Vintage Ohlins Shock Restoration

Been doing a lot of ground- up restorations for people around the country lately, here are 2 examples:
First one is a 1983 Husqvarna 500CR Ohlins I.T.C. blue shock with the Hyd. stop inside.
Third one is one of the first remote reservoir shocks to come into the states I've seen with a shock code on the body of KAC6-5. The eye to eye was 13 3/4" so these would be for the 1978 KTM 250Mc.
Take a good look at the 1977 & 78 World 250 Champ Guennady Moisseev KTM, these are the same shocks they were using. I have changed the eye rod length to 15 1/4" to go on the 1980 KTM 420 Mc for a customer, a rare find.

Vintage Pro -- are you revalving this also?

I have a pair like the older ones on bottom. From a 77/78 Husky.

I have them on my 81 PE 250 - higher leverage ratio (think 2.2:1) I have the heavier yellow springs like on first shocks in your post.

I revalved for more rebound dampening so far.

I have the old Ohlins manual that's on the web and it gives some dampening specs for various models but they're mostly MX and I'm using them in the woods.

Any thoughts or guidance is great. Changing shims isn't too hard but it's not so easy that I can experiment too much (not like pulling a fork apart)

Yes I did revalve for this Ap. The 77/78 came with Girlings rear shocks.

Maybe mine were '79 or IDK - I seem to remember the ad saying '78

The code, I believe, is HB 01-3

I did believe I just bumped compression to "A" and the rebound to "3" (my notes aren't with me) and I did add the second hole to the comp. washer per the note on the application chart.

I based my increases on looking at what "settings" came with other bikes like the RM models the manual lists...

I was just wondering if you've found good starting points for changes in dampening for these old shocks and bikes.

I find lots of people discussing modern shock and fork valving (using restacker and such to calculate dampening stacks) but not much on this old stuff.

That's a very old Ohlins spec. sheet, they don't even show any 2 stage valving recommendations to the chart. If you need some help in that area call on my land line.

what tool are you using to compress the springs to remove/install the spring retainers?
I don't see any scratches in the paint on your springs, well done

I’ll send you a message to get your info and best time to call. Thanks

Those shocks look fantastic! How do I get in touch with you? I'm restoring my dad's 1984 WR400 (owned it since 1985). It's a special bike (at least to us) and I want to do it right. Thanks in advance.

Vintage Pro, good to install those black body wear guards. Other than the multiple seal head retaining clips, the rebuild of my 1981 KTM 495mc shocks was like memory lane of rebuilding shocks in the 1970s.
Not in the business any more to do suspension work, just my own and for friends.
Stashed away, waiting on a bike they fit, I have a set of freshly rebuilt very early non pressurized Works Performance shocks. I also have now tucked away,a pair of non pressurized Curnutts that I had been running on my 73 OSSA MAR. The OSSA MAR got new rear shocks. Again period correct Moto X Fox coil over trials shocks. Rebuilding those was fun, and they got brand new shafts and more. My Rickman Yamaha kept the Yamaha theme since the original Gas Girlings were not easily saved. Bought 6 used Yamaha Thermal Flows and made one very nice set that were installed on the Rickman. Even those more modern Works Performance shocks on my friends 1981 Maico 490 were done recently. Guess the photos of other rebuilds are on the other cumputer.

Randy 661-821-9952

Looks like you put a smart carb. on the Ossa , how does it work? The Curnutts should work well on the OSSA Trials. Some years ago ( Mid-90s ) I used a par of early Fox shocks with the Holley main jet on the bottom of the shaft on my Montesa Cota 348 in the AHRMA Nationals.

Actually, the Curnutts, even after making mods to the damping are not even close the the vintage Fox Shox. The other benefit of running the Fox Shox is availability of springs.
As for the Smart Carb, yes, I did install and run one for a couple of seasons. Got bored with it and installed an OKO from Roger at Mid Atlantic Trials. I did take the time to test both carbs, back to back, same riding area, same fuel, and within an hour of each other to avoid temp and humidity possibilities. Both carbs have merits. Both ran well. As mentioned, just got bored with the Smart Carb and sold it. OKO carbs are easy, and with a no tools needed Pilot Air Screw, lets the bottom end be truly spot on.

Curious if any of you have sourced hoses for those vintage Ohlins remote shocks? I recall those are BSP threads while most hoses (Fox) are NPT. Amazingly I’ve found some don’t leak despite the outer rubber layer disintegrating, but I’ve had a few that weaped a little or just too sketch.

I found thread adapters that I bored out to match the ID of the hoses to allow NPT hoses, but not as clean as I’d like. I thought Venhill could make some up, but haven’t worked through that yet. Ohlins stuff for mainly CanAm here.

Not testing you, just asking. Are the hose threads BSP, or BSPP? If BSPP, it likely has an O ring. My first thought would have been Venhill also. Have you researched Aeroquip, in the race car catalog stuff?

Danfoss ay also be a good possible source.

Great question. If I once knew the answer it is lost somewhere in my mental file cabinet. They do not have o-rings, so likely BSP.

Appreciate the ideas too. I will take a look. Admittedly I stopped the deeper dive here last year when I bought a set from Thor Lawson and used thread adapters, but I have another set that need to be replaced and would prefer to not have those fittings.

One thing I liked about Venhill’s product line is they let you spec line diameters and materials from a decent selection. It seemed some hydraulic lines were smaller ID, which to me risks making them restrictive as they can be 12” long. I may just need to find a distributor in the UK or go direct.

Adding a photo just because.

BTW, not a fan of this rez mounting. Husqvarna hoses here.

^^^^^Too cool

Cool Can Am. Our Can Am has three wheels.
Regarding the hoses, have you spoken with Jerry at Ohlins USA about replacements or thread type?

If you know Craig Fox, here in Florida, possibly he may know a source since he is a big Can Am guy.

Very similar to the same-era marzocchi stradas. Rebuilt a set a couple years ago.

Jerry is awesome. I’ve rebuilt a few odd Ohlins for Cagivas and ATKs. He’s always come up with build sheets and tips. I hope they reward him well as he’s top notch and makes me want to buy Ohlins. He didn’t have replacement options for hoses but gave me knowledge of what to look for.

I forgot about Mr Fox on Can-Ams, good tip. I’m a CanAm junky as it’s what I rode in the early 80’s as a teenager. I’ve built my own stash to keep them usable so never needed that connection. I like having enough parts I can enjoy breaking stuff as much as building it, LOL!