Updated Rally and Track OM

8/13/2019 Updated Rally and Track OM

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Rally

Rally RaidRally Cross

Owners Manualhlins Shock AbsorberTPX/TTX44 Automotive


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It was the 1970ths, a young mannamed Kenth hlin spent most of his

spare time pursuing his favourite sport:motocross.

A careful observer, Kenths attentionwas continually drawn to one specificdetail - motocross bikes had more engine

power than their suspension couldhandle. It was not long before Kenthrealised that better performance could beachieved by improved wheel suspension.

hlins Racing was established in 1976,and just two years later the company wonits first World Championship title. Despitebeing in the business for 30 years, thesearch for perfection and new functions isstill the main focus of the company.

You are now the owner of an hlinsShock Absorber. More than one hundredWorld Championships and other majorworld titles are definitive proof that

hlins shock absorbers offer outstandingperformance and reliability.

Every product has gone throughrigorous testing and engineers have spentthousands of hours, doing their very bestto use every possible experience from our30 years within the racing sport.

hlins Racing AB - The Story

The product that you now have in yourpossession is pure racing breed that isbuilt to withstand. By installing an hlinsshock absorber on your vehicle you have

made a clear statement you are aserious rider with a focus on getting themaximal handling ability and outstandingfeedback from your vehicle. Along comesthe fact that your shock absorber will bea long lasting friend, delivering the verybest of comfort and performance everytime you go for a ride.

Go explore!

Congratulations


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Contents

Design and Function 4

Spring Preload 5

Compression and Rebound Damping 6

Adjustment and Set-up 7

Camber bushings 10

Inspection and Maintenance 11

hlins Racing AB. All rights reserved.

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


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hlins Racing AB cannot be heldresponsible for any damage to the shock

absorber or vehicle, or injury to persons,if the instructions for installing andmaintenance are not followed exactly.

Similarly the warranty will becomenull and void if the instructions are notfollowed.

NOTE!

hlins products are subject to continuousimprovement and development.Therefore, although these instructions

include the most up-to-date informationavailable at the time of printing, theremay be minor differences between yourshock absorber and this manual. Pleaseconsult your hlins dealer if you have anyquestions regarding the contents of the

manual.

Before riding the vehicle, always makesure that the basic settings made byhlins are correct. See the Mounting

instructions for recommended Set-updata. Contact an hlins dealer if you have

any questions about setting the shockabsorber.

WARNING!

Installing a shock absorber, that is notapproved by the vehicle manufacturer,may affect the stability of your vehicle.hlins Racing AB cannot be heldresponsible for any personal injury ordamage that may occur after installing theshock absorber.

Please study and make certain that youfully understand this manual and the

mounting instructions before handling thisshock absorber. If you have any questionsregarding proper installation proceduresor maintenance, please contact an hlinsdealer.

Refer to the vehicle service manual wheninstalling this shock absorber!

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2.

3.

Safety SignalsIn this manual, mounting instructions and

other technical documents, importantinformation concerning safety isdistinguished by the following notations:

The Safety Alert Symbol means:Warning! Your safety is involved.

WARNING!

The Warning Symbol means: Failure tofollow warning instructions can result in

severe or fatal injury to anyone workingwith, inspecting or using the shock

absorber, or to bystanders.

CAUTION!The Caution Symbol means: Special

precautions must be taken to avoiddamage to the shock absorber.

NOTE!The Note Symbol indicates informationthat is of importance regarding

procedures.

Safety Precautions

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The hlins shim system offers infinitecombinations of shim stacks with a wide

spectrum of different character with oneand the same piston. The whole systemis pressurized by nitrogen gas behind afloating piston to ensure separation of thegas and fluid.

The hlins TPX/TTX44 shockabsorbers are a racer friendly shockabsorber, easy to set up, dial in andrebuild. Support is always available from

the hlins distributors worldwide.

Congratulations on choosing thehlins TPX/TTX Rally shock absorber

- the most unique and powerful racingshock absorber available today. TheTPX 44 is of a McPherson type andTTX 44 is of a twin tube type shockabsorber. Both are 3 way adjusted.High and low speed compression withRebound adjusters. Both are availablewith the new updated ProgressiveDamping System (PDS). The TPX/

TTX44 shock absorber design is theculmination of two decades of hlinssuccessful participation in WorldChampionship events.

This shock absorber draws on all theexpertise developed by hlins whilewinning more than a hundred WorldChampionships.

The TPX/TTX44 shock absorbers

are designed to handle the demandingdamping characteristics needed for alltypes of tracks, from hard packed soil tosoft sand tracks.

The hlins TPX/TTX44 featurespatented pending concept with a uniquedesign, that allows for the gas pressureto always back-up the low-pressureside of the piston to keep pressure at

a controlled level. Both concepts givethe possibility to have totally separatedadjusters for compression and rebounddamping.

The temperature stability is maintainedby using a flow restriction design inthe bleed valves that create a turbulentflow at very low piston velocities. Also,materials with different thermal expansionrates are used to compensate for the

viscosity change of the fluid caused bychanges in temperature.

Design and Function

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Spring Preload

TPX McPherson

TTX shock absorberSpring Preload

When adjusting the spring preloadyou move the spring seat. This will loweror raise the vehicle ride height. The rideheight is an important criteria for thebehavior of your vehicle.

Set the Spring Preload

For TTX shock absorber use C-spanner

00710-02 and C-spanner 01796-01 toundo the lock nut and turn the springplatform to the desired position.

For TPX McPherson use 2 C-spanners01796-01 to undo the lock nut and turnthe spring platform to the desired position.

Spring

platform

Springplatform

C-spanners

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Compression and Rebound DampingFunction and Reset

Compression and Rebound Damping

Compression damping controls theenergy absorption when the shockabsorber is being compressed, thuscontrols how easy the shock absorbercompresses when you hit a bump.

Rebound damping controls the energyabsorption when the shock absorber isbeing extended and controls how fastthe shock absorber returns to its normal

position after being compressed.The TPX compression adjuster islocated under the reservoir and therebound is located in centre at the bottomof the damper.

The TTX compression and reboundadjusters are located on the cylinder headclose to the reservoir.

To reset the adjuster

Turn the adjuster clockwise to fully closedposition (position zero [0]). Then, turncounter clockwise to open, and count theclicks until you reach the recommendednumber of clicks. See recommended Set-up data in the Mounting Instructions foreach shock absorber/strut.

CAUTION!Do not use force, delicate sealing

surfaces can be damaged. Handtightenonly.

Compression Damping Adjuster

Low speed compression is mainlyused to control chassis movements and

response but it also affects the traction.It affects how the car behaves duringbreaking, turn in and acceleration. Lesslow speed compression gives more

chassis movement but in many cases itcan improve traction and grip. Thereforeit is possible to balance the car byadjusting the low speed compression.

High speed compression mainlyaffects how the car absorbs bumps and

jumps. In rougher conditions or with alot of jumps more high speed damping isoften necessary to control the big chassismovements.

Rebound Damping Adjuster

Rebound adjuster affects chassismovement in a similar way as the lowspeed compression but has even moreinfluence on traction. Use this adjuster tocontrol chassis movements over crestsor after jumps. More rebound gives lessmovement and better stability but too

much will cause a loss of traction. It istherefore a powerful balance tool togetherwith the low speed compression adjuster.

For slippery conditions when griplevels are low, a softer set up on bothrebound and low speed compression is away to gain more traction.

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AdjustmentsCompression and Rebound Damping

Tool 01822-03

Rebound Damping Adjuster

Rebound damping on TTX 44 isadjusted by turning the golden slottedscrew located in the black end-piece .Total number of clicks on the reboundadjuster is approximately 18-20.

Rebound damping on TPX 44 isadjusted with the special tool (01822-03) which is delivered with the damper.The total number of clicks is more than

60 but the useful range is 30-50. It isrecommended to adjust rebound in stepsof 2-3 clicks.

Compression Damping Adjuster

Low speed compression is adjusted byusing a 3 mm Allen key.

High speed compression is adjustedwith a 12 mm wrench.

It is recommended to adjust lowspeed compression in steps of 2-3 clicksand high speed 3-5 clicks to fine tunethe set up. The low speed adjuster hasapproximately 40 clicks and high speed50 clicks.

TTX Shock absorber

TPX McPherson

Low speedcompressiondamping

High speedcompressiondamping

Rebounddamping

TPX McPherson

High speedcompression

damping

Low speedcompressiondamping

Rebounddamping

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AdjustmentsShaft jet valve and Spring set-up

Spring set-up

A number of springs are available forboth gravel and Tarmac to suit all differentconditions. For rougher gravel conditionsit is recommended to use one step stiffersprings but also increase ride height10-20 mm depending on the conditions.It usually gives a better result than to usean even stiffer spring and less ride heightchange.

For very rough conditions like Middle

East rallies even stiffer springs isrecommended.

To get support, to find your ownoptimal set-up, contact your local hlinsService Centre. hlins also have got awide assortment of springs. For specificsprings to your vehicle please see list inthe hlins mounting instruction.

Shaft jet valve

On the TTX the fading compensationsystem is located in the piston shaft.This system is based on a valve thatcompensates for the viscosity changesof the fluid caused by changes in thetemperature.

The Shaft jet valve adjuster is set at anideal position (18 clicks) from the factory.However, if the limit of the reboundadjuster has reached its minimum or

maximum recommended position, isthere a possibility to compensate this byeither open or close the shaft valve andthen go back on the rebound adjuster.

This adjuster is very sensitive andshould not be turned more than 1- 2clicks without consulting an hlinsservice center. The reset procedurefor this adjuster is the same as for the

compression and rebound adjusters.

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Setting up your vehicle

Installing new shock absorbers mayalter ride height, wheel angles etc. onyour vehicle. Therefore, it is wise to doa complete set-up check of the vehicleafter you have installed the hlins shockabsorber.

Perform the following steps andalways take notes before using the shockabsorber;

Check ride height, front and rear.Adjust if necessary.

If scales are available check cornerweight, front and rear. Adjust if necessary.

NOTE!Always consult your hlins dealer if youhave any questions regarding settings ofthe shock absorber/strut.

Making adjustments

Suspension settings are dependent onyour vehicles weight, youre driving style,road conditions etc. If you are not happywith our recommended settings, here area few guidelines and ground rules how tomake adjustments.

To make improvements, it is important

to understand the function of the shockabsorbers and through testing learn howthey affect the handling of your vehicle.

NOTE!Always start with the settingsrecommended by hlins.

NOTE!Higher click numbers give less dampingforce.

When making adjustments:

Take notes, make the adjustmentsin small steps (2-3 at a time) and notoutside the usable click range. Seemounting instructions.

When you think you have made animprovement, go back to what youstarted with and double check to besure.

Pay attention to changes in conditions

like tires or temperatures, etc. Ingeneral, compression damping changesshould be used to influence the vehiclesstability and response, while rebounddamping changes should be used toinfluence comfort and traction.

When you need more damping force,you should mainly try to increasecompression damping and use as little

rebound damping as possible. Thisusually means that you gain comfortand handling performance.

AdjustmentsSetting up your vehicle and Making adjustments

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Camber bushings

Unlike most standard McPhersonshock absorbers, the hlins shockabsorbers feature camber bushings thatenable you to alter the wheel camber.

Depending on how you mount thebushings, with the eccentric hole facingthe wheel or away from the wheel,different camber angles will be obtained.

Camber Bushings

Camber bushing identification

The bushings are as follows:

Part.No Marking Distance (A) mm

05794-00 0 3,00

05794-01 1 2,44

05794-02 2 1,88

05794-03 3 1,32

05794-04 4 0,76

05794-05 5 0,20

A

Eccentric hole on bushing

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Inspection and Maintenance

When and how?

Inspection points - Normal use1. Check ball joints/ brackets forpossible excessive play or stiction.

2. Check the piston shaft for damagethat can cause leakage.

3. Check the shock absorber body forexternal damage.

4. Check the external reservoir fordamage that can restrict the floating

piston from moving freely.

5. Make sure that the reservoir isprotected against stone chip.

6. Check the attachment of the shockabsorber to the vehicle.

Inspection points - Every 300-400 km(Mc Pherson shock absorber only)

1. Remove the scraper holder from theouter tube with a suitable friction tool.Cover the circlip groove at the top ofthe cylinder tube with tape and pullthe scraper holder off the cylinder tube- see figure.

2. Remove the cartridge from the frontouter tube by removing the bottomscrews.

3. Clean all parts with a soft detergent.

4. Check scraper and bushings forwear and/or damages and change ifnecessary.

5. Apply a layer of hlins red grease,part no. 00146-01 (100 grams) or00146-02 (400 grams) on the cylindertube, scraper and bushings. The spacebetween the bushings in the outer tubeshould be filled with a layer of hlins

red grease up to the bushing surface.6. Assemble the strut and tighten allbottom screws (10 Nm). It is vital to usecopper paste on the threads.

7. Install the scraper holder on tothe outer tube and handtigthen with

a suitable friction tool. (For examplehlins tool 01835-01).Tighteningtorque maximum 15-20 Nm.

Maintenance

Service your damper(s) at an hlinsservice center every 800-1200 km.If the dampers are used under morerough conditions, maintenance could berequired more frequently.

WARNING!Never alter the gas pressure. Special

purpose charging equipment and accessto nitrogen is required. The gas pressure

should normally never be altered.

Tape

Scraper

holder

Removing the scraper holder

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hlins tool 01835-01


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OwnersManual074

40-02TPX/TTX44

20080123

hlinsR

acingAB

AnnetteAsph/Larssth

hlins Racing AB Box 722

S 194 27 Upplands Vsby Sweden

Phone +46 8 590 025 00

Fax +46 8 590 025 80

Documents

Updated Rally and Track OM