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Including:

Safety

Designfeatures

Basicadjustments

Technicalinformation

Owners ManualMX & Enduro steering dampers SD 415, 425

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hlins Racing AB.All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofhlins Racing AB is prohibited.

Printed in Sweden.

Introductionhlins steering dampers are designed towithstand very tough treatment in conjunctionwith competitions. Many years experience andclose cooperation with World Championship

teams in motocross and enduro has helped usdevelop unique know-how.

Before installationhlins Racing AB can not be held responsible forany damage whatsoever to shock absorber orvehicle, or injury to persons, if the instructions

for fitting and maintenance are not followedexactly.Similarly, the warranty will become null and voidif the instructions are not adhered to.

Safety signalsImportant information concerning safety isdistinguished in this manual by the followingnotations:

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!

Failure to follow warning instructions could result

insevere or fatal injuryto anyone working with, inspecting or using the suspension, or tobystanders.

CAUTION!

Caution indicates that special precautions must be taken to avoid damage to the

suspension.

NOTE!

This indicates information that is of importancewith regard to procedures.

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WARNING!

1. Installing a steering damper, that is notapproved by the vehicle manufacturer, may affectthe stability of your vehicle. hlins Racing ABcannot be held responsible for any personal injury

or damage whatsoever that may occur afterfitting the steering damper. Contact an hlinsdealer or other qualified person for advice.

2. Please study and make certain that you fullyunderstand all the mounting instructions and theowners manuals before handling this steering

damper kit. If you have any questions regardingproper installation procedures, contact an hlinsdealer or other qualified person.

3. The vehicle service manual must be referredto when installing the hlins steering damper.

CAUTION!Make sure that the steering stops work properly.If not, its necessary to adjust the steering stops(use washer or suchlike). If the damper is used

as stop it can be damaged.

hlins products are subject to continualimprovement and development. Consequently, al-though these instructions include the most up-to-date information available at the time of printing,

there may be minor differences between your sus-pension and this manual. Please consult yourhlins dealer if you have any questions with regardto the contents of the manual.

NOTE!

During storage and transportation, especially athigh ambient temperature, the oil and grease

used for assembling may run out inside thepacking and damage the expanded polystyrenepacking material. This is not unusual and is in noway detrimental to the steering damper.

NOTE!

Please note that all bikes require bars with a mini-mum of 40 mm between crossbar and main bar for

damper to fit. For applications with less than thisclearance use: PROTAPERS, Scotts Renthals orspecial handlebars with no crossbar. Youre goingto pre-assemble everything before permanently

mounting or drilling anything. This will insure properalignment and fit, otherwise you may find some hid-den problems you didnt anticipate.

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DesignThe hlins steering damper is a hydraulicdamper that counteracts wobble, alleviatesshock against the front wheel and prevents headshake/cast by the motorcycle, which gives saferriding.

The damper is fitted on the upper fork crown,in the centre over the steering stem (fig.1). Whenturning, and in the event of wobbling, shock, etc,the link arm of the damper is twisted, thus forcingfluid through three independently acting valvesystems in the damper cover.

1

SettingThe steering damper has three external settingpossibilites, ie, setting of the damper valve, high-speed valve and sweep valve, which regulatethe damping area (fig.2).

Low speed valvehlins steering damper is delivered with the lowspeed valve set in a basic position that gives maxi-mum basic damping. For enduro and motocrossit is suitable to set the low speed in position 4-8,depending on the track and the rider.

Turn clockwise to increase damping and

counter clockwise to reduce it (fig.3).High speed valveThe high-speed valve (fig.4) is set between 11/4to 2 turns from the bottom position, suitablefor enduro, motocross and off-road.

WARNING!

For all riding purposes the high-speed valve mustbe loosened at least 1 turn from the bottom.Otherwise the damping forces will become too

high, making the ride hazardous.

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High speedadjustment

Steeringdamper body

Link arm

Sweepadjustment

4

Low speed adjustment

Sweepadjustment

Damping sweep controlsDamping sweep controls (fig.8) are located on eachside off the damper body. Damping is in position2, (12 oclock), when delivered from hlins. Thissetting is fitted for enduro, motocross and

off-road riding.

WARNING

Always ensure that valve setting is within thepermitted ranges.

NOTE!Both damping sweep controls must always beset in identical positions.Always use positions according to the clock.

2

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Position 1

9 oclock

Position 212 oclock

Position 33 oclock

Position 46 oclock

Position 1Damping 34




Sweep control valveLocated on the sideof the unit

Damping range

Maintenance and inspectionThe steering damper is a precision instrument,with extremely fine tolerances. It is thereforeessential that it is maintained in a correct manner.Maintenance and service should be carried outby an authorised service center.

- After washing the motorcycle wipe clean andspray with all-round oil.

CAUTION!

Never subject to direct high-pressure cleaningsince water may otherwise penetrate the damper.

Technical data

External measures 70x70x35 mmSeals Low friction typeOil hlins part no.

01306-01

Sweep controls located oneach side are normally set atthe twelve oclock position.

12

9

6

3

Suitable starting position:Motocross pos.1 or 2Enduro pos.2 or 3Off-Road pos.2, 3 or 4

5

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CAUTION!

Ensure that there is no leakage of fluid and thatthere is no visible damage to the housing and

mounts.

Change the fluid regularly. In new dampers after10 hours riding and then every 20 hours riding.

Use only recommended fluid that is tested andapproved by us. We cannot guarantee fullyacceptable operation using other fluids.

NOTE!Regular maintenance and inspection counteracts

possible malfunction.

If the steering damper needs service, hlinsagents have the proper tools and know-how to

solve all technical problems.

NOTE!

Discarded hlins products should be handledover to an authorized work shop or distributorfor proper disposal.

Trouble Shooting

Little or no damping1Debris in valving or worn parts internally, needservice.2Shear pin on bottom has broken due to a crashor over stressing. This can be replaced easily byremoving the link-arm with a link-arm puller(4954-01) and installing a new shear pin.

Dampens more to one side

than the other1Its new, give it a little time to seat the valving.2The oil is dirty and it need servicing.

Knob has come off

1Dont panic, it will still work. To repair it, removethe set screw, put the knob back on and allow itto seat over the o-ring. Reinsert the steel ball,then the spring and finally the set screw untilflush with the top of the knob.

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Weld-on tower forhlins Off Road steering dampers

Mounting Instruction

1Remove the original upper handlebar mounting

clamps and the fuel tank of the motorcycle.2Install the one-piece upper handlebar mount provided.Tighten the bolts evenly to allow fine adjustment later.Keep the gap equal as shown in figure. According tothe handle bar clamp mounting instruction.

3Install the damper to the new handlebar mount.Use the two Allen bolts provided.

NOTE!

If the damper does not fit between the main barand the crossbar, bow or bend the crossbar slightlyto allow clearance. Minimum 40 mm is required.

4With the damper fitted and the handlebar boltsevenly seated, hold the weld-on tower temporarily

in position. Mark where it must be cut for perfect fitbetween the frame and the link-arm of the damper.

NOTE!

The tower pin is not to be installed into thetower yet.

5

The weld-on tower can becut at either end for properlenght. Cutting at the top isusually the easiest waySometimes grinding at thebase of the tower to matchthe frame is required.

Cut here forproper lenght

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CAUTION!

When installed the tower pin must reach 0.5 mmabove the upper surface of the link-arm.This is spe-cially important when handlebar has rubber

mounted lower mounts, where handlebar is al-

lowed to flex downvards. If the link-arm touchesthe frame bracket the damper can be damaged.

CAUTION!

The weld-on tower is made of steel and can bewelded with standard weldning rod. This should becarried out by qualified personnel. Tig weldning is

prefered.. Gas welding requires carefull protectionof the bearings and seals of the triple clamps.

6With tower cut to correct height, deburr the holein top before installing the tower pin. Grease the

pin slightly before installation.7Weld the tower to the frame (tig welding recom-mended). Make welds om both sides of thetower. (A tower of correct height will need noadditional holding devices to the frame)

CAUTION!

To gain a strong weld it is of importance to care-fully remove paint and debris.

WARNING!

Certain modifications can be necessary to install theweld-on tower. It is vital that the mounting instruc-tions are carefully followed.

0,5 mm

Weld

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Handlebar clamp forhlins Off Road steering damper

Mounting instructions

1Replace the stock handlebar upper bracketsmount with the handlebar clamp provided.

CAUTION!

It is vital that the centre of the steering dampermounting bolts are aligned with the centre of thesteering stem

2When the lower handlebar brackets arereversible, the brackets must be positionedaccording to the above mentioned caution.

Handlebar clamp

AlignmentSteeringclamper

Handlebarclamp

Weldon tower

Motorcyclesteering column

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Steering damper

1 Attach the steering damper with the boltsenclosed.

NOTE!The steering damper link arm should be at least0.5 mm below the upper edge of the lower pin.

2It is possible to make smaller adjustments with the

four bolts holding the handlebar clamps. If the frontbolts are tightened and the rear bolts are slackenedthe distance is decreased and vice versa.

NOTE!

Ensure that the pin is in the middle of the linkarm groove (see illustration).

CAUTION!

Make certain that the steering stops are workingproperly. If the damper acts as a stopper it canbe damaged.

Link arm

min 1 mm min 1 mm

0.5 mm

NOTE!Make sure that all bolts are tightened to the cor-

rect torgue and that nothing fouls or restricts thehandlebar when beeing turned to each side. Whentesting, the damper adjuster must be in soft damp-

ing position)

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07270-04,TekniskIllustration,OM

MX&EnduroSD415,425.0504

.

hlins Racing ABBox 722, SE-194 27 Upplands Vsby, SwedenPhone +46 8 590 025 00, fax +46 8 590 025 80

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