Öhlins DH38, Workshop Manual

Page 1: ...Workshop Manual Rebuild air spring cartridge...

Page 2: ...ke sure that the vehicle is washed and cleaned properly Do not use alcobased products on the outside or inside of the product Product Specific Warnings Warning This product was developed and designed...

Page 3: ...sealant Fork lubrication fluid 01336 01 Renep CGLP 68 Fork lube 1L Air spring lubrication fluid 01337 06 Renep CGLP 220 Air spring lube 0 6L Function grease 01338 22 Renolit SI 410 M Silicone grease...

Page 4: ...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 0...

Page 5: ...e 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 t...

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

Page 7: ...tive 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 sock...

Page 8: ...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...

Page 9: ...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 con...

Page 10: ...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...

Page 11: ...e 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 a...

Page 12: ...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 to...

Page 13: ...ff 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...

Page 14: ...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...

Page 15: ...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 DH38 RXF38 m...

Page 16: ...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...

Page 17: ...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...

Page 18: ...UILD 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...

Page 19: ...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 Remov...

Page 20: ...se 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 damage...

Page 21: ...d the piston into the cylinder tube Use a torque wrench with a 6 8 mm hex socket to tighten the piston to 8 Nm 59 Carefully clean the piston using disc brake cleaner and a paper cloth or rag to remove...

Page 22: ...the grease 63 Apply a thin layer of function grease on the o ring and the back up rings on the main piston 64 Insert main piston in the cylinder tube and add 0 5 ml of air spring lubrication fluid in...

Page 23: ...mm hex socket 18860 01 or a cassette lockring tool to tighten the top cap to 32 Nm Caution Do not use an adapter between wrench and socket as this will increase the risk of damaging the anodized finis...

Page 24: ...lower two 2 threads of the top cap male 3 Reinstall the Air spring cartridge into the stanchion tube 4 Use a torque wrench with a 28 mm hex socket 18860 01 to tighten the top cap to 32 Nm Caution Do...

Page 25: ...25 REBUILD AIR SPRING CARTRIDGE Appendix A Part no of the fork can be found at the bottom of the steering tube...

Page 26: ...26 REBUILD AIR SPRING CARTRIDGE...

Page 27: ...retailer Phone 46 0 8 590 025 00 Fax 46 0 8 590 025 80 www ohlins com hlins Racing AB Box 722 SE 194 27 Upplands V sby Sweden Workshop Manual WSM_Rebuild air sprind cartridge Issued 2021 06 14 hlins...