Öhlins motorcycle suspension

Engineering the next generation of MotoGP

Discover how Lesjöfors applied extensive industry experience, advanced materials, and a dedicated R&D program to achieve an engineering first in motorcycle suspension for Öhlins.

Project overview: Enhancing Öhlins motorcycle suspension

Öhlins is a global leader in suspension for motorcycles, mountain bikes, and automotive applications across aftermarket, OEM, and elite motorsport. With more than 400 world titles, their systems set the benchmark at the highest levels of racing.

When Öhlins engaged Lesjöfors, the objective was clear – to further elevate rider control and on-track performance in MotoGP through advanced spring engineering.

了解我们的螺旋弹簧

Design criteria for the motorcycle suspension system

What was the brief?

Öhlins required rear motorcycle suspension springs that delivered a consistent, linear spring rate throughout the full stroke. At the same time, the components needed to be produced using the lightest possible material to unlock performance gains for their MotoGP teams.

What makes the project special?

This project advanced MotoGP component manufacturing by combining decades of expertise with modern engineering processes, blending skilled craftsmanship with advanced analysis and testing. This approach enabled Lesjöfors to fully control material behavior while meeting both the performance and aesthetic requirements of the finished motorcycle suspension spring.

What did Lesjöfors do?

Recognizing that titanium, with its high strength-to-weight ratio, could deliver the required force pattern, we explored numerous manufacturing processes over a two-and-a-half-year development period to meet the exact requirements specified.

Looking to design a custom component?

What our clients say

A unique, highly engineered product

"Balancing coiling and manufacturing process methodology with the requirements of the design and material restrictions associated with titanium has been a lengthy but rewarding process. It has been a long-term learning investment which has delivered a unique, highly engineered product."

Olof Jonsson, Sales Manager

The next generation of motorcycle racing springs

"Lesjöfors have manufactured the next generation of springs for motorcycle racing."

Jonas Torstensson, Design Engineer, Öhlins Racing

The Öhlins motorcycle suspension engineering journey

Mass industrial production of this specific suspension spring design and dimension had never been achieved before. To make it possible, Lesjöfors and Öhlins undertook a multi-step R&D program over many months:

To secure the required aesthetic quality, the titanium wire had to be manually coiled to prevent scratch marks on the material.
The spring design required parallel end fittings; however, grinding is a lengthy and complex process when working with titanium.
Cutting the wire delivered the required parallel end finish but introduced challenges related to spring stress and dimensional tolerance.
Carefully controlled heat-treatment processes were applied to relieve stress before and after cutting. Following extensive experimentation, the manufacturing process was successfully mastered.

Learn more about our manufacturing services

What's next for Öhlins?

There are three race teams under the elite Öhlins Factory Racing umbrella currently using the new spring, and supply to the MotoGP teams is ongoing.

“Evidence has shown that the new Lesjöfors suspension spring has resulted in a considerable weight reduction without any compromise on the performance. In fact, the fatigue properties of the titanium spring far outweigh the properties of its corresponding steel spring, and to achieve this, as well as weight reduction, secures a uniquely high-performance spring.

"This has not only been proved by our laboratory tests, but numerous tests have also been done on the racetrack where the MotoGP riders report the same feeling with the titanium springs as with a steel spring.”

- Jonas Torstensson, Design Engineer, Öhlins Racing.

Learn more about our technology