Shocking workmanship

[Robert Taylor]

It has come to my attention that a number of Ohlins road and track front forks have recently been rebuilt in Auckland. The standard of ''workmanship'' was despicable for the following reasons;

1) The top caps were spun off using the 17mm preload adjusters instead of the annular pin holes in the outer bodies. That could result in the preload threads inside the cap jamming up..........but for the lack of the proper Ohlins tool or a good quality close fitting adjustable pin spanner TOTALLY UNACCEPTABLE

2) It is clear that a water based degreaser was used to ''clean out'' the fork internals as when the oil was drained there was also a sizable quantity of water, that in turn has rusted the valving shims and check plate springs. The screw in cartridges would have remained in place and if any flushing is done you absolutely cannot get rid of all the flushing fluid without removing the cartridges. It is very clear that the cartridges were not removed as a special tool is required to remove them that is very specific to those forks. I have sold 3 of these tools around NZ over and above the one in my own workshop, to service agents that actually care about doing the job properly. AGAIN, TOTALLY UNACCEPTABLE.

3) Low quality high drag seals were used that have failed in short order. It is also as well to point out that production forks with coatings such as titanium nitrate and dlc etc are sensitive over the long term to seal drag friction and material. These coatings are all microscopically thin and will have accelerated wear when combined with low quality seals. AGAIN, TOTALLY UNACCEPTABLE.

It just isnt good enough to trust a shop at its word that they can do the job to an acceptable standard, do they have the tools, do they have the specific training for that product etc etc??.... CAVEAT EMPTOR

[Disco Dan]

So tell us.. how can the laymen person tell they are getting good forks?

[Robert Taylor]

So tell us.. how can the laymen person tell they are getting good forks?

By implication and my own experience very often they sadly are not. Its a hard question to answer, but there is also a very scary clue in that I was not requested by the said dealer ( and I know who it is ) were their tools and service information available? Frankly, this is take it to ''Fair Go'' material.

[Patch]

So tell us.. how can the laymen person tell they are getting good forks?

by buying from a reputable chap who specializes in their particular field - this does not just apply to forks or bikes.

There is no point asking an aircraft mechanic (who has trained to fix/repair/service a SkyHawk) to apply his trade to a Boeing - in fact, it could be very lethal without being re-trained (and that takes years)

You must ask yourself, if this shits itself - will I live??
If the service agent is not a specialist (in his given field), can you confidently answer that question??

If you are unsure about his background - ask him/her. Their answer or lack of answer (dodgy body behaviour) will speak volumes.

Is "cheap" worth the risk??

[SixPackBack]

Upon request and to help the young fella out [twosmoker], I manufactured a set of tools to allow the disassembly of his Ohlins forks. 'tis not a difficult task for a competent Toolmaker/Engineer. The tool set consisted of the following:

• A cap removal device.
• A spanner with extended jaws.
• A long tube threaded internally.

If anybody needs to save a few dollars give me a yell, the plans are free.

[Robert Taylor]

Upon request and to help the young fella out [twosmoker], I manufactured a set of tools to allow the disassembly of his Ohlins forks. 'tis not a difficult task for a competent Toolmaker/Engineer. The tool set consisted of the following:

• A cap removal device.
• A spanner with extended jaws.
• A long tube threaded internally.

If anybody needs to save a few dollars give me a yell, the plans are free.

But thats only half the equation is it not? How about brand specific training and familiarity with the particular idiosyncracies and precautions involved when servicing / repairing such a product? And I think given the example I cited above the job wouldnt have been done properly anyway, correct tools or not. A little bit of knowledge is often dangerous.

[boostin]

Just out of interest is it usually nessacery to flush/clean out a fork when just changing the oil.

I am talking about standard 93 ZXR400 forks. Thanks

[FilthyLuka]

Just out of interest is it usually nessacery to flush/clean out a fork when just changing the oil.

I am talking about standard 93 ZXR400 forks. Thanks

It couldn't hurt...

How about brand specific training and familiarity with the particular idiosyncracies and precautions involved when servicing / repairing such a product?

Only one way to find out really.

[jrandom]

But thats only half the equation is it not? How about brand specific training and familiarity with the particular idiosyncracies and precautions involved when servicing / repairing such a product? And I think given the example I cited above the job wouldnt have been done properly anyway, correct tools or not. A little bit of knowledge is often dangerous.

Ohlins products, in spite of your frequent assertions to the contrary, are not made from unobtanium.

The fact that Ohlins design their products to require proprietary tools for disassembly, thereby locking in most users to service agents chosen by the manufacturer, does not imply anything other than that Ohlins wish to tightly control the market's use of their product.

I don't buy the "suspension is black magic" line. Any number of mechanical engineers throughout this country and many others operate as effective and knowledgeable engine tuners, and a high-performance internal combustion engine is not any less complicated or subtle than a suspension damping unit.

If there's any fundamental difference between products shipped by Yoshimura and products shipped by Ohlins other than the secretiveness, heavy-handed market tactics and utterly opaque pricing policies of the latter manufacturer, I'd like to know what it is.

Frankly, your endless bombastic assertions without supporting data or logic are growing tiresome.

The fact that one particular mechanic managed to screw up servicing of some Ohlins products implies absolutely nothing in general terms, and the fact that you have not named the outfit you speak of leads me to believe that you're attempting to leverage an isolated incident to create general fear, uncertainty and doubt that will benefit your business.

Name and shame, if you have the evidence to do so, or STFU. A simple statement that Workshop XYZ has shown themselves unfit to service Ohlins products would suffice.

[vifferman]

Just out of interest is it usually nessacery to flush/clean out a fork when just changing the oil.

There's usually a build-up of crud in the oil, and sediment etc. in the bottom of the forks. Any bits that have worn off the fork internals (sliders, seals, etc.) and any water or dirt that may have found its way in, will be in the old oil. If the fork oil hasn't been changed since 93, there may also be a nasty emulsion of oil, water, etc. in there. If you don't want it contaminating the new oil, of course you need to clean them out.
No doubt Dr Taylor will be along soon to tell you what's the best thing to use, but most bike bits are cleaned with kerosene: the old oil is soluble in it, and it doesn't usually do any harm to anything. Whatever you use, you will need several rinses, moving the fork sliders up and down to stir it all around. Make sure too that the forks are left to drain thoroughly, as you don't want the new oil diluted by kero.

[SixPackBack]

But thats only half the equation is it not? How about brand specific training and familiarity with the particular idiosyncracies and precautions involved when servicing / repairing such a product? And I think given the example I cited above the job wouldnt have been done properly anyway, correct tools or not. A little bit of knowledge is often dangerous.

Robert. Expecting all motorcyclists within N.Z to utilise the services of a pro like yourself with a corresponding wait time and expense is impractical.
Hydraulic shock absorbers are mechanically simple devices, and while the nuances of set-up escapes most Kiwi's most are going to'give it a go'

[jrandom]

Hydraulic shock absorbers are mechanically simple devices...

Burn him!

[HenryDorsetCase]

What I dont get is if you have spent a small shedload of money on top quality bits of kit (Ohlins Superbike forks wannit? If you've got a spare set you're going to butcher, send them to me!) why wouldnt you pay the extra for the extra peace of mind knowing they've been serviced properly.

[edit: there is a secondhand (although new unused set of Ohlins forks on my watchlist on tardme, and the buy now on them is three grand: new they're about 6! even the shocks are 1600 (and good value at that IMO]

Just saying.

Our punter who had his forks worked over probably thought he was doing the right thing....

[avgas]

Bring back SHOWA and KONI!!!!!
Marzocci are lovely too.
Never had much luck with Ohlins for some reason.

[Tony.OK]

Our punter who had his forks worked over probably thought he was doing the right thing....

Thats the real issue.................most ppl are in general trusting and going to a workshop would be seen as doing the right thing.
Me............after a few bad experiences,I try and do everything myself now,firstly to know its done right and secondly because I'm tight,but some ppl aren't into that sort of thing either.
There are things I concede that need to be done by an expert,but theres also alot that once researched isn't as scary as ppl think.
I'd hope that Robert has been in contact with "said" workshop to offer advice for any future work,if only to ensure a safety standard exists in future.