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Öhlins DH38 Workshop Manual

Rebuild air spring cartridge
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Workshop Manual - Rebuild air spring cartridge

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Summary of Contents for Öhlins DH38

  • Page 1 Workshop Manual - Rebuild air spring cartridge...

  • Page 2: Table Of Contents

    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) ..................

  • Page 3: Tools

    REBUILD AIR SPRING CARTRIDGE Tools 18860-01 Hex socket 28 mm 18860-03 Seal head tool 14 19245-01 Multi clamp TTX18 Cassette lockring tool Oil, grease, thread locker and 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 225g...

  • Page 4: Kit Contents

    REBUILD AIR SPRING CARTRIDGE Kit contents 18850-13 Rebuild kit air spring The following service kits (expiring) can also be used: DH38: 19242-02 00576-23 00338-39 00576-06 03070-01 18649-01 18641-01 18639-01 O-ring O-ring O-ring Scraper Bump rubber Back-up ring X-ring 18637-01 18629-02...

  • Page 5: Remove Air Spring From Lower Legs (Rxf34/Rxf36/Rxf36 M.2)

    REBUILD AIR SPRING CARTRIDGE Remove air spring from lower legs (RXF34/RXF36/RXF38) Note! 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.
  • Page 6 REBUILD AIR SPRING CARTRIDGE 5. Slide the air spring off the stanchion tube.

  • Page 7: Remove Air Spring From Lower Legs (Dh38)

    REBUILD AIR SPRING CARTRIDGE Remove air spring from lower legs (DH38) Note! 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.
  • Page 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.

  • Page 9: Rebuild Of Air Spring Cartridge

    REBUILD AIR SPRING CARTRIDGE Rebuild of air spring cartridge Note! 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! Use a vise and the appropriate shaft clamps when servicing the front fork. 1.
  • Page 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.
  • Page 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.
  • Page 12 REBUILD AIR SPRING CARTRIDGE 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.
  • Page 13 REBUILD AIR SPRING CARTRIDGE 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.
  • Page 14 REBUILD AIR SPRING CARTRIDGE 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.
  • Page 15 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. RXF34/RXF36 RXF38 m.2 RXF38 m.1/DH38 RXF34/RXF36 RXF38 m.2 RXF38 m.1/DH38 RXF34/RXF36 RXF38 m.2...
  • Page 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 REBUILD AIR SPRING CARTRIDGE 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.
  • Page 20 REBUILD AIR SPRING CARTRIDGE 53. Apply a halv turn of Loctite 577 thread sealant to the base cap 55. Use the Mounting sleeve shaft 14/8 tool (18860-03) to prevent threads (cylinder side). Lubricate the o-ring (18628-01) with assem- damages to the x-ring and support ring in the seal head when sliding bly grease.
  • Page 21 REBUILD AIR SPRING CARTRIDGE 57. Apply a halv turn of Loctite 577 thread sealant to the piston threads. Lubricate the o-ring (18628-01) with assembly grease. 58. Thread 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.

  • Page 22: Reinstall Air Spring Cartridge (Rxf34/Rxf36/Rxf36 M.2)

    REBUILD AIR SPRING CARTRIDGE 62. Apply 2 ml of function grease at the inside of the cylinder tube (smeared around). Add 0,5 ml of air spring lubrication fluid distributed on top of the grease. 63. Apply a thin layer of function grease on the o-ring and the back- up rings on the main piston.

  • Page 23: Reinstall Air Spring Cartridge (Dh38)

    REBUILD AIR SPRING CARTRIDGE Reinstall air spring cartridge (RXF34/RXF36/RXF38) Note! If the 28 mm hex socket was used to loosen the top cap perform step 66 applying loctite. Skip step 66 if the cassette lock ring tool was used since the top cap has preapplied loctite.
  • Page 24 REBUILD AIR SPRING CARTRIDGE Reinstall Air spring cartridge (DH38) 1. Inflate the ramp up chamber (A) at the bottom and the positive air chamber (B) at the top to the desired air pressures. ✋ Caution! Inflate the ramp up chamber (A) at the bottom first.
  • Page 25 REBUILD AIR SPRING CARTRIDGE Appendix A Part no of the fork can be found at the bottom of the steering tube.
  • Page 26 REBUILD AIR SPRING CARTRIDGE...
  • Page 27 Your Öhlins retailer: Öhlins Racing AB Box 722 Phone: +46 (0)8 590 025 00 Fax: +46 (0)8 590 025 80 SE-194 27, Upplands Väsby Sweden www.ohlins.com...

This manual is also suitable for:

Rxf36 m.2Rxf36Rxf34Fdmtb-3820-2110Fgmtb-3617-2060