Öhlins 38MXF Front Fork Owner's Manual PDF

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Summary of Content for Öhlins 38MXF Front Fork Owner's Manual PDF

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Including:

Setting up your bike

Fine-tuning

Service the fork

General handling set-up

Technical info

Spare parts

Owners Manual hlins Front fork 38 MXF for Motocross

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 hlins advanced suspension products are adapted to the brand and model. This means that length, travel, spring, action and damping charac- teristics, are tested individually just for your motorcycle.

Before installation hlins Racing AB can not be held responsible for any damage whatsoever to front fork 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.

hlins Racing AB. All rights reserved.

Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited.

Printed in Sweden.

Contents Safety signals ................................................ 2 Introduction ................................................... 2 Before installation .......................................... 2 Tuning the suspension ................................... 3 Design ........................................................... 3 Settings ......................................................... 4 Setting the spring preload ............................. 4 Fine tuning the bike ....................................... 5 Preload adjustment ....................................... 7 Changing springs .......................................... 9 Assembling .................................................. 12 Technical specification ................................. 14 Spare parts .................................................. 15 General handling set-up .............................. 18 Change of high speed compression spring ... 19 Maintenance ................................................ 19

CAUTION When delivered the front fork legs have no springs installed. Provided are two different spring pairs, rate 3.1 and 3.5 N/mm. If a rate of 3.3 N/mm is desired a combination is made by using a 3.1 N/ mm spring in one fork leg and a 3.5 N/mm spring in the other fork leg. When the springs are mounted make sure that the spring support is fitted too. See Mounting Instructions for set-up data.

NOTE! hlins products are subject to continuous improvement and development. Therefore, although these instructions include the most up-to-date information available at the time of printing, there may be minor differences between your suspension and this manual. Please consult your hlins dealer if you have any questions regarding the contents of the manual.

WARNING! 1. Installing a shock absorber, that is not approved by the vehicle manufacturer, may affect the stability of your vehicle. hlins Racing AB cannot be held responsible for any personal injury or damage whatsoever that may occur after installing the shock absorber. 2. Please study and make certain that you fully understand the mounting instructions and the Owners Manual before handling this shock absorber kit. If you have any questions contact an hlins dealer. 3. The vehicle service manual must be referred to when installing the hlins shock absorber.

!

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Tuning the suspension

Motorcycle road holding qualities All motorcycles are designed with a suspension geometry that includes height and fork angle. The changing of components can affect this and it is therefore essential that both the rear and the front ends match each other.

Changing to hlins suspension gives optimum performance only when both the front fork and the rear suspension interact properly. It is of the greatest importance that the front and rear loaded heights are within the specified values. In the Mounting Instructions, see section: Setting the spring pre-load.

trapped above the oil) that work together with the real spring. You adjust the air-spring by raising or lowering the oil level in the legs. By using different combinations of springs and

air-springs you can alter the characteristic of the fork. For example, a soft spring in combination with a small air-spring (high oil level) makes the fork progressive; see Fine-tuning the bike.

Marking All hlins front forks are marked. You will find the part number at the fork bottom.

Recommended settings The front fork in your kit is adjusted to the hlins recommended setting for your bike. We advise you to use this as your start setting.

Design hlins new upside-down (USD) front fork is designed to combine the advantages of com- fortable, safe conventional forks and rigid, light USD forks. The result is a unique combination of being rigid, precise in corners and during hard braking yet comfortable, forgiving during over- landing and in big bumps. Your new hlins USD front fork has aluminium

outer legs and 38 mm steel inner legs, with a polished surface for lowest possible friction. The new USD fork features the hlins cartridge

damping system. The fork is fully adjustable with external adjuster

for compression and rebound damping. The compression adjuster is located at the

bottom of the fork leg (Fig.1), the rebound adjuster at the top (Fig.2). Spring pre-load is set with a spring support.

Optional springs are available to suit different tracks and riders. In the legs there are also air-springs (the air

1. The compression adjuster is located at the bottom of the fork leg.

2. The rebound adjuster is located at the top of the fork leg.

3. Spring pre-load is set with a spring support. Optional springs are available.

Spring support

4

Settings

Basic settings Always ensure that the basic setting made by hlins is correct. It is adapted to the make and model (in its original state) and for a rider of average weight.

WARNING Incorrect spring action can produce a fork angle that is too steep or too flat.This in turn will give a tendency for oversteering or understeering, which could seriously affect the handling characteristics of the motorcycle.

The original setting of the front fork, when delivered from hlins, should always be a base when the settings are changed by use of the adjustment devices.

Recommendations The difference should not deviate from the following sizes, if no other recommended settings are given in the Mounting Instructions:

Free sag: (R1-R2), (F1-F2) Rear: 255 mm Front: 255 mm

Ride height: (R1-R3), (F1-F3) Rear: 30% of the total stroke Front: 605 mm

Setting the spring pre-load

Measuring Pre-load on the spring/springs is very important, because it affects the height of the motorcycle and the fork angle. Consequently, handling characteristics can be changed, even negatively. Proceed as follows (it will be much easier if done by two persons):

Place the motorcycle on a stand, so the front fork and the rear end are in fully extended position.

Measure the distance, eg. from the lower edge of the rear mudguard or from a point marked by a piece of tape, immediately above the rear wheel axle, to the wheel axle (R1).

Make a similar measurement on the front axle, e.g. from the bottom of the upper fork crown to the front wheel axle (F1).

Allow the motorcycle (without rider) to apply load on the springs and repeat the measuring procedure (R2, F2).

Then take the same measurements with the rider and equipment on the motorcycle (R3, F3). It is important that the rider has a correct riding posture, so that the weight is balanced on the front and rear wheel in the same way as when riding.

Bike on a stand.

F1

R1

Bike on the ground.

F2

R2

Bike with rider on.

F3

R3

5

Fine-tuning the bike Learning how to use the adjusters will take time but you quickly appreciate them once you know the tricks. Even the specialists sometimes need a specialist! With the adjusters you optimize the suspension

for your riding style and the track you are com- peting on. The same basic guidelines go for both the front

fork and the rear shock absorber. Too much compression damping will give you a

harsh ride as your bike jumps along the track. With too much rebound damping your bike will

have difficulties with several bumps in a row. The suspension will not extend fast enough between bumps, your bike will ride lower and lower and eventually the suspension will bottom!

External adjusters On the hlins front fork the adjusters are bleed valves, completely separated from each other. The compression bleed valve controls the flow

in the cartridge tube during the compression stroke, the rebound bleed valve controls the flow during the rebound stroke.

CAUTION! Using too much force when closing the adjust- ers will destroy important sealing surfaces.

Make sure that you have the correct springs and the correct spring pre-load before making any adjustments. And always start with the hlins recommended settings.

Compression stroke Rebound stroke

Flow in compression valve Flow in rebound valve Flow in compression valve Flow in rebound valve

NOTE! Higher click numbers give less damping force.

When making adjustments, keep notes, make adjustments one at a timeand in small steps. The adjusters should normally not be adjusted

in steps of more than 2 clicks at a time and not outside the usable click range. When you think you have made an improvement,

go back to what you started with and double check to be sure. Pay attention to changes in conditions like tires, temperatures etc.

NOTE! See Mounting Instructions for recommended settings.

Both the adjusters have a normal right-hand thread. Click position zero (0) is when the adjusters are turned clockwise to fully closed. The adjustment range, from fully closed until maximum open valve (anticlockwise), is 20 clicks. In order not to click in the wrong direction; always first close the adjuster, then dial-in the new setting.

Making adjustments To make improvements using the adjusters, it is important to understand the function of the front fork and the shock absorber and through testing learn how they effect the handling of your bike.

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In general, compression damping changes should be used to influence the bikes stability and re- sponse, while rebound damping changes should be used to influence comfort and traction. When you need more damping force, you should

mainly try to increase compression damping and use as little rebound damping as possible. This usually means that you gain comfort and

performance in handling.

Oil level adjustment As the air trapped between the oil and the top nut acts as an air-spring, a change in oil level will effect the damping forces. Not in the early stage of fork travel, but a great deal in the later stage. A general description of how the oil level/air-

spring effects the damping forces are shown in Fig.4. The air-spring gives the hlins USD fork a

progressive spring rate, preventing it from bottoming out hard.

By using different combinations of springs and oil levels/air-springs you can alter the characteristic of the fork and tailor it to suit different tracks and conditions.

CAUTION! The oil level must be the same in both front fork legs. Riding a bike with different oil levels will cause instability.

When the oil level is raised The air-spring in the later half of travel is strong, and thus the front fork hard.

When the oil level is lowered The air-spring in the later half of travel is soft, and thus the front fork soft.

CAUTION! Adjust the oil level with the fork leg fully com- pressed and no pre-load washer or spring installed.

NOTE! See Mounting Instructions for recommended oil level.

The oil level is measured from the top of the outer leg, with the top nut off (Fig. 5). Changes in oil level should be made in small

steps. We recommend a change of 5 mm at a time and not outside the range of 80-130 mm.

Oil level Fig. 5. Oil level is measured from the top of the outer leg, with the top nut off, the fork fully compressed and no pre-load washer or spring installed.

O il

le ve

lAir spring Fig. 4. A change in oil level will effect the damp- ing forces, not in the early stage of fork travel but a great deal in the later stage.

F o

rc e

Stroke

Oil level 100 mm

Oil level 110 mm Oil level 120 mm Oil level 130 mm

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Changing springs 1 Put the bike on a stand and loosen the screws in the top fork crown that hold the fork legs.

NOTE! On most MX-bikes you have to take the handle bar off before you can unscrew the top cap.

Remove the adjustment wheel and the springs and balls of the adjuster.

2 Unscrew the top cap, use tool (1860-01). Put a box under the front wheel so that the springs are visible.

3 Remove the top cap from the damper rod extender. Use a 17 mm wrench and tool (1860-01) on the top cap and a 17 mm wrench to hold the shaft assy.

Adjustment wheel

Balls and springs Tool (1860-01)

Top cap

17 mm wrench

Damper rod assy

Damper rod extender

Tool 1860-01

17 mm wrench

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4 Remove the spring support and the spring.

5

NOTE! Closing the compression and the rebound valves will keep the damper rod extended making it easier to install the new spring.

Check the oil level according to page 6 and 10. Pull out the damper rod as far as possible and

then close the compression and the rebound valve (clockwise).

6 Install the new spring.

NOTE! Check the free length of the spring. Original length is 430 mm. If the spring length is under 423 mm the spring must be changed.

L 430 mm

Spring support

Compression adjuster

9

Adjustment wheel

Top cap

Spring support

7 Fitthe spring, the spring support and the top cap. Tighten the top cap and lock nut to a torque of 30 Nm.

CAUTION! The piston shaft must bottom in the top cap before the lock nut is tightened.

Refit the adjustment wheel. Tighten the bolt in the top fork crown to 20 Nm.

NOTE! The top nut only has to be tightened by hand, without extending tool.

Adjust the compression and the rebound valves according to specification card. Fit the fork legs to the motorcycle. Tightening torques: top fork crown 20 Nm and

bottom fork crown 10 Nm.

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Dismantling the front fork (cont.) 8 Perform steps 1-4 on page 7 and 8. Loosen the cylinder tube cap, on top of the cylinder

tube, with tool 1797-05. Lift up the damper rod assembly and drain the

oil. Pull up the scraper with a screwdriver, release

and remove the circlip.

9

CAUTION! The fork legs have two fixed bushings and one sliding bushing. Be very careful when disassem- bling the fork legs.

Fasten the fork leg horizontally in a vice with soft jaws. Use a hot air gun to warm up the outer leg where the bushings are located. The first bushing is located at the bottom end of

the outer leg, the second approximately 120 mm further up the leg. Between them is a sleeve to maintain the dis- tance.

10 Use the special tool 1702-11 to remove the bush- ings. Install the tool in the top of the inner steel leg. Screw the top cap onto the tool and install the

cap in the outer leg. Rotate the tool to press out the bushings. If tool 1702-11 is not avaliable, push the inner

steel leg to the bottom and then pull it back quickly, so that the fork is topping out hard. Repeat this procedure until the seal and the

bushings can be pulled out from the outer leg.

CAUTION! This must be carried out with great care to avoid damages on surface and bushings.

Tool 1797-05

Cylinder tube

Damper rod assy

Inner leg Outer tube

Upper bushing Lower bushing 120 mm

Outer tube

Bushing

Sleeve

Seal

Bushing Tool 1702-11

Inner leg

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11 Remove the seals and bushings and check them for wear and damage. Replace if necessary.

CAUTION! When removing the oil seal and bushings use a small plastic bag to cover the bushing attachment groove and edges of the inner tube, to avoid damage to the seals.

12 Fasten the damper rod assembly in a vice with soft jaws.

CAUTION ! Fasten the damper rod assembly in a vice. Be carful not to tighten too hard. The piston rod is very delicate.

Remove all parts from the piston holder.

NOTE! If the correct order is lost, use the specification card as a guide.

13 Remove the compression valve assembly from the fork bottom using a 17 mm socket. Fasten the valve assembly with soft jaws in a

vice. Remove all parts from the valve body and put

them in the right order on the bench. Clean all parts thoroughly. Inspect all parts for wear and damage, replace

if necessary. Assemble the compression valve.

Bushing

Bushing

Sleeve

Seal

Rebound valve assembly

Compression valve assembly

Put them in the correct order on the bench. Clean all parts thoroughly. Inspect all parts for wear and damage, replace

if necessary. Assemble the damper rod.

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Assembling 14 Apply a thin layer of hlins red grease (146-01) on the scraper ring and on the sealing surface of the fork seal.

CAUTION! When installing the oil seal and bushings use a small plastic bag to cover the bushing attachment groove and edges of the inner tube, to avoid damage to the seals.

Mount the scraper, circlip, fork seal, support ring and the bushings separated by the sleeve on the inner steel leg.

16 Apply some hlins red grease on the seals. Again, use tool 1799-05, flip it around to install

the seal in the outer leg. Install the circlip and the scraper.

CAUTION! Make sure the circlip is fitted correctly into the groove in the outer leg.

15 Fasten the outer leg in a vice with soft jaws. Install the inner leg and mount the upper bush-

ing with tool 1799-05, and the sleeve. Mount the lower bushings.

Inner leg Scraper

Circlip Seal

Washer Bushing

Bushing

Sleeve

Bushing

Sleeve

Bushing

Tool 1799-05 Circlip

Scraper

Outer leg

Seal

Inner leg

Tool 1799-05

13

17 Fasten the fork leg, at the fork bottom, in a vice with soft jaws. Install the compression valve assembly in the

fork bottom. Tightening torque 60 Nm. Apply some front fork oil on the outer surface of

the inner leg, and push the outer leg up and down a few times. First, fill up the cartridge tube, then raise up the

outer leg about 250 mm and add the remaining oil.

19 Install the fork top cap and the lock nut. Tighten the top cap and the lock nut against

each other, use tool 1860-01. Tighten to 30 Nm. Fit the fork legs on the motorcycle. Tighten the

upper triple clamp to 20 Nm and the lower triple clamp to 10 Nm.

Adjust the compression and the rebound valves according to the specification card.

18 Install the damper rod assembly into the cylinder tube. Use Loctite 542 on the cylinder tube cap. Tighten with tool 1797-05. Tightening torque 60 Nm.

Pump the damper rod up and down a few times to check that there is no air left. Measure the correct amount of oil according to

the specification card. Pull out the damper rod as far as possible and

close the compression and the rebound valves. Install the spring and the spring support.

Compression valve assy

60 Nm

Damper rod assy

Cylinder tube

Cylinder tube cap

17 mm wrench

17 mm wrench

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Technical specifications Rebound and compression adjustment Refer to mounting instruction for set-up data. Maximum open rebound and compression valve: 20 clicks.

Free Spring Length: All forks: 430 mm (service limit 423 mm).

Spring rate: (depending on models) 2428-31: 3.1 N/mm Included

Tighten torque: Fork top crown bolt: 20 Nm Fork bottom crown bolt: 10 Nm Compression valve: 60 Nm (Base valve). Cylinder tube cap (cartridgetube): 60 Nm Compression valve, 8 mm nut 8 Nm. Rebound valve, 8 mm nut 8 Nm.

Grease: hlins Front Fork grease 00146-01 (Red grease).

Service Intervals: Every 20 hours.

2428-33: 3.3 N/mm Optional 2428-35: 3.5 N/mm Included 2428-37: 3.7 N/mm Optional 2428-39: 3.9 N/mm Optional

Settings: Compressing adj. 14 clicks Rebound adj. 14 clicks

Oil level: Adjustment range: 80-130 mm.

CAUTION! Use only hlins high performance front fork fluid No. 5 (1311-01).

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5

6

9

16

17

15

8

1

2

3

4

8

20

21

19

Spare parts Pos. Part No. Pcs. Description Type/remarks

1 02474-01 1 Top Cap 2 02476-01 1 Bump rubber 3 02470-01 1 Slide washer 4 02471-01 1 Spring support 5 02468-31 1 Spring front fork 3,1 N/mm (Incl.)

02468-33 1 3,3 N/mm (Optn.) 02468-35 1 3,5 N/mm (Incl.) 02468-37 1 3,7 N/mm (Optn.) 02468-39 1 3,9 N/mm (Optn.)

6 02460-xx 1 Fork leg outer see spec. card 7 00329-12 1 Circlip 8 02464-01 2 Bushing lower 9 02467-01 1 Sleeve 10 02332-08 1 Cover Sticker hlins 11 02463-01 1 Washer 12 02461-01 1 Seal 13 02465-01 1 Circlip 14 02462-01 1 Scraper 15 02339-03 1 Cylinder tube cartridge 16 02466-01 1 Bushing upper 17 02469-01 1 Fork leg inner 18 00438-94 1 O-ring 19 1 Fork bottom left see spec. card 20 1 Fork bottom right see spec. card 21 1 Base valve assy see page 17

10

12 11

13 14

7

18

16

19

Spare parts Pos. Part No. Pcs. Description Type/remarks

1 00828-01 1 Screw 2 03253-03 1 Adjustment knob 00438-02 1 O-ring 3 01473-06 1 Circlip 4 00338-79 1 O-ring 5 02405-01 1 Adjustment screw 6 00884-01 2 Ball 7 00833-01 2 Spring 8 01050-01 1 Screw 9 00338-59 1 O-ring 10 02474-01 1 Top cap 11 00438-96 1 O-ring 12 02366-14 1 Adjustment rod 13 02402-01 1 Lock nut 14 02472-01 1 Spring guide 15 01499-02 1 Circlip 16 02527-38 1 Cylinder tube cap 17 00110-03 1 Bushing 18 02528-01 1 Washer 19 02393-02 1 Shaft 20 02473-01 1 Spring

1 2

8

10

11

13

14

15

18

6 7

3 4 5

9

12

16

17

20

Tools 1860-01: Top cap releasing tool 1863-01: Base valve tool 1799-05: Mounting sleeve 1797-05: Cartridge tool 1702-11: Bushing remover

1860-01

1863-01

1799-05

1797-05 1702-11

17

Comp. valveReb. valve Spare parts Pos. Part No. Pcs. Description Type/remarks

28 00438-31 1 O-ring 29 02356-03 1 Rebound needle 30 02322-01 1 Spring 31 02320-04 1 Piston holder 32 - Clamp washer see spec. card 33 - Shims stack see spec. card 34 02520-01 1 Piston rebound 35 01447-02 1 Piston ring 36 - Shims see spec. card 37 - Clamp washer see spec. card 38 00153-01 1 Washer 39 00430-05 1 Nut

40 00430-05 1 Nut 41 00153-01 1 Washer 42 02056-01 1 One-way valve seat 43 00530-18 3 Shim 44 01149-01 1 Wave washer 45 00530-22 1 Shim 46 00438-03 1 O-ring 47 02406-01 1 Piston 48 0018x-xx - Shims see spec. card 49 00641-01 1 Clamp washer see spec. card 50 00438-02 1 O-ring 51 02054-04 1 End piece 52 01242-08 1 Adjustment needle see spec. card 53 01248-01 1 Spring 54 00884-04 2 Ball 55 00338-53 1 O-ring 56 01473-02 1 Circlip

40

41

42

43

44

45

46

47

48

49

50

51

52 53 54 55 56

29

30

31

32

34

35

36

37

39

33

38

28

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General handling set-up Front suspension.

Front fork travel is not used to its full capacity. Harsh feeling, front wheel grip is not satisfactory in bumpy turns. Suspension too hard.

Decrease the front fork compression damping.

Change to softer springs.

Suspension bottoming, too soft during entire travel. Spring too weak or compression damping too soft.

Increase oil level 5 mm. Increase compression damping. Change to stiffer springs.

Suspension bottoming, but can handle smaller bumps. Damping force not progressive enough.

Increase the oil level.

Can handle smaller bumps but is too hard during the last part of the travel. Damping force is too progressive.

Decrease the oil level.

Front end feels low, initially feels soft, but is not bottoming. The initial spring rate is too soft or spring preload is too low.

Increase the spring pre-load.

Feels harsh over small bumps, but using full wheel travel. Too much spring pre-load or too much compres- sion damping.

Increase the oil level or change to softer springs.

Decrease the compression damping. Decrease the spring pre-load. Clean the oil seals and scrapers. Use hlins

grease 146-01 for regreasing.

Can handle the first in a series of bumps but feels hard after a few more bumps. Frontal grip insufficient in rough and bumpy turns. Too much rebound damping.

Decrease the rebound damping.

Front end rebound too fast after a bump. Front wheel grip insufficient in bumpy curves. Not enough rebound damping, or too much spring pre-load

Increase the rebound damping. Decrease the spring pre-load.

Front end ploughs, understeers. Shallow front fork angle. Front end too high in comparison to rear end.

Decrease the front fork compression damping.

Raise the fork legs approximately 5 mm in the triple clamp.

Change to softer fork springs.

Front end unstable at high speed, unstable when accelerating out of curves. Front fork angle too steep. Front end too low in comparison to rear end.

Lower the fork legs approximately 5 mm in triple clamp.

Change the front fork springs to harder ones.

Front end unstable during deceleration. Front fork angle too steep during braking. Front end too low or rear end too high.

Increase the oil level in the front fork. Change to harder fork springs. Increase the front fork

compression damping.

Front end falls into the curves (oversteering) especially in sand. Steep front fork angle. Front end too low in com- parison to rear end.

Increase the front fork compression damping.

Change to harder springs. Lower fork leg approximately

5 mm in the triple clamp.

19

Maintenance Telescopic front forks depend on smooth, friction free action. Make sure your forks are regularly serv- iced. Do not use strong solvents, such as brake cleaner,

to clean the front forks. This will dry out the seals and the steel tubes and cause friction or leakage.

After every race Clean externally and spray with an all-purpose oil after washing with detergent. Check externally for damage. Put a little hlins red grease (146-01) on the steel

tubes and work it in by pushing the fork up and down.

Every 20 hours Dismantle the fork and check all parts for wear and damage, replace if necessary, see Dismantling.

Cleaning the scrapers The purpose of the scrapers is to protect the fork tube from dust and dirt. However, dirt may after some time end up behind the scrapers. If this dirt is not removed there is risk that the oil seal- ing rings will start to leak. Lift the scrapers out of the outer tubes with the

help of a screwdriver and slide them downward. Clean the scrapers, the outer tubes and the front tubes thoroughly, then oil them with hlins front fork fluid No. 5 (1305-01). When done, simply re- place the scrapers by pushing them into the outer tubes.

NOTE! Discarded hlins products should be handled over to an authorized work shop or distributor for proper disposal.

NOTE! Use only hlins high performance front fork fluid No. 5 (1305-01).

Breather plug front fork Make sure to ventilate the telescopic fork at regu- lar intervals. Put the motorcycle on a stand so the front wheel is clear of the ground, then loosen the vent screws to rid the inside of the fork of excess pressure.

CAUTION! Too high pressure inside of the fork may cause leakage. If this is the case, open the breather plugs before replacing the seals.

Maintenance intervals Item After break-in Every race Every 20 hours As required Front forks Inspect and adjust x x - x Replace oil x - x Replace oil seal - - - x

Front fork oil seal and dust seal Clean and lube x x - -

Scraper

Breather plug

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