hlins 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 hlins dealer if you have any questions with regard to the contents of the manual.
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 detrimental to the suspension component.
Kit contents Before installing the suspension components, please check the contents of the kit, listed on the front page of this instruction. If anything is missing, contact your hlins dealer.
Description Pcs. Part No. 2-way base valve 2 3200-40 Spring 20 N/mm (125-250cc) 2 4107-02 Spring 30 N/mm (450-650cc) 2 4107-03 Spring 40 N/mm (Supermotard) 2 4107-04 Poppet valve tool 1 1863-01
Delivered with spring 04107-02 (20 N/mm) pre- assembled
Optional springs available Spring 50 N/mm 4107-05 Spring 60 N/mm 4107-06 Spring 70 N/mm 4107-07
Before installation hlins Racing AB can not be held responsible for any damage whatsoever to suspension components 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! 1. Installing suspension components, 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 fitting the suspension components. Contact an hlins 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 components kit. If you have any questions regarding proper installation procedures, contact an hlins dealer or other qualified person.
3. The vehicle service manual must be referred to when installing the hlins suspension components
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 precautions must be taken to avoid damage to the suspension.
NOTE! This indicates information that is of importance with regard to procedures.
Base valve housing
WARNING! 1. Its advisable to have an hlins dealer or other qualified person to fit your front fork. 2. Instructions in the motorcycle workshop manual are to be followed when removing the front fork. 3. When working on the motorcycle it must be securely supported to prevent it from falling over.
Mounting instructions
1 Turn the fork leg upside down and fasten the fork bottom in a vise with soft jaws
2 Remove the original compression (base) valve. Use a 17 mm socket. Fit the new compression valve. Use a 23 mm wrench. Tighten to a torque of 65 Nm.
3 The high speed compression damping is adjusted with a 12 mm socket. The low speed compres- sion damping is adjusted with a 3 mm allen key.
4 The damping is increased when the adjuster nut is turned clockwise and decreased when the adjuster nut is turned counter clockwise.
NOTE! Do not use too much force when turning the ad- justers. Delicate sealing surfaces can be dam- aged.
Change of high speed compression spring
5 Fasten the valve in a vise with soft jaws.
6 Use tool (1863-01) or a pair of pointed pliers to loosen the poppet valve seat and remove it to- gether with the poppet valve and the spring.
7 Install the new spring, refit the poppet valve and the poppet valve seat. Tighten to a torque of 5 Nm.
8 Refit the valve unit to the fork bottom as de- scribed above.
Tool 1863-01
Poppet valve seat
en
