The translation !!!
Ohlins shock Grand prix refection
Dismantling : been meeting problems while dismantling these shocks, I describe here the dismantling for the beginners. There’s also a PDF in English (
http://pureenduro.free.fr/Div/OhlinsJPC/OhlinsOverhaul.pdf) where refection is explained in details.
1)Remove springs , spring retainers, and take off gas in order to take off oil shock.
2)Press reservoir end down 1 or 2 centimeters in order to see the circlip. You can push softly with a plastic hammer if it resists.
3)Remove circlip and be careful not to damage the inside.
4) Remove reservoir end.
5) Remove the reservoir piston.
If the piston is locked in the the reservoir, you can screw a long M3 screw on it.
These operations can allow you to control the good shape of pistons and seals.
This allow you to take off all the oil. In my case all was good.
6)Remove scraper retainer ( Cap). It is not screwed but only pulled down.
You can use a screwdriver and a hammer. Be careful. Push gently all around the scraper retainer (Cap).
7)Push down the internal part ( see picture) until you see the first circlip.( There are three on these shocks).
Then remove the circlip.
8) Then you can remove this part ( see picture)
9) Do the same with the next part to remove the circlip.
10)Then, normally you can remove the part. But it is here I’ve got a big difficulty. Impossibility to remove this part.
This part moves up and down on several centimeters, but it don’t want to go out easily. And nothing on it to pick it up. I had the same problem on the two shocks. I tried to use a steel wire to get it out, but it didn’t work.
I sacrified this part, but no problems because the three parts piled up are now replaced by ohlins by one part (ASSY).
I made a hole in this part with a DREMEL , screwed a screw for wood and pull on it ( see picture).
11) Remove the 3rd circlip and the next part. Then you can pull the piston shaft and all the parts on it.
12)All you’ve got to do now, is to unscrew the nut and pull all the parts. Note the order of the parts or keep them together with a plastic wire ( Serflex = see picture) .
All the parts:
Painting: The painting has been made by a professional because I couldn’t find myself the originals colors.
Reservoirs are painted In gold and have been also varnished. Springs have been painted in black and marine blue.
They are not always blue.
Ohlins parts:
Before assembling, you must find spare parts to change: They are available at French ohlins importer.
PFP Racing
2 r Marc Seguin
ZA Mamou
15130 Arpajon sur Cère Téléphone 33.(0)4.71.48.15.34
Fax 33.(0)4.71.64.25.93
With that PDF, you can find the numbers of the parts wanted.
http://pureenduro.free.fr/Div/OhlinsJPC/ohlins.pdf
It costed me 250 € for the parts. It is not easy to find the right number for the parts because several numbers are possible. Better to phone to the importer to have help.
The “kit”:
In this KIT, there’s a new part which remplaces the three parts ( right), so you need to put back only two circlips.
Stickers:
I took these sold by PLAN PLAN ( French stickers maker)
http://membres.lycos.fr/bpiimprimeur/
Assembling:
all the parts
Instructions for assembling.
(then you can translate the whole page of the ohlins workshop manual .Between N° 6 and N°7 it is added
rder of parts on the shaft).
In the end , I’ve got that !!!
It makes me a beautiful pair of öhlins shock for 450 €.
Jean-Philippe.
