Before you start
WARNING! Installing a shock absorber, that is not ap- proved 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 fitting the shock ab- sorber. Contact an hlins dealer or other qualified person for advice.
hlins Racing AB can not be held respon- sible for any damage whatsoever to shock absorber 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.
WARNING! Please study and make certain that you fully understand all the mounting instructions and the owners manuals before handling this shock absorber kit. If you have any questions regarding proper installation pro- cedures, contact an hlins dealer or other qualified person.
WARNING! The vehicle service manual must be re- ferred to when installing the hlins shock absorber.
NOTE! hlins products are subject to continual improvement and development. Conse- quently, 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 with re- gard to the contents of the manual.
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 sus- pension, or to bystanders.
CAUTION! Caution indicates that special precautions must be taken to avoid damage to the sus- pension.
NOTE! This indicates information that is of impor- tance with regard to procedures.
Kit contents Before installing the shock absorber, please check the contents of the kit, listed on the front page of this instruction. If anything is missing, contact your hlins dealer.
NOTE! During storage and transportation, espe- cially at high ambient temperature, the oil and grease used for assembling may run out inside the packing and damage the expanded polystyrene packing material. This is not unusual and is in no way detri- mental to the shock absorber.
hlins Racing AB. All rights reserved.
Any reprinting or unauthorized use without the written permission of hlins Racing AB is prohibited.
Printed in Sweden.
WARNING! 1. Its advisable to have an hlins dealer or other qualified snowmobile mechanic to fit your shock absorber. 2. Instructions in the vehicle workshop manual are to be followed when chang- ing the shock absorber. Read and truly understand these instructions. 3. When working on a lifted vehicle it must be securely supported to prevent it from falling.
Mounting Instructions
1 Lift the front end of the snowmobile so the skies have ground clearance. Make sure it is steadily positioned and will not fall down.
CAUTION! For certain snowmobiles it is not advisible to roll it over or lay it on its side. Especially for machines with injection oil system, loss of lubrication due to air in the system can damage the engine. Also fuel can leak from the gasoline tank.
NOTE! When disassembling suspension com- ponents its always easier first to loosen, but not remove all bolts, before remov- ing the components. Reversed order when assembling, tightening all bolts is the last thing you should do.
2 Remove the standard shock absorbers.
3 Fit the hlins shock absorbers. Fit spacer in front of the shock absorber lower end eye on attachment
4 The hose attached reservoir is to be fit- ted in the groove in the bellypan. Before it is positioned, two slots have to be made for the hose clamp. Open the hose clamp, push it through the holes and fix the reservoir. The banjo bolt shall point straight downwards to the ground. The hose clamp shall be located on the large di- ameter of the rerservoir, so that the in- ternal floating piston can move freely without friction from an oval reservoir.
NOTE! Make sure that the hose is positioned without sharp turns, so it not can rub against any surface and not restricts the suspension movements
NOTE! Make sure that all bolts are tightened to the correct torque and that nothing fouls or restricts the movement of the shock absorber when the suspension is being fully compressed or extended.
5 Continue your work according to the hlin