Öhlins Tools Manual Shock. Struts. Front forks Steering dampers

Transcription

1 absorbers Öhlins Tools Manual Shock Struts 2017 Front forks Steering dampers

2 Please read before using this manual Note that the tools in this manual are presented in ascending part number order. Although, if a tool is a part of a tool assembly it will be presented together with the assembly, therefore some tools can not be found in their natural part number order. See example below; If you have any questions regarding Öhlins Tools, please contact Öhlins Racing AB Bench Vice Assembly Vertical reservoir Bench Vice Assembly Horizontal reservoir Note! Part numbers not in ascending order. Part number can only be used together with part number Damper Holder Use together with tool TTX40, Ø 49mm Öhlins products are subject to continuous improvement and development, therefore, although these instructions include the most up-to-date information available at the time of printing, minor updates may occur. Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited. 2

3 00704 Tool End Cap To loosen end cap Twin TTX Shaft spacer AT-kit TTX 44 MX with seal head TTX ORQ XMXX C-spanner For 36mm dampers To adjust spring pre-load C-spanner For 46mm dampers To adjust spring pre-load C-spanner For TTX36 dampers To adjust spring pre-load For DU 340/ Arm Assy For 36 dampers To loosen upper circlip Screwdriver, sharp To remove circlips on all shock absorbers 3

4 Screwdriver, blunt To remove circlips on all shock absorbers Measure Pin Assy 3mm For dividing piston Measure Pin Assy 6mm For dividing piston 44mm reservoir and FGR-kit Disassembly Tool, End Cap To remove reservoir end cap Measuring Tool dia 25 For dividing piston TTX46 McPherson Retainer Floating Piston 49 Assy 6mm For 49mm reservoir Use together with tool

5 00721 Mandrel Ball Joint ,7mm ,7mm ,8mm mm mm MTB Dism. Mandrel for mandrel ball joints mm mm mm mm Soft Jaws mm, 35mm wide mm, 35mm wide mm, 35mm wide mm, 25mm wide mm, 55mm wide mm, 35mm wide ,8mm 35mm wide mm 55mm wide FGR 15X-16X ,5-14mm 35mm wide Car R&T mm 35mm wide ,2mm 35mm wide, FKS 2xx 5

6 Dial Gauge Assy For Schrader valve (can be used with needle ) Valve Connection Schrader Turnbuckle Use together with level arm

7 00737 Gripping Sleeve To remove damper tubes Use together with tool or Sleeve Ø 56x50 for Sleeve Ø 56x51 for Sleeve Ø 56x52 for Sleeve Ø 56x50.5 for Sleeve Ø 56x49 for Sleeve Ø 56x42 for Sleeve Ø 56x43,1 for Sleeve Ø 56x54,6 for Sleeve Ø 56x36 for Sleeve Ø 56x40 for Sleeve Ø 56x48,1 for Sleeve Ø 56x39 for Sleeve Ø 56x45,8 for Sleeve Ø 70x57 for Sleeve Ø 70x62 for Sleeve Ø 70x65 for Sleeve Ø 70x64.1 for Sleeve Ø 70x50 for Gripping Spanner Use together with series sleeves Ø 56mm Ø 70mm Mounting Sleeve for seal head /00102 shaft shaft shaft Assembly Tool Thread Washer For seal and scraper

8 Clamping Tool Seal Head dia 46 To hold the seal block All single shocks Ø 46mm Assembly Mandrel For lock nut For lock nut Spring Assembly Tool Adapter Ring for Ti Springs Use together with spring tool For Ti-spring Adapter Ring Use together with spring tool x70mm (for twin shocks) Ø id 46mm x76mm TTX36 springs Ø id 51mm x90,5mm ORQXMXX Ø id 70mm 8

9 00757 Gas Piston Holder Assy To set and hold the gas piston on 46D shocks mm mm Plastic Cover CERBO196 For cylinder tube Ø 46mm Clamping Tool 50mm Ø 50mm Bench Vice Assy Vertical reservoir Bench Vice Assy Horizontal reservoir Damper Holder Use together with tool TTX40, Ø 49mm 9

10 Damper Holder Sleeve Ø 45,8mm, for TTX36 Use together with tool Cartridge Holder Sleeve Ø42,1mm, for MX Cartridge. Use with tool Needle for ,7x30mm ,7x40mm Needle Holder Assy Use together with T-handle FG 2Tooth Öhlins front forks RR125 Superbike fork Ø 42mm MX-forks 1997 FG704, FG705, FG706 and FG Fork Tube Tool For inner tube Ø 42mm For inner tube Ø 38mm For inner tube Ø 46mm For inner tube Ø 58mm For inner tube Ø 43mm For inner tube Ø 48mm For reservoir FG FGR700/ For inner tube Ø 41mm For inner tube Ø 49mm 10

11 00787 Cylinder Tube Holder For cartridge Ø 24mm For cartridge Ø 23,85mm RR 125 front fork For cartridge Ø 29,10mm MX, R&T conv. front fork and FGRT For cartridge Ø 28,10mm RR&SB front fork For cartridge 20mm For cartridge 34,1mm NIX For cartridge 36,1mm FGR 15x-16x pressurized kit Clamping Tool dia 40 Ø 40mm Holding Tool, Gas Piston for retainer Screwdriver Allen Key Stop Ring For 46 DR cylinder tubes For 36 DR cylinder tubes For 46 DR cylinder tubes 11

12 00797 Sleeve Pin Top nut older RR&SB, FGK kit NIX and end piece McPherson Top nut MX front fork conventional type Top nut RR 125 older type front fork R&T conventional Top nut R&T front fork TTX46 McPherson For valve housing SD 2, Top nut FG/RT 2008, FGR 700, FGR 710 and FGR 800, FGR900, FGK-kit NIX Top nut RWU Retro Preload Tube 31/32 To set dividing piston on FGR-kit Disatool FF MX MX/Enduro Ø 46mm inner tube MX/Enduro Ø 48mm inner tube MX front fork Ø 38mm inner tube C-spanner 30/32 30/32 12

13 Assembly Tool Balls Assy For installing the steel balls in the adjusting knob on SD R&T Guide Diam 8 Mountin sleeve shaft-seal SD R&T Tool Knob SD R&T Sleeve Pin for check valve SD 0XX R&T Mandrel 14.5 Removal tool for seals and bushings Steering damper R&T T-handle FG 6 Pins For cartridge tube MX-front forks FG504, FG505, FG506 and FG507 13

14 Flex-Hone Dia 20 Ø 20mm 01726/27 Flex-Hone Ø 29mm for polished alu. tubes Ø 38mm for polished alu. tubes Ø 38mm for polished steel tubes 600 SC grid Ø 38mm for polished steel tubes 800 SC grid Ø 41mm for polished steel tubes 800 SC grid 01728/41 Flex-Hone Ø 47mm to polish alu. tubes Ø 47mm to polish steel tubes 600 SC grid Ø 47mm to polish steel tubes 800 SC grid Ø 32mm to polish alu. tubes Ø 60mm to polish alu. tubes Flex-Hone Ø 51mm to polish Alu.tubes Ø 51mm 600 SC Ø 51mm 800 SC 04901/04902 Flex-Hone Ø 45mm to polish Alu.tubes Ø 48mm to polish Alu.tubes Adjustment Tool For rebound adjustment on car shocks (Honda S2000 and Porsche) Oil Retaining Cup Ø 54,5mm cylinder tube Ø 57,5mm cylinder tube Ø 55,5mm TTX46 cylinder tube 14

15 Rod Aluminum 4.5 To insert rebound adjustment needle in the shaft end Oil Retaining Cup 40 Assy 40mm cylinder tube Oil Retaining Cup 50/51 Assy 50/51mm cylinder tube T-handle For the hydraulic preload adjuster 46mm shock absorbers T-handle For the compression valve 36mm shock absorbers T-handle For the hydraulic preload adjuster 36mm shock absorbers 15

16 Front Fork Bushing Tools Tool, Attachment Bar FF Front Fork bushing Tool, Bar Guide 46 FF For attachment bar Tool, Bar Guide 42 FF For attachment bar Tool, Bar Guide 43 FF For attachment bar Tool, Bar Guide 48 FF For attachment bar Tool, Bushing Mounting 46 FF For attachment bar Tool, Bushing Mounting 42 FF For attachment bar Tool, Bushing Mounting 38 FF For attachment bar Tool, Bushing Removal 46 FF For attachment bar Tool, Bushing Removal 42 FF For attachment bar Tool, Bushing Removal 38 FF For attachment bar Tool, Bushing Removal 43 FF For attachment bar Tool, Bushing Mounting 43 FF For attachment bar Tool, Bushing Removal 48 FF For attachment bar Tool, Bushing Mounting 48 FF For attachment bar

17 Peg Spanner Dia 6 at Dia 32 For seal head TT40/44 and TTX40, Top cap MX Tool, Cylinder Cap Top cap MX-front forks USD Peg Spanner dia 5 Pegs at Dia 41 For TTX40 reservoir end cap Pin Spanner, EC-Top Cap For 43 and 48 EC Front forks. 17

18 01764 Tool, Needle Housing For needle housing on TT44 shocks 42mm length For needle housing on TT44 shocks 100mm length Tool, Pull Up Top-Out Spring M12x1,25 outside shaft Top out spring Superbike front forks ø 43 Use together with tool Replaced by M16x1/M12x1,25 outside shaft FGR800, FGK kit FGR 15X-16X pressurized kit Use together with tool M12x1,25/M10x1 outside shaft for various OEM forks M12x1/M12x1,25 outside shaft for FG/RT

19 M6 for R&T Front fork 6mm inside shaft Adaptor for M12x0,75mm outside shaft Tool, Pull Up FKC kit M8 outside shaft Tool, Pull Up FL/RT M7x0,75 inside shaft Clip for FG Racing FG , FGR700/800 Use together with tool

20 Shaft Retainer 10/12mm shaft Use when mounting top cap on front forks. Universal Shaft Retainer 8/10/12mm shaft Use when mounting top cap on front forks. Universal Tool, Pre-load Tube Pusher FF Preload tube pusher Superbike front forks Use together with tool Tool, Pre-load Tube Pusher FF Universal Push Tool To press down seal head on WCJ / MCJ shocks when setting gas piston position, 120mm To press down seal head on WCJ / MCJ shocks when setting gas piston position, 85mm 20

21 01769 Push Tool Spacer Use with tool when setting the gas piston position mm mm mm mm Wrench 63mm Use on lock nut on TT44 shocks Wrench 21mm For end eye lock nut on TTX40 shocks Oil Retaining Cup Assy For TT44, cylinder tube Ø 52mm MX aluminium tube For TTX40 shocks, Ø49mm For TTX36 shocks, Ø46mm For CCJ damper, Ø52mm 21

22 Gas Fill Device Assy One set contains: O-ring Valve housing Bracket Pressure gauge Needle 0,7x30mm Needle 0,7x40mm Hose Quick coupling female Needle housing Needle cap Box Gas Needle Housing M10/M Additional adapter for TTX Assembly Tool FG7040 FG7050 FG7060 FG7070 FG Mounting Sleeve For mounting seal head assy mm, for shaft mm, for shaft mm, for shaft Mandrel, Shaft Jet For PDS shock 22

23 Tool End Piece Complete for For end piece outer tube Peugeot 206 WRC, 5/6 D Damper Holder NV57 Assy WCJ/MCJ (Winston Cup) shock absorbers C-spanner McPherson To adjust spring preload on McPherson struts and Tool Cylinder Cap FF and Cartridge Tool FG Ø 43 Superbike, FG070, 170, 270, 370 and older FGK-kit Superbike, 25mm cartridge, and MX/Enduro 1998 and on all models 46 and 48mm FG , FGR FGR 15X-16X press. kit and MX 38mm MX 48mm FGK kit, FGRT FGR FGR 15X-16X press. kit R&T conventional R&T USD Plug, Cylinder Tube mm mm mm TTX44 One way valve ,6 mm 23

24 01799 Tool Bush and Seal MX USD46 For installing bushing and seals on MX front forks with 46mm inner tube from USD48 For installing bushing and seals on MX/Enduro front forks with 48 mm inner tube USD For installing bushing and seals on MX forks with 38 mm inner tube Bush Tool 43mm Conventional FF To mount bushing and seals on R&T conventional front forks Mounting Tool For circlip on shafts, used with tool Mounting Tool For TTX30, used with Mounting Sleeve For TTX30, use with and Shaft tool for ORQ 50 dampers To mount circlip and stop washer on ORQ 50 dampers, to be used together with tool and

25 Dolly, Lower McPherson Outer Tube To mount lower bushing into 50mm McPherson strut Bushing/ Seal Mounting/Removal Tool Bushing mounting 50/39 mm McPherson strut Bushing mounting 50/126 mm McPherson strut Seal mount tool TPX Bushing removal TPX Bushing removal TPX Mounting sleeve main seal TPX Seal removal TPX Scraper Mounting Tool McPherson To mount scraper into 50mm McPherson strut Dolly, Upper McPherson Outer Tube To mount upper bushing into 50mm McPherson strut Tool Cylinder Head McPherson To tighten cylinder head and

26 Tool Cylinder Head MNR For cylinder head Mini Tool Bottom Nut RERXL52 For Renault Megane R4 Note! Can not be ordered from Öhlins, please order from Renault part no Clamping Tool mm, for McPherson outer tube mm, for McPherson outer tube ,1mm, for front fork R&T conventional Support Sleeve For tool when tightening cylinder head Allen Key 7/10/72 For mounting and dismantling shaft unit on stage 3 rally shocks Piston Holder Tool M12x1.25/150 For mounting shaft units on stage 3 rally shocks 26

27 01822 Adjustment Tool For adjusting rebound damping on Rally shock absorbers (3mm hex) For adjusting rebound damping on Rally shock absorbers (3x1,5mm pins) Wrench for Lock Nut bottom plug and cylinder cap For stage 3 Rally shocks Retainer Floating Piston To set the gas piston on Toyota Rally shocks mm mm Filling hose for for and

28 No longer available Additional tools for : To set piston position in DR shocks together with series Retainer for 46DR shocks with cylinder tubes Retainer for 36DR shocks with cylinder tubes Retainer for 46DR shocks with cylinder tubes Adapter M Adapter M11x1 for SD RT 1XX Adapter M4, MX/Enduro Steering damper SD Adapter M Adapter M8, MX/Enduro Steering damper SD5XX Adapter M10x1 for SD RT 0XX Adapter M3x4 for FGMX 85/150 cart. kit Retainer floating piston 44 assy Retainer floating piston 49 assy Retainer floating piston 58 assy , -05 Filling Machine SP4 Assy Automatic and computerized vacuum machine with twin oil tanks. Delivered with hose adapters for various applications V version V version Adapter to use to on /-03 Filling machine Gasket Set for One set contains: 2x Gasket for oil reservoir 2x O-ring for waste oil tank 1x O-ring for filling bolt 1x O-ring for ventilation bolt 1x Mounting Instruction 28

29 Additional tools for TTR Positioning pin Spacer for , 13,5mm Use together with Spacer for , 18,5mm Use together with Spacer for , 21,5 mm Use together with Spacer for , 24,5mm Use together with Spacer for , 54,5mm Use together with Spacer for , 84,5mm Use together with Spacer for , 102,5mm Use together with Additional tools for 2WD Adapter M10x1 2WD Assy Holder Endcap Assy Gas Piston Set Tool TTX MX Fork FGMX cartridge kit Cord Filling Machine for Cord 230V Filling Machine EUR Tube and Connection Kit for

30 Additional tools for TTX Separating piston pos. tool. For and Goes with , -02, Separating piston pos. tool. For Goes with , -06, Spacer for , 5,4mm Use together with Spacer for , 10,4mm Use together with Spacer for , 22,4 mm Use together with Spacer for , 25,4mm Use together with Spacer for , 55,4mm Use together with Spacer for , 85,4mm Use together with Spacer for , 34,4mm Spacer for , 55,4mm Use together with / Spacer for , 85,4mm Use together with / Spacer for , 103,4mm Use together with and Spacer for , 55,4mm Use together with Spacer for , 85,4mm Use together with Tool Seal Holder TPX McPherson Tool Cylinder Head McPherson McPherson Ø 40mm For cylinder head and With sleeve for cylinder head , , and For cylinder head Rally TPX 30

31 Tool Cylinder head , POR Historic Tool Seal Head McPherson Seal head McPherson shocks Positioning Tool Divider piston 57,6x41mm WCJ/SCJ Divider piston 57,6x28 TTX 36 IL Divider piston 57,6x35 TTX 36 IL Divider piston 57,6x36 TTX 36 IL Divider piston 57,6x23 TTX 36 IL Divider piston 57,6x30 TTX 36 IL Tool Comp Adjuster Bob Top cap EMX front fork TTX46 comp/reb adjuster Tool EC unit SA Tool End Cap FGR-kit 31

32 01861 Mounting Sleeve for piston band TT TT TTX46 McPherson TTX40 w Ø36mm inner tube TPX44 Rally TTX Mounting Tool for piston band , TTX 46 shock absorber , TTX 22 Cartridge kit Tool, Comp Adj MX Front Fork For MX front fork Tool Dual Comp Adj For /-37/-38 and /-08 adjuster Tool for HD 203/204 HD Softail Use together with tool

33 Spring Tool for HD 203/204 HD Softail Use together with tool Mandrel for Ø 82mm HD Softail Clamping Tool For Ø 82mm HD Softail Tool for HD Softail Tool for End Cap FF 48 MX/Enduro front fork Puller 2WD 2WD chain sprocket 33

34 01875 Tool for For 2-way comp adjuster, circlip For 2-way comp adjuster, TTX40 circlip Syringe 5ml Luer For Syringe Kit For oil level TTX Mounting Tool Piston TTX46MT TTX46 McPherson Mounting Tool Piston TTX46MT TTX46 McPherson Mounting Tool Seal Head TTX46MT MkII For upper seal head for TTX46 McPherson MkII and TTX46CS for Seal head TPX damper for Seal head TTX30 damper 34

35 Mounting Tool TPX44 Seal head TPX 44 and sealhead / Mounting Tool Seal Head TTX30 For seal head Tool Seal Head TTX36 TTX36 / TTX Tool Seal head TTX44 TTX44 MX Bleed Tube TTX BIGBOB TTX Tool, Damping Cup TTX44 For PDS cupttx44 MX shock Tool, End Plug TTX FG for TTX MX front fork cartridge kit 35

36 Wrench 44 44mm FGMX 85/150cc cartridge kit Mounting Tool, TPX for Piston Assy TPX Rally Tool, Mounting Sleeve TPX TPX for piston holder Mounting Socket for TPX Piston Holder TPX for piston holder Tool End Cap TTX36 IL Tool, Mandrel 30mm Sleeve For seal head XX on TTX46NT 36

37 C-spanner AMF For scraper holder TPX 44 Rally Adjuster House Tool TTR Adjusting Tool TTR Clamp Tool Ø33mm Ø40mm Ø52mm Ø58mm Tool Preload Adjuster For shocks S Tool Preload Adjustment For shocks S36 37

38 Mounting Socket CES Valve CES valve EC damper Mount Tool To remove or install the compression check valve on high/low compression adjuster XX Cartridge Tool See page Spanner 17mm for FG RT Spanner 19mm Replaced by Spanner 19mm 5mm thick for FG RT Mandrel X-ring For Off Road steering damper. To protect the X-ring when mounting the wing in damper housing Bracket Tool SD4200 For testing damping function after service SD Use together with

39 Handle SD4200 Test device Use together with tool Mandrel 21.5/25 For Off Road steering damper Use together with tool Mandrel 14.7/ 25 For Off Road steering damper. Use together with tool Holder for linkarm For Off Road steering damper to dismount the lock nut Tool High Speed Valve SD Wing For Off Road steering damper 39

40 Tool NV19 For steering stem nut SD Tool NV30 For nut SD Tool SD 2.0Clamp Clamp tool SD Tool SD 2.1 Clamp Clamp tool SD

41 Tool for SD 6XX 2 pins x 3mm Tool for SD 6XX 2 pins x 2,5mm Piston tool SD 3,0 For Off Road steering damper Shaft tool ORQ 50 dampers To mount stop washer on 18mm shaft, to be used together with Torsion Bar Press Mandrel Set SD 6XX Off Road steering damper 41

42 T-handle tool Car R&T Mounting tool hex. 17mm Car R&T Sliding hammer 14,5/50/90 Car R&T Bushing tool Ø Ø 44,5 Car R&T Bushing removal tool Ø 40-44,5 Car R&T Washer for bushing removal tool Ø Ø 44,5 Car R&T 42

43 24612 Scraper fitting tool Car R&T Ø Ø 44, Fitting sleeve 12,5/12/120 Car R&T Shaft fixation tool adjustable from 120 to 200mm PDS cup tool Peugeot/Citroen R5 shock absorbers Bushing holder tool, to open and close bushing holder on Peugeot and Citroen R5 shock absorbers Mounting socket for TPX/PSA piston holder on Peugeot and Citroen R5 shock absorbers. 43

44 Seal head bushing removal tool, TTX/TPX 16mm seal head Cylinder head tool, TPX McPherson shock absorbers Sleeve cylinder head, TPX McPherson shock absorbers. To be used together with EC diagnostic tool kit 44

45 45

46 Tools Manual Part No _30_ Issued Öhlins Racing AB