Owners Manual Öhlins Shock Absorbers Type CCJ for Short Track Racing Including: Key features Design How the shock absorber works Technical info 1
2 Safety signals Important information concerning safety is distinguished in this manual by the following notations: The Safety alert symbol means: Caution! Your safety is involved. WARNING! Failure to follow warning instructions could result in severe or fatal injury to anyone working with, inspecting or using the suspension, or to bystanders. CAUTION! Caution indicates that special precautions must be taken to avoid damage to the suspension. NOTE! This indicates information that is of importance with regard to procedures. Öhlins Racing AB. All rights reserved. Any reprinting or unauthorized use without the written permission of Öhlins Racing AB is prohibited. Printed in Sweden. Introduction All of Öhlins advanced suspension products are adepted to the brand and model. This means that length, travel springaction and damping characteristics, are tested individually just for the vehicle that you have decided to fit with Öhlins suspension. Before installation Öhlins Racing AB can not be held responsible for any damage whatsoever to suspension or vehicle, or injury to persons, if the instructions for fitting and maintenance are not followed exactly. Similarly, the warranty will become null and void if the instructions are not adhered to. Contents Safety... 2 Key features... 3 Design... 5 How the shock absorbers work... 6 Optional parts... 8 Service tools... 8 WARNING! 1. Installing a suspension, that is not approved by the vehicle manufacturer, may affect the stability of your vehicle. Öhlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after fitting the suspension. Contact an Öhlins dealer or other ualified person for advice. 2. Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this suspension kit. If you have any uestions regarding proper installation procedures, contact an Öhlins dealer or other ualified person. 3. The vehicle service manual must be referred to when installing the Öhlins suspension. NOTE Öhlins products are subject to continual improvement and development. Conseuently, although these instructions include the most up-to-date information available at the time of printing, there may be minor differences between your suspension and this manual. Please consult your Öhlins dealer if you have any uestions with regard to the contents of the manual.
Technical information Öhlins CCJ series Designed for Short Track Racing, Late Models, Modifieds & Sprints. Lightweight threaded steel body Quick response for best handling Optimum consistency on long runs Optional coil-over kit Optional internal reservoir with floating piston Optional external reservoir Optional piston Owner rebuildable Easy to dial-in, reshim, rebuild and service Professional technical support Total stroke Extended length Spring length (with or without pre-load) Total stroke Extended length Part numbers Description Type Extended length/stroke CCJ 1960 Universal 19/6 non adj. 46EW 495/153 mm CCJ 2170 Universal 21/7 non adj. 46EW 546/178 mm CCJ 2380 Universal 23/8 non adj. 46EW 597/203 mm 3
Design Gas Dividing piston Fluid Main piston Fluid 1. Fluid under gas pressure 2. Internal dividing piston 3. External gas reservoir with dividing piston The CCJ shock absorber is of a mono tube pressurized model, using a piston with shims to control the damping (fig. 1). The CCJ shock absorber can be fitted with an internal dividing piston (fig. 2) or an external reservoir with a dividing piston (fig. 3), keeping the gas separated from the shock absorber fluid. This prevents the risk of cavitation that can wear out internal components and cause inconsistent damping. It also eliminates aeration of the damping fluid, which also causes inconsistent damping. It improves the cooling, since the fluid is in direct contact with the outer tubing. It gives more consistent damping, regardless of the shock absorber s working temperature, and it makes the shock absorber last longer. The internal pressure is balanced to cope with temperature build up and to prevent any chance of cavitaion, yet reducing the fluid compressibility and the friction from the pistons and the shaft seal. + Fluid Main piston Fluid + Dividing piston Gas 4. Flow regulated by shims Shims stack Comp. flow The CCJ shock absorber can be delivered in three different lengths to fit into different competition classes and is designed to be used as a coil over suspension unit when fitted with spring seats and adjusters. The new Öhlins shock absorbers are built to perform and endure. They are easy to set up and to sort out. Thanks to the design of the main body they are also easy to maintain and to rebuild. All Öhlins shock absorbers are built with a desire to win and with precision that ends up in uality, a uality you can see and feel. Rebound flow 5. Piston with apertures Washer 6. Piston and shim stack Clamp shim Shims Centering shims Ring shim Sealing shim Piston How the shock absorbers work The flow through the piston and is regulated by a rebound shim stack and a compression shim stack (fig. 4). The main piston (fig. 5), is specially developed for oval track racing. Thanks to the shape of the apertures in the piston the damping force builds up rapidly. The result is excellent short stroke/high force performance. The shim stack s resistance to opening is decided by the uantity, thickness and diameters of the shims (fig. 6), and are carefully chosen to make each shock give optimum results. 4
C-spanner 7. Mechanical adjustment NOTE! On shock absorbers that have mechanical type adjustment the position of the adjusting/preload rings can be adjusted. Setting the spring pre-load Preload on the spring/springs is very important, since it affects the height of the vehicle and the wheel angles. Conseuently, road holding characteristics can be changed, even negatively. Mechanical adjustment is made with the rings on the shock absorber (fig. 7). Hold the upper ring and adjust the lower one to the desired position, then lock with the upper ring. 5
1 3 2 4 1 5 Inspection points: Inspection and maintenance Keep the shock absorbers clean and always spray them with oil (QS 14, WR40 or CRC 5-56) after washing the vehicle. Inspection points: 1. Check ball joints for possible excessive play. 2. Check the piston shaft for leakage and damage. 3. Check the shock absorber body and for external damages. 4. Excessive wear of rubber components 5. Fastening to the vehicle Check the hose euipped models for leaks in hose and inlet plugs. Preventive maintenance and regular inspection reduces the risk of functional disturbance. If there is any need for additional service, please get in touch with an authorized Öhlins service centre. There they have the necessary tools and knowhow for whatever you need. WARNING! Never alter the gas pressure. Special-purpose charging euipment and access to nitrogen is reuired. The gas pressure should normally never be altered. NOTE! Make certain that your shock absorbers are always filled with Öhlins High Performance Shock Absorber Fluid. Remember! Regular maintenance, fluid change and inspection contribute to the prevention of functional disturbances. Recommended service intervals: Road: Once a year or every 20 000 30 000 km NOTE! Discarded Öhlins products should be handled over to an authorized service centre or distributor for proper disposal. 6
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More info www.ohlins.com The ultimate suspension site. Find out everything about your suspension. Download mounting instructions, manuals and brochures. And a lot more. Öhlins USA, Inc. 703-C Old Spartanburg Road, Hendersonville, NC 28792 Tel: 828-692-4525 Fax: 828-692-0595 Manufactured by Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden 07412-01 OM CCJ, Teknisk Illustration 05 11 24 8