will affect the stability.
Note!1
Read and ensure you understand the information in this manual and other
technical documents provided by Öhlins, before using the product.
Note!1
Öhlins Racing AB can not be held responsible for any damage to the shock
absorber/front fork/steering damper, vehicle, other property or injury to persons, if
the instructions for mounting, usage and maintenance are not followed exactly.
Warning!⚠
After installing the Öhlins product, take a test ride at low speed to ensure your
vehicle has maintained stability.
Warning!⚠
If the suspension makes an abnormal noise, or the function is irregular, or if you
notice any leakage from the product, stop the vehicle immediately and return the
product to an Öhlins Service Centre.
Warning!⚠
The product warranty shall only apply if the product has been operated and
maintained in accordance with recommendations in this manual. If you have any
questions regarding usage, service, inspection and/or maintenance please contact
Öhlins.
Note!1
Before working on the product make sure that the vehicle is washed and cleaned
properly. Do not use alcobased products on the outside or inside of the product.
Product Specic Warnings
Warning!⚠
This product was developed and designed exclusively for a specic vehicle model
and shall only be installed on the intended vehicle model in its original condition as
delivered from the vehicle manufacturer.
Warning!⚠
This product is pressurized. Do not open, service or modify this product without
proper education (authorized Öhlins dealer/distributor) and proper tools.
Caution!✋
Do not use a pressure washer or a power washer when cleaning the fork.
SAFETY SYMBOLS
In this manual, mounting instructions and other technical documents,
important information concerning safety is distinguished by the following
symbols:
The Safety Alert Symbol means: Warning! Your safety is involved.
Warning!⚠
The Warning Symbol means: Failure to follow warning instructions can result
in severe or fatal injury to anyone working with, inspecting or using the shock
absorber/front fork, or to bystanders.
Caution!✋
The Caution Symbol means: Special precautions must be taken to avoid
damage to the shock absorber.
Note!1
The Note Symbol indicates information that is important regarding procedures.
TABLE OF CONTENTS
Tools ...........................................................................................................................................3
Overview - General layout..........................................................................................................3
Kit contents.................................................................................................................................4
Remove air spring from lower legs (RXF34/RXF36/RXF36 m.2)...............................................5
Remove air spring from lower legs (DH38) ................................................................................7
Rebuild of air spring cartridge.....................................................................................................9
Reinstall air spring cartridge (RXF34/RXF36/RXF36 m.2).......................................................22
Reinstall Air spring cartridge (DH38) ........................................................................................23
Appendix A................................................................................................................................24
SAFETY PRECAUTIONS

3
REBUILD AIR SPRING CARTRIDGE
Tools
12
118860-01 Hex socket 28 mm
218860-03 Seal head tool 14
319245-01 Multi clamp TTX18
4 - Cassette lockring tool
Oil, grease, thread locker and sealant
Fork lubrication uid 01336-01 - Renep CGLP 68 Fork lube 1L
Air spring lubrication uid 01337-06 - Renep CGLP 220 Air spring lube 0.6L
Function grease 01338-22 - Renolit SI 410 M Silicone grease 225g
Assembly grease Slickoleum / Buzzy’s Slick Honey
Loctite 243 01791-03
Loctite 577 01791-07
43
Overview - General layout
1
2
3
1
2
3
Chassis
Air Spring
Cartridge
Damper
Cartridge

4
REBUILD AIR SPRING CARTRIDGE
Kit contents
1
118850-13 Rebuild kit air spring
The following service kits (expiring) can also be used:
DH38: 19242-02
00576-23
O-ring
00338-39
O-ring
00576-06
O-ring
x2
03070-01
Scraper
18649-01
Bump rubber
18641-01
Back-up ring
18639-01
X-ring
18637-01
O-ring
18629-02
X-ring
18628-01
O-ring
x2
18607-01
Air valve schrader
x2
18556-03
Back-up ring
x2 x2
00638-86
O-ring
00438-57
O-ring
00338-68
O-ring
00338-57
O-ring
18612-04
O-ring

5
REBUILD AIR SPRING CARTRIDGE
Remove air spring from lower legs (RXF34/RXF36/RXF38)
1
Note!1
Record the rebound adjuster setting and the pressure in the positive air chamber
and ramp up chamber before service. We recommend using a bike stand to clamp
the steering tube when working on the fork.
1. Thoroughly clean the outside of the fork from dirt or grit. Place the
fork in a bike stand accoring to picture with air spring side pointing
upwards and the fork on the right hand side of the clamp jaws.
2. Release the air from the positive air chamber at the top and the
ramp up chamber at the bottom.
3. Use a socket wrench with a 12/14 mm deep hex socket to remove
the nut and the washer (for 12 mm) on the lower air valve.
4. Use a socket wrench with a hex socket 28 mm (18860-01) or a
cassette lockring tool to loosen the air spring.
Caution!✋
Do not use an adapter between wrench and socket, as this will increase the risk of
damaging the anodized nish of the top cap.
Note!1
When removing the Air Spring cartridge, it is easy to damage the Top Cap. Put
pressure on the wrench while unthreading the Top Cap.
2
3
4

6
5
5. Slide the air spring off the stanchion tube.
REBUILD AIR SPRING CARTRIDGE

7
REBUILD AIR SPRING CARTRIDGE
Remove air spring from lower legs (DH38)
Note!1
Record the rebound adjuster setting and the pressure in the positive air chamber
and ramp up chamber before service. We recommend using a bike stand to clamp
the steering tube when working on the fork.
1. Thoroughly clean the outside of the fork from dirt or grit.
2. Release the air from the positive air chamber at the top and the
ramp up chamber at the bottom.
3. Remove the golden bash cap for the air spring side by unscrew-
ing it by hand.
4. Remove the nut on the air spring side by using a socket wrench
with a 14 mm deep hex socket.
5. Use a socket wrench with a hex socket 28 mm (18860-01) or
a cassette lockring tool to loosen the air spring to loosen the air
spring.
Note!1
When removing the air spring cartridge, it is easy to damage the top cap. Put
pressure on the wrench while unthreading the top cap. If needed use tripple clamp
to hold stanchion tube.
1
23
4
5

8
REBUILD AIR SPRING CARTRIDGE
6. Slide the air spring off the stanchion tube.
Warning!⚠
Make sure the pressure inside the air spring is removed.
6

9
REBUILD AIR SPRING CARTRIDGE
Rebuild of air spring cartridge
Note!1
Clean all parts using disc brake cleaner and a rag to remove dirt, old grease and
thread sealant before reassembling. Lubricate new o-rings/x-rings etc. with fresh
Assembly grease.
Note!1
Use a vise and the appropriate shaft clamps when servicing the front fork.
1. If you used a cassette tool to undo the top cap leave the pre-
applied thread locker(reusable) and continue. If you used a 28 mm
socket clean top cap threads (male and female) using a rag covered
by degreaser or brake cleaner. Use a nylon bristled brush to remove
any remaining residue from threads.
1
Pre-applied thread locker
Continue!

10
REBUILD AIR SPRING CARTRIDGE
2. Remove the old o-ring (00576-06/00576-23) from the top cap.
3. Install a new o-ring (00576-06/00576-23) on the top cap.
4. Remove the old air valve schrader (18607-01) from the top cap.
5. Install a new air valve schrader (18607-01) into the top cap.
6. Remove the old o-ring (00438-57) from the seal head.
7. Install a new o-ring (00438-57) on the seal head.
8. Remove the old o-ring (18612-04/00338-57) from the base cap.
9. Install a new o-ring on the base cap. For end shaft nut M10 use
18612-04 and for M12 use 00338-57.
2
3
6
7
8
9
4 5

11
REBUILD AIR SPRING CARTRIDGE
10. Remove the old air valve schrader (18607-01) from the base
cap.
11. Install a new air valve schrader (18607-01) into the base cap.
12. Use a socket wrench with a hex socket 28 mm (18860-01) or a
cassette lockring tool to remove the top cap.
13. Remove the old o-ring (00338-68) from the top cap. Clean using
disc brake cleaner and a paper cloth or rag to remove old thread
sealant.
14. Install a new o-ring (00338-68) on the top cap. Apply assembly
grease on o-ring.
12
13 14
10 11

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REBUILD AIR SPRING CARTRIDGE
15
16
15. Apply a halv turn of Loctite 577 thread sealant (01791-07) to the
top cap threads.
16. Thread the top cap into the cylinder tube. Use a torque wrench
with a 28 mm hex socket or a cassette lockring tool to tighten the
top cap to 10 Nm.

13
REBUILD AIR SPRING CARTRIDGE
17
18
17. Use a 19/24 mm wrench to loosen the seal head. Slide the cylin-
der tube off the air spring.
18. Remove the two old o-rings (00638-86) from the upper air
chamber cylinder tube.
19. Install two new o-rings (00638-86) on the upper air chamber
cylinder tube. Apply assembly grease on o-rings.
20. Remove the old o-ring (18637-01) from the piston.
21. Remove the the two old back-up rings (18556-03).
19
20 21

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REBUILD AIR SPRING CARTRIDGE
22 23
25
22. Use a 6/8 mm hex wrench to remove the piston.
23. Remove the old o-ring (18628-01) from the piston.
24. Clean the piston using disc brake cleaner and a paper cloth or
rag to remove old grease, thread sealant and dirt.
25. Install a new o-ring (18628-01) on the piston.
26. Use a 14/16 mm wrench to remove the base cap.
24
26

15
REBUILD AIR SPRING CARTRIDGE
28
29
27. Remove the old o-ring (18628-01) from the base cap.
28. Clean the base cap using disc brake cleaner and a paper cloth
or rag to remove old thread sealant.
29. Install a new o-ring (18628-01) on the base cap.
27
RXF34/RXF36 RXF38 m.1/DH38RXF38 m.2
RXF34/RXF36 RXF38 m.1/DH38RXF38 m.2
RXF34/RXF36 RXF38 m.1/DH38RXF38 m.2

16
REBUILD AIR SPRING CARTRIDGE
Only for DH38/RXf38 m.1 forks!
30. Put the shaft assembly in the multi clamp (Ø8) with the base cap
facing upwards and use a 16mm wrench to remove the base cap.
31. Turn the shaft assembly upside down and place it in the multi
clamp with the seal head facing upwards and use a 12mm wrench to
remove the seal head.
32. Remove the old o-ring (00338-39) inside the base cap.
33. Clean the threads inside the base cap using disc brake cleaner
and a paper cloth or rag to remove thread sealant and dirt.
34. Install a new o-ring (00338-39) inside the base cap. Lubricate
the o-ring with assembly grease.
35. Remove the old o-ring (00338-39) inside the seal head.
36. Clean the threads inside the seal head using disc brake cleaner
and a paper cloth or rag to remove thread sealant and dirt.
37. Install a new o-ring (00338-39) inside the seal head. Lubricate
the o-ring with assembly grease.
30
31
32 33 34
35 36 37

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REBUILD AIR SPRING CARTRIDGE
38. Clean the threads on both ends of the shaft using disc brake
cleaner and a paper cloth or rag to remove thread sealant and dirt.
39. Apply 2 turns of loctite 577 to the threads on one of sides of the
shaft.
40. Thread the base cap onto the shaft. Use a torque wrench with a
16mm hex socket to tighten the base cap to 8 Nm.
41. Apply 2 turns of loctite 577 to the threads on the other side of the
shaft.
42. Thread the seal head onto the shaft. Use a torque wrench with a
12mm hex socket to tighten the base cap to 8 Nm.
38
40
42
39
41

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REBUILD AIR SPRING CARTRIDGE
43. Remove the seal head from the cylinder tube.
44. Remove the old backup ring (18641-01) from inside the seal
head.
45. Remove the old x-ring (18639-01) from inside the seal head.
44
43
45

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REBUILD AIR SPRING CARTRIDGE
47
48
49
52
46. Apply function grease on the new x-ring.
47. Install the new x-ring (18639-01) inside the seal head.
48. Install a new backup ring (18641-01) inside the seal head.
49. Remove the third chamber piston and the bump rubber from the
cylinder tube. Stick a long rod or similar in the other end of the cylin-
der to push them out.
50. Remove the x-ring (18629-02) from the third chamber piston.
51. Apply function grease on the new x-ring.
52. Install the new x-ring (18629-02) on the third chamber piston.
50
46
51

20
REBUILD AIR SPRING CARTRIDGE
53
54
56
53. Apply a halv turn of Loctite 577 thread sealant to the base cap
threads (cylinder side). Lubricate the o-ring (18628-01) with assem-
bly grease.
54. Thread the base cap into the cylinder tube. Use a torque wrench
with a 14/16 mm hex socket to tighten the base cap to 8 Nm.
55
55. Use the Mounting sleeve shaft 14/8 tool (18860-03) to prevent
damages to the x-ring and support ring in the seal head when sliding
through the cylinder tube.
56. Reinsert the third chamber piston and a new bump rubber
(18649-01) into the cylinder tube.