INSTALLATION MANUAL USER MANUAL TRIAL CLASSICS
Contents
1. 2 als gt wig e GEJ x 9 os saj 6 Ula m 5 oy W Wie vi A alid TET oag Sged SEBS EGS vw kL 55 zii Euw all a o a 2 0 x 2522 ZUA lt 4202 AoW Ww E Y vaT e o t E i e EE Hm i x g y Erir ar eae j x 9 3 Introduce HFS springs Figure 9 Read GUIDE FOR SPRING SELECTION chapter In figure it is shown medium stiffness spring two marks Figure 8 6112 HFS SUSPENSIONES www suspensionhfs com 4 Install gas spring element Figure 10 4 1 Make sure that element is nor pressurised press valve s inner axle to release pressure completely 4 2 Make sure that element s cap o ring is installed 4 3 Introduce the element There are some models that could fit a plastic spacer under thrust washer In these cases check that it is correctly fitted Figure 15 We have observed that in some classic motorbikes the fork that is installed is not the original from the manufacturer or also sometimes inner parts have been altered from the original design Before tightening HFS element it is necessary to check a control dimension according following steps o HFS spring must be Extend completely Introduce Measure control fitted Intro the bar HFS element HFS element dimension X push upper valve extended It should be to allow alr getting 28 5 mm in2. PULLING In control dimension is not 28 5 mm please contact your dealer or www suspensionhfs com 4 4 Press slightly and screw in the bar Tightening torque 20 Nm Figura 11 5 Install handlebar 6 Put pressure in gas element In this operation front suspension must be unloaded 6 1 Unscrew valve s cap Figure 12 6 2 Screw in pump terminal Figure 13 6 3 In classics Trial models it is recommended 3 bar as starting set up pressure Make sure that you check pressure in pump s manometer as much perpendicular to the scale as possible In Figure 14 it is indicated 3 bar as an example 2 5 bar corresponds to the small mark right before 3 bar s 6 4 Screw valve s cap do not over tighten Figure 12 T Put the motorbike on the ground WWW suspensionhfs com 7 12 HFS9 SUSPENSIONES a Do not apply more than 5 bar pressure This limit is because of behaviour not due to element s performance It is recommended to make a first set up with 2 5 bar ride in an authorised and known road and increase or decrease in e of 0 25 bar depending on feeling c Increasing or decreasing element s pressure it is modified static sag Pilot can leave it to his choice After the first adjustment or re adjustments drive carefully to feel change in response e Apply same pressure in both elements WHEN UNSCREWING PUMP TERMINAL AIR LEAK NOISE IS NORMAL _ D c PRESSURE CHECK OR RE ADJUSTMENT WARNING 1 AD
3. 1 Lift front wheel from ground 1 2 Disassemble original spring and adjustment of fork s oil GENERAL WARNING Each motorbike is different During disassembly process described from now on probably you will need to disassembly parts to be able to follow the installation procedure For instance plastic covers handle bar hand guards If this should be the case please refer to the Manufacturer s Workshop Manual making sure that all disassembled parts are assembled according to specification www suspensionhfs com 5112 2 1 Loose fork s upper clamp bolts it is not necessary to disassemble completely 2 2 2 Disassembly fork s bar upper caps 3 2 3 Take out spring and spacer if any 5 in some models it Could be necessary to disassemble handlebar 4 This system requires less fork oil volume in fork s bottle than specified by manufacturer This can be done in two ways pouring all fork oil and refilling with the adequate volume see 2 4 1 2 4 3 or maintaining existing fork oil and taking out some volume 2 4 Adjust fork oil volume make this operation for each fork Method 1 2 4 1 Unscrew pouring screws in bottle s lower area or disassemble complete fork if there are no pouring screws Figure 6 2 4 2 Take out oil completely Leave some time for a complete drain Assemble pouring screws or complete fork 2 4 3 Fill with following specified volume Figure 7 In normal conditions it is necessary to a
4. equipment included For pilots around 80 Kg it is recommended to start with Standard spring 2 5 bar set up pressure Install recommended spring For pilots over 85 90 Kg it is Adjust recommended to start with YES pressure Test End Higher Stiffness spring 2 5 bar 2 5 bar set up pressure For pilots around 70 Kg it is Ir is desired It is desired softer stiffer recommended to start with Lower Increase Stiffness spring 2 5 bar set up pressure To find behaviour differences it is recommended to change pressure in steps of 0 25 bar Reduce pressure to 2 25 bar pressure to 2 75 bar Increase pressure to 3 0 bar Change to upper stifness spring Change to lower stifness spring WWW suspensionhfs com 10 12 HFS9 SUSPENSIONES When HFS optimum configuration is selected it is possible to try different fork oil viscosities for instance to obtain a slower response in extension it can be increased oil viscosity index and then test again For competition use a good try can be increasing 5 or 10 units in SAE index SAE 15W o 20W coming from SAE10W With HFS system it is not usual to reduce fork oil viscosity with respect to manufacturer s specification FIGURES e t is included following pictures to help in HFS kit installation e Use tooling and fixtures reliable to avoid accidents e Assure correctly the motorbike when front end is lift e Tools require
5. is admitted variation with respect to the recommended value as indicated in the mentioned graph or written instruction Do not pass indicated limits both lower and upper www suspensionhfs com 4 12 HFS9 SUSPENSIONES ASSEMBLY INSTRUCTIONS GENERAL 1 When a suspension system not approved by motorbike s manufacturer is installed in the motorbike behaviour could be affected HFS SUSPENSIONES is not responsible for damage or accidents after its kit installation in the motorbike Please contact HFS SUSPENSIONES technical service for advice entering in www suspensionhfs com If you have doubts about installation procedure contact HFS SUSPENSIONES entering in www suspensionhfs com or with qualified personnel For assemblies related to original parts it is mandatory to refer to manufacturer s motorbike Workshop Manual HFS SUSPENSIONES products are in a continuous update process manuals include latest available version about installation procedure Should you find differences please contact HFS9 SUSPENSIONES entering in www suspensionhfs com If the element is pressurized being unassembled the element has to be in vertical position with valve upwards before releasing the air from inside through the valve It is possible that a small amount of oil is poured through the valve this is due to the small retention of oil in narrow holes that there s in the valve circuit Never release air with valve downwards INSTALLATION PROCEDURE
6. IANBIRUID FORK SUSPENSION AHFS INSTALLATION MANUAL USER MANUAL TRIAL CLASSICS 12 2010 V 3 3 UK www suspensionhfs com 1 12 HFS SUSPENSIONES This Manual covers following models 1964 FANTIC 1981 FANTIC 240 Profesional 1983 FANTIC 1984 320 TL Guanaco 1978 320 TL New 1981 82 350 Jumbo 1983 APRILIA 320 Roja 1979 81 APRILIA 320 Blanca 1982 83 APRILIA TX 300 1984 MERLIN DG 3 50 1983 84 MER HONDA TLR 200 1982 HTO1 HONDA TLR 250 1982 2 www suspensionhfs com 2112 HFS9 SUSPENSIONES This Manual covers following models cont AJS G80 CS marzocchi 1958 www suspensionhfs com 3 12 HFSe SUSPENSIONES ENGLISH HYBRID FORK SUSPENSION SYSTEM Hybrid Fork Suspension system HFS consists in a gas spring and in a helicoidal spring for each fork Gas spring is received assembled from factory and ready to be installed in your motorbike After installing the system it is necessary to adjust it using the pump that is provided with the kit following instructions that will be explained later SAFETY INSTRUCTIONS For kit installation you must read this manual carefully making sure that you fully understand all its content If you do a step without considering safety recommendations it may appear damages in your motorbike or in kit components that might cause an accident during its installation process or during its usage Indicates that if safety instructions are not followed it might cause s
7. JUST ELEMENT S PRESSURE WITH NO LOAD IN FRONT FORKS A 2 NEVER USE A COMPRESSOR TO APPLY PRESSURE DO NOT USE PETROL STATION OR WORKSHOPS DEVICES 3 DO NOT DEPRESSURIZE THE ELEMENT WITH SUSPENSION LOADED BECAUSE OIL LEAKAGE WILL OCCUR AND REPAIR WILL BE NEEDED For checking or re adjustment make following steps Lift front suspension from ground Unscrew valve s cap in both elements Screw pump s terminal to the valve Apply some more pressured than desired adjust required value stepping down pressure with pump s micro button Unscrew the pump A SMALL AIR LEAK NOISE IS NORMAL Screw valve s cap do not over tighten Repeat same steps in the other fork Put the motorbike on the ground Qo c Ox d popa cx PRESSURE ADJUSTMENT PUMP USE INSTRUCTIONS 1 General Itis a pump to apply pressure to suspension forks It has a small button for micro adjustment 2 Instructions 2 1 Connect terminal to element s valve If pump terminal is ON OFF type connect it to the valve with the small lever released figure 1 OFF to pressurise turn the lever 90 as indicated in figure 2 ON position Figure 1 OFF position Figure 2 ON position 2 2 Pump until it is reached desired pressure It is recommended to overcome target value a little and to use small micro adjustment button to reach desired value www suspensionhfs com 8 12 HFS SUSPENSIONES Each time micro adjustment button is
8. ce it is obtained an increase in overall suspension s spring rate along fork s stroke It is obtained a higher bottoming limit and it is adequate for pilots with a higher weight loaded motorbikes extra capacity fuel tanks or only to have stiffer suspension behaviour An estimated threshold of pilot s weight to choose a medium or heavy rate spring can be around 85 90 Kg equipment included Combining spring change and pressure set up you can obtain a very wide range of adjustments A constant rate spring or vice versa Optimum configuration is reached through tests In case of doubts put in contact with www suspensionhfs com or with your distributor i BEFORE DISASSEMBLY OF HFS ELEMENT for instance to change the springs A IT IS NECESSARY TO RELEASE ALL PRESSURE FROM THE ELEMENT PAYING ATTENTION TO UNLOAD FRONT WHEEL BEFORE SUSPENSION WITHOUT LOAD What has been indicated above is just an orientation It might happen that a pilot that is lighter would prefer a higher www suspensionhfs com 9 12 HFS9 SUSPENSIONES 2 Springs identification Different Springs are identified with marks in one of its ends Difference is only spring rate 2 1 Standard stiffness Identified with 2 marks figure 1 2 2 Lower stiffness Identified with 1 mark figure 2 2 3 Higher stiffness Identified with 3 marks figure 3 Figure 1 Figure 2 Figure 3 3 Initial recommendation for classics Trial motorbikes indicated weights are with
9. d LIFT THE MOTORBIKE Appropriate support Appropriate socket LOOSEN UPPER FORK CLAMP Appropriate socket REMOVE HANDLE BAR Appropriate socket REMOVE FORK S CAP Appropriate socket TAKE OUT THE SPRING Metal wire with hooked end of a magnetic tip Used cloths for drips TAKE OUT FORK s OIL screwdriver for drain screw See procedure Syringe 100 c c Plastic tube An accurate volume measuring device Used cloths for drips IMPORTANT JOINTS see HFS manual Dynamometric wrench and manufacturer s workshop manual TIGHTENING OF HFS ELEMENT Appropriate socket REMOVE VALVE S CAP Wide screwdriver to prevent part damage In attached figures the process is explained based on an OSSA 250 MAR Use it as a guide of the different steps making adaptations according with the motorbike you are working in www suspensionhfs com 11 12 HFS SUSPENSIONES 2 I Figure 10 Figure 11 5 Ji Figure 12 amu a Figure 13 Figure 14 Figure 15 www suspensionhfs com HFS SUSPENSIONES
10. dd 60 c c less than Manufacturer s specified volume ARZUIT Nevertheless make sure that with the fork extended completely damping duct remains completely covered by oil Make this check following the procedure showed later When you install the new spring you must hear it is falling on fork oil Should this were not the case add small quantities until procedures condition is reached Consult 59 SUSPENSIONES in case of doubts Method 2 This method can be applied only if oil volume into the fork is manufacturer s exactly specified volume 2 4 4 Take out the volume specified later using a large syringe with a tube fitted in its end It is possible that you need so suck several times Use a device with good and clear indications to check extracted volume Repeat this in each fork Extract 60 c c from each fork ALZU Nevertheless make sure that with the fork extended completely damping duct remains completely covered by oil Make this check following the procedure showed later When you install the new spring you must hear it is falling on fork oil HFS SUSPENSIONES Should this were not the case add small quantities until procedures condition is reached Consult HFS SUSPENSIONES in case of doubts Procedure to check minimum fork oil volume ort covered by oll Is Spring su E E wi ij 5 c m m 5 x o Es o Qua w3 c SESS 9o z2 So 5955 zi a9 4 t 5 2
11. evere or fatal injuries A to the person that is working with the suspension inspecting it or using it GENERAL WARNING TO RIDE ON BIKE IS A RISKY ACTIVITY THAT REQUIRES THE DRIVER KEEPING UNDER CONTROL THE MOTORBIKE UNDER ANY CIRCUMSTANCE TO REDUCE PROBABILITY TO SUFFER INJURIES OR A FATAL ACCIDENT READ COMPLETELY THIS MANUAL AND COMPLY WITH WARNING POINTS INDICATED IN IT SHOULD YOU HAVE ANY PROBLEM WITH KIT INSTALLATION PLEASE CONTACT HFS SUSPENSIONES VIA WEB PAGE www suspensionhfs com WARRANTY HFS9 SUSPENSIONES guarantees that during a period of two 2 years from original purchase date that its products are free of defects in its materials or in its manufacturing All HFS9 SUSPENSIONES products must be inspected in the factory If during the inspection HFS9 SUSPENSIONES would detect a material or manufacturing defect HFS SUSPENSIONES will choose between replacement of the damaged part or its repair This warranty is the only and exclusive compensation that the customer has right to HFS SUSPENSIONES will not be responsible of any other damage or indirect injuries Warranty exclusions This warranty will not be applied to those products incorrectly installed or adjusted without following installation instructions provided by HFS9 SUSPENSIONES This warranty does not cover damages that could suffer the product as a consequence of accidents impacts improper use not complying with manufacturer instructions or any other circu
12. mstance in which the product has been used with forces or loads that has not been design to receive This warranty does not cover any damage caused by modifications done in the product It will be required the purchase justification invoice including the serial number without modification or distortion Repairing or substitution during warranty period will be valid only by presenting the original purchase invoice sent directly to HFS9 SUSPENSIONES together with the product with paid transport The decision to repair or substitute the product will be adopted under the exclusive criteria of HFS9 SUSPENSIONES after product and invoice inspection This warranty does not cover wearing or ageing of the parts that are under wearing conditions in normal usage The following parts can suffer normal wearing or ageing piston seal piston sliders o rings screws or springs WARNING YOU MUST NEVER UNINSTALL GAS SPRING WITHOUT RELEASING PRESSURE FROM THE ELEMENT If you try to unscrew the element from the fork without releasing air pressure you could make irreparable damage in upper cup s thread or having an accident during disassembly or its utilisation WARNING A IF YOU USE YOUR MOTORBIKE WITH AN INCORRECT PRESSURE IN THE ELEMENT YOU COULD LOSE CONTROL AND MIGHT HAVE SERIOUS OR FATAL INJURIES In this instruction manual it is included a graphic or written indications in order to do pressure adjustment in the gas element depending on driver s weight It
13. pressed it is released some pressure between 138 and 207 mbar 2 3 psi Remark 1 Due to large end of scale it is recommended adjustments in steps of 0 25 bar This is enough from functionality point of view See following figures Pumps with dial in black colour Observe that after 0 first indication is 2 bar Pumps with dial in white colour Each mark is 0 5 bar 2 5 bar setting 3 bar setting 2 75 bar setting First mark is 1 bar Recommendation for setting in motorbike testing is with steps by 0 25 bar indicator between two marks 2 3 If pump is ON OFF type turn the lever to OFF position figure 1 2 4 Unscrew pup terminal Remark 2 When unscrewing pump terminal you will hear a small air leak noise This is normal it is the air occluded in pump s circuit GUIDE FOR SPRING SELECTION Applicable for kits with 2 or 3 spring sets 1 General HFS kit can be supplied in two configurations with 1 2 or 3 sets of springs The difference is the spring rate and it is used for performance fine tuning With this it is available suspension set up possibilities changing the springs additionally to pressure adjustments When element pressure is changed the result is a change in static sag It is also changed bottoming limit as well as the response of suspension in extension Change of spring is basically related to two factors pilot s weight and preferences regarding suspension performan
Download Pdf Manuals
Related Search