1
Owners Manual
Öhlins Shock Absorbers Type CCJ for Short Track Racing
Including:
Key features
Design
How the shock
absorber works
Technical info
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 pre-
cautions must be taken to avoid dam-
age to the suspension.
NOTE!
This indicates information that is of
importance with regard to procedures.
Introduction
All of Öhlins advanced suspension products are
adepted to the brand and model. This means that
length, travel springaction and damping character-
istics, 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.
© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
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 qualified
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 questions
regarding proper installation procedures,
contact an Öhlins dealer or other qualified
person.
3. The vehicle service manual must be referred
to when installing the Öhlins suspension.
NOTE
Öhlins products are subject to continual improve-
ment and development. Consequently, although
these instructions include the most up-to-date
information available at the time of printing, there
may be minor differences between your suspen-
sion and this manual. Please consult your Öhlins
dealer if you have any questions with regard to
the contents of the manual.
Contents
Safety ............................................................ 2
Key features .................................................. 3
Design ........................................................... 5
How the shock absorbers work ..................... 6
Optional parts ................................................ 8
Service tools .................................................. 8
3
Technical information
Öhlins CCJ series
q Designed for Short Track Racing,
Late Models, Modifieds & Sprints.
q Lightweight threaded steel body
q Quick response for best handling
q Optimum consistency on long runs
q Optional coil-over kit
q Optional internal reservoir with floating piston
q Optional external reservoir
q Optional piston
q Owner rebuildable
q Easy to dial-in, reshim, rebuild and service
q Professional technical support
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
Total stroke
Extended length
Total stroke
Extended length
Spring length
(with or without
pre-load)
4
Design
The CCJ shock absorber is of a mono tube pres-
surized model, using a piston with shims to con-
trol the damping (fig. 1).
The CCJ shock absorber can be fitted with an
internal dividing piston (fig. 2) or an external res-
ervoir 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 damp-
ing fluid, which also causes inconsistent damp-
ing. It improves the cooling, since the fluid is in
direct contact with the outer tubing. It gives more
consistent damping, regardless of the shock ab-
sorber’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.
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 quality, a
quality you can see and feel.
2. Internal
dividing piston
3. External gas
reservoir with
dividing piston
+
+
6. Piston and shim stack
Washer
Clamp shim
Shims
Centering shims
Ring shim
Sealing shim
Piston
5. Piston with
apertures
Dividing
piston
Gas
Fluid
Main
piston
Fluid
Dividing
piston
Fluid
Gas
Main
piston
Fluid
1. Fluid under
gas pressure
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 de-
cided by the quantity, thickness and diameters
of the shims (fig. 6), and are carefully chosen to
make each shock give optimum results.
4. Flow regulated
by shims
Rebound
flow
Comp.
flow
Shims
stack
5
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. Consequently, 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 po-
sition, then lock with the upper ring.
NOTE!
On shock absorbers that have mechanical type
adjustment the position of the adjusting/preload
rings can be adjusted.
C-spanner
7. Mechanical adjustment
6
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 know-
how for whatever you need.
WARNING!
Never alter the gas pressure. Special-purpose
charging equipment and access to nitrogen is
required. The gas pressure should normally never
be altered.
NOTE!
Make certain that your shock absorbers are al-
ways filled with Öhlins High Performance Shock
Absorber Fluid.
Remember!
Regular maintenance, fluid change and inspec-
tion contribute to the prevention of functional dis-
turbances.
Recommended service intervals:
Road: Once a year or every 20 000 – 30 000 km
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
q Check the hose equipped models for leaks in
hose and inlet plugs.
1
1
3
2
4
5
Inspection points:
NOTE!
Discarded Öhlins products should be handled
over to an authorized service centre or distribu-
tor for proper disposal.
7
Notes
8
07412-01 OM CCJ, Teknisk Illustration 05 11 24
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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
More info
www.ohlins.com
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