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Thread: Ohlins Shock Install Pictorial

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    Kool Aid Dispenser! jimvonbaden's Avatar
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    Ohlins Shock Install Pictorial

    I documented the installation of my new Ohlins shocks. There were few surprises, but the end result came out very nice!

    We took a few measurements of the bike before making any changes.


    Rear no load.


    Rear loaded.


    Me on it, showing what a 28ÔÇØ inseam looks like.


    Fron the side. I am a short FF, arenÔÇÖt I?


    First remove the bags and side covers.


    Next remove the tank bolts, and slide the tank back about 5-6ÔÇØ. No need to disconnect any hoses or wires.


    Using a 15mm wrench and a 5mm Allen, remove the top nut.


    Removing the top nut. You can leave the rubber washer, and steel sleeve in place.


    I found the crash bar, H&B or BMW, removal or moving was necessary to allow the Telelever to drop down enough.


    I left the rear bottom bolts loose, but in place, and dropped the bars down forward.


    Remove the lower shock bolt. Looked like it had a dry anti-seize on it, but no heat needed.


    This shows the front shock loose, but in place. You need to jack the front of the bike a little, put your foot on the rim, and pull up on the frame near the beak to make the Telelever droop enough to get the shock off. (Note, the crash bars had not been moved in this picture)


    It is tight, but the front shock will come out past the hoses and wires. Just be gentle and careful.


    Since we were doing two bikes, we were able to compare the front .5ÔÇØ lower (top), to a stock height Ohlins. It looked like the same shock, just moved along the threads to make it lower.

    See how the adjusters are moved? The numbers on the shocks were the same, but, of course, different weight springs.


    Another view.



    Comparred to a stock WP shock. It is definitely shorter.


    Might be able to see the differences better here.


    Look what I caught!


    Carefully thread the shock past the wires and hoses. Note that the springs are larger around, and it makes it tight, but it fits. On the first bike we removed the belt cover to get clearance, but realized on mine that it wasnÔÇÖt necessary.


    I put the top nut on first, and it left a gap.

    To get the bottom in we ended up having to take the bike off the centerstand and push the forks down hard until they unstuck, sticktion? Not sure if it is because we pulled them up too far, or what, but it didnÔÇÖt hurt anything.

    Continued...

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    Kool Aid Dispenser! jimvonbaden's Avatar
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    Clean the lower bolt and reinstall it. I used nothing on the threads, but the book says to use High-temperature assembly grease. Mine was dry, so it stayed that way. 40NM tightening torque.


    Tighten the top nut with a 15mm wrench on the nut, and a 7mm wrench on the shock flats. Use blue locktight, and tighten to 34NM.

    Reinstall the tank, side panels, and little panels.

    Time, about 45 minutes. But you really need a helper.

    Next came the rear. Not bad, easier than the front.


    The muffler must come off to allow clearance to the lower shock bolt, and easier removal of the shock. Loosen the muffler clamp.


    Remove the upper muffler bolt.



    Remove the muffler.


    Lift the bike with a jack.


    Prop the rear wheel so it doesnÔÇÖt drop when the shock bolts are removed.


    Have someone hold the bike steady, or strap it down.


    Loosen the upper bolt.


    Remove the bolt and put a screwdriver or a punch in the hole to hold it in place.


    Remove the lower bolt. Pull up on the frame while stepping on the rear wheel to break it loose.


    Pull the shock out the side.


    This is the rear lower bolt with blue Locktight on it. Clean it off, and the threads on the swingarm.


    This is the upper nut, and oval locking nut.


    I removed the stock shock cover and installed it on the Ohlins.


    It took a slight trimming at the top, but seems to work fine in a 75 mile trip, and had plenty of clearance to the spring.


    Stock shock compared to the Ohlins. The Ohlins was .5ÔÇØ shorter.

    Slide the new shock in place.


    Install the upper bolt. Tighten to 50NM, no locktight, though, no doubt BMW would have you replace the locking nut, I simply reused it.

    Continued...

  3. #3
    Kool Aid Dispenser! jimvonbaden's Avatar
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    Install the lower bolt with blue locktight and tighten to 58NM. You may have to work it a bit, as the bushing is a tight fit.


    Shock installed. I placed the preload adjuster on the left side where the fuel vapor canister used to be. You could put it on the other side if you still have the canister.

    Simply place the clamping bracket in place and tighten it all down snugly.



    Install the muffler, making sure to align it horizontally, the duel exhaust holes should be parallel with the ground.


    Beautiful, isnÔÇÖt it?


    Measured static.


    Measured loaded.














    And the result? Basically the same height! Maybe slightly taller, but barely noticeable. SO, it is true, stock height Ohlins WILL raise the bike about an inch, where .5ÔÇØ lower Ohlins will only raise it maybe half an inch!



    Not a problem, I was already used to it anyhow.

    The REAL result?

    The shocks made me comfortable going up to 10 mph faster on my favorite tight twisty loop.

    The shocks come with full hard rebound damping set, but NO preload, so some adjustments needed to be made.

    I ordered 210-220 pound rider shocks, and need zero preload, just the way I want it.

    I adjusted the front damping 5 clicks down from full hard, and the rear 10 clicks down from full hard.

    This made for a very nice ride, but firm enough to handle the fun stuff with ease!

    Jim

  4. #4
    Registered User burnszilla's Avatar
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    Great report! Thanks.
    Stephen Burns - 2007 R1200GS
    BMW MOA Lifetime Member
    www.burnsmoto.com

  5. #5
    Registered User mistercindy's Avatar
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    Jim, I always enjoy your "how to" threads. Well done, sir. BTW, I can't believe there is two inches of difference between load and no load on the rear with the stockers!

    BTW, I thought you had an Aeroflow on your 12GS?!?
    Grant
    '05 R1200GS
    Former owner of an '03 R1150R
    BMWMOA #113847

  6. #6
    Kool Aid Dispenser! jimvonbaden's Avatar
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    Quote Originally Posted by mistercindy View Post
    Jim, I always enjoy your "how to" threads. Well done, sir. BTW, I can't believe there is two inches of difference between load and no load on the rear with the stockers!

    BTW, I thought you had an Aeroflow on your 12GS?!?
    Nope, not me, that was Jed Hargrave, a friend of mine.

    Jim

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