ON-ROAD Installation and User Manual

BRANDS INCLUDED IN THIS MANUAL:

BMW HONDA YAMAHA SUZUKI KAWASAKI TRIUMPH MOTO GUZZI HARLEY-DAVIDSON

03/2016 (V3.6) (UK)EX

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Models included in this Manual:

BMW F 650 (1994-) F 800 S (2006-) F 800 ST (2006-) F 800 R (2009-)

HONDA CBF 600 N (2004-) CBF 600 S (2004-) CBR 600 F2 (1991-93) NC 700/750 X (2013-)

YAMAHA XT 660 X FZ6 Fazer (2004-06) FZ6 N (2004-06) FZ6 Fazer S2 (2007-) FZ6 S2 (2007-)

SUZUKI SV 650 (2001-) SV 650 S (2001-) GSF 600 Bandit (2001-04) GSF 600 Bandit S (2001-04) 650 Bandit (2005-) 650 Bandit S (2005-) GSX 750 Inazuma (1998-) Gladius 650 (2009-) GSR 600 (2006-)

KAWASAKI Z 750 (2003-06) Z 750 S (2003-06) ER6n (2005-) ER6f (2006-)

TRIUMPH THRUXTON (2004-) SCRAMBLER (2007-)

HARLEY-DAVIDSON

Sportster 883 R Sportster 883 Custom Sportster 883 Low XL Sportster 1200 Nightster

MOTO GUZZI V7 (Marzocchi) (2009-2012) V7 II (Kaifa) (2013-) EXAM

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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 pro-vided 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 consider-ing safety recommendations, it may appear damages in your motorbike, or in kit components that might cause an accident during its installa-tion process or during its usage.

Indicates that if safety instructions are not followed, it might cause severe or fatal injuries 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 COM-

PLETELY 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 HFS© 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 HFS© SUSPENSIONES products must be inspected in the factory. If during the inspection HFS© SUSPENSIONES would detect a material or manufacturing defect, HFS© SUSPENSIONES will choose between replacement of the dam-aged 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 HFS© 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 circumstance 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 HFS© SUSPENSIONES together with the prod-uct with paid transport. The decision to repair or substitute the product will be adopted under the exclusive criteria of HFS© 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 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 is admitted variation with respect to the recommended value, as indicated in the mentioned graph or written instruction. Do not pass indi-cated limits, both lower and upper. EX

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Assembly instructions

GENERAL INDICATIONS

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.

2. If you have doubts about installation procedure, contact HFS© SUSPENSIONES entering in www.suspensionhfs.com, or with qualified personnel.

3. For assemblies related to original parts, it is mandatory to refer to manufacturer’s motorbike Work-shop Manual.

4. HFS© SUSPENSIONES products are in a continuous update process; manuals include latest available version about installation procedure. Should you find differences, please contact HFS© SUSPEN-SIONES entering in www.suspensionhfs.com.

5. 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 process (each bar)

1. Lift front wheel [Picture 1]. Use a safe way, not damaging user or motorcycle. Front suspension must be unloaded (do not lift from stanchion’s lower ends).

2. Dismount original spring and spacers

General warning Each motorcycle is different. It would be necessary to uninstall other parts to perform steps described here below. I.e.: plastic protectors, handle bar, fenders, … If it were the case, please refer to manufacturer’s manual.

2.1. Loose screws fixing upper steering bracket (not necessary to unscrew completely). [Picture 2]

2.2. Uninstall bar’s upper caps [Picture 3]

2.3. If handle bar does not allow to take out the springs and spacers, dismount handle-bar:

a) Take out fixing screws b) Apart handle bar in order to take out springs and spacers. c) Take out spring and spacers [Picture 4]

3. Reduce fork oil volume

You must follow following instructions. Fork oil volume to add with HFS is included in a ta-ble at the end of this Manual, and depends on each motorcycle model.

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There are two ways to reduce fork oil volume:

3.1 Taking out completely old fork oil and refilling with volume as indicated in table at the end of this Manual.

a) Take out all oil in each bottle: follow manufacturer’s instructions (draining screw or dismounting the bar from motorcycle).

b) Pour completely all oil from inside (making several axial movements will help oil going out.

c) Re-install the forks or pouring screw.

d) Put reduced fork oil quantity (see table at the end of this manual) according to your motorcycle model.

If bar has been disassembled from motorbike, you have to re-install them before inserting HFS cartridge [step 5.3]; if not it will not be possible due to valve’s end bigger tan bar’s diameter.

3.2 Extracting the volume to reduce, in each bar In this case, it is necessary that each fork do have

correct fork oil volume as per manufacturer’s instructions

a) Needed material: - Syringe (60 c.c.) - Plastic tube fitted to syringe.

b) Put tube inside stanchion [Picture 5].

c) Suck oil as much as possible.

d) Un-fit syringe from tube and put oil in a safe container. Check extracted amount.

e) Note extracted amount.

f) Repeat steps b) – e) until amount to extract is reached. Refer to "TABLE: FORK OIL VOLUME TO ADD WITH HFS SYSTEM, BY MODEL" at the end of this manual.

4. Introduce HFS® springs [Picture 6] When spring is introduced, it has to contact oil. If it were not

the case, it indicated that hydraulic tube is not completely covered by oil. Then, add more oil in 10 c.c. steps until spring in contact with oil is reached.

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5. Introduce HFS® air cartridges

5.1 Make sure that element is unpressurized (push valve core with element in vertical position).

5.2 Make sure that upper o-ring is installed in HFS® cartridge.

5.3 Introduce HFS® cartridge on top of spring [Picture 7].

5.4 Press slightly and screw on bar. Tightening torque approximately 20 Nm [Picture 8] Do not screw or unscrew element using upper

valve as element to turn.

5.5 If valve final position is not correctly oriented towards exterior [Picture 9] , turn bar until a good and accessible position is reached.

5.6 For this, loose lower bracket screws [picture 10].

5.7 After all screws are loose, turn bar until valve is correctly accessible to pump [Pic-ture 11]. Check that both bars are set at same height as they had initially.

5.8 Tighten all bar fixing screws to brackets [Picture 12].

5.9 In case of Harley-Davidson models, an external cap for upper valve is supplied unin-stalled. Install it after pressurizing the air element.

6. Install handle bar

7. Pressure set-up Identify adjustment pressure according to graph included at the end of this manual; it will depend on rider’s weight gear included.

8. Apply pressure to element (see pressure indication examples below) There are pumps with and without "on-off" lever, and can be used indistinctly. If it does not have lever, skip steps 8.1-8.2 and 8.5.

8.1 Connect pump terminal to valve, with lever in “OFF” position. Pumps has "ON-OFF” lever to assure that no air is lost from inside element when unscrewing terminal. Lever in “OFF” position Lever in “ON” position

8.2 After terminal is screwed to the end, set lever to “ON”.

8.3 Pump until reaching desired pressure. It is recommended to put more pressure than desired and use adjustment micro-button for the final set-up.

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8.5 Set lever to “OFF” and unplug terminal from pump.

8.6 Screw valve’s cap.

9. Put motorcycle’s wheel on ground.

10. As it is first pressure adjustment, it is recommended to dive suspension several times and re-set HFS pressure.

11. Check again pressure following previous procedure, with front suspension without load.

12. General safety indications

a) Do not exceed pressure limits indicated in adjusting graph.

b) It is recommended to make first adjustment at recommended value or slightly lower; check behavior and make changes in steps of 0,25 bar depending on your feeling.

c) Increasing or decreasing pressure it is modified static sag of front suspension. It can be adjusted according to rider’s choice.

d) After any adjustment, ride carefully and with precaution to check behavior.

e) Apply same pressure to both elements.

f) Noise of small air leak produced when unplugging pump terminal (with pump lever in “OFF” setup) is normal.

g) Do not put air pressure with petrol station tire equipments.

h) Do not reduce air pressure with front suspension loaded (Wheel on road), because oil could pour out and repair would be needed). Install yellow decal reminding about it in order not to forget it.

i) Check element’s pressure periodically. Normal interval can be 6 months or even more frequently.

j) Check pressure if you detect any sensible change in behavior. Contact www.suspensionhfs.com if necessary.

13. Riding …

Once the system is installed, start riding with normal precaution after a new installation has been done in motorcycle. If installation has been correctly done, front suspension travel should be smooth. Try new system in a known track so that you can notice changes in front end behavior. You can contact www.suspensionhfs.com for doubts or clarification needed. EX

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14. Check or pressure re-adjustment Check recommended adjustment pressure and its limits in graph at the end of this Manual.

To apply pressure to HFS® el-ement, front suspension has to be unloaded.

(remind decal previously installed) To check or re-adjust pressure, follow next steps:

1. Lift front Wheel unlading front suspension (or assure that suspension is fully ex-tended).

2. Unscrew valve’s cap. 3. Screw pump terminal (with pump terminal lever in “OFF” position). 4. Change pump terminal lever to “ON” position. 5. Apply pressure (1-2 bar more tan target); reduce pressure to target pushing mi-

cro-adjustment button several times. 6. Change pump terminal lever to “OFF”. 7. Unscrew pump terminal (small ait leakage is normal). 8. Screw valve’s cap. 9. Repeat same operation in other element. 10. Put front suspension on ground.

15. Examples of pressure indication in pump manometer

Following images are included to clarify pump manometer indications.

a) Pumps with black dial:

3,5 bar 4 bar 4,25 bar

Each step is 0,5 bar Observe that after “0”, first long mark is 2 bar ( )

b) Pumps with white dial:

Each mark is 0,5 bar 2,5 bar 3 bar 2,75 bar First short mark is 1 bar ( )

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16. Required tools for installation (estimation, may change by model)

Operation Tool

LIFT MOTORCYCLE. - Stand

LOOSE UPPER BRACKET - Allen or socket depending on model

DISMOUNT HANDLE BAR - Torx, allen or socket depending on model

DISMOUNT STANCHION’S UPPER CAP - Socket, fix or adjustable wrench

TAKE OUT SPRING - Metal wire hooked end shape or magnetic tip device. - Have some rags ready to clean possible oil.

TAKE OUT FORK OIL (See procedure)

- Screwdriver or fix wrench - 60 c.c syringe - Plastic tube firmly adjusted to syringe’s end. - Test tube or similar to measure extracted oil volume. - Have some rags ready to clean possible oil.

RE-TIGTHENING OF PARTS (as re-quested by manufacturer Manual)

HFS ELEMENT TIGHTENING - Socket, good quality fixed or adjustable wrench

17. Information included in this manual

a) Pictures describing installation process. It has been used as illustrative a Yamaha Fazer; for other models, procedure is similar (paying special attention to specific parts to me removed). In any case, follow manufacturer Workshop Manual to dismount and re-install the original motorbike components. In case of doubt, contact with www.suspensionhfs.com.

b) List of estimated required tools.

c) Table with oil to introduce into the fork when HFS® system is installed.

d) Pressure adjustment graphic, depending on rider’s weight.

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Images are corresponding to Yamaha Fazer; basic steps are equivalent in other models. Check carefully possible differences. In case of doubt, CONSULT IN AUTHORIZED WORKSHOP OR IN MANUFACTURER’S MANUAL. EX

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CASE 1: FORK OIL QUANTITY IS DEFINED BY VOLUME

Original fork oil volume[ Note 1 ]

Volume to extract

[ Note 2 ]

Fork oil volume with

HFS®

F 650 (1994-) 600 c.c. 160 c.c. 440 c.c.

F 800 S

F 800 ST

F 800 R 584 c.c. 120 c.c. 464 c.c.

CB 600 F N (2004-)

CB 600 F S (2004-)

CBR 600 F2 (1991-93) 525 c.c. 130 c.c. 395 c.c.

NC 700/750 X 514 c.c. 80 c.c. 434 c.c.

486 c.c. 115 c.c. 371 c.c.

ANNEX: FORK OIL VOLUME TO ADD WITH HFS SYSTEM, BY MODEL

MODELO

520 c.c. 130 c.c. 390 c.c.

Note 1) Confirm "Original Fork Oil volume" of your motorcycle checking it in authorized dealer or in Manufacturer's Service Manual.

Note 2) In case of oil extraction procedure, make sure that existing volume inside fork is the one specified by motorcycle manufacturer.

Consult us in case of doubt.

NC 700/750 X 514 c.c. 80 c.c. 434 c.c.

SV 650 N (2001-)

SV 650 S (2001-)

GSF 600 Bandit (2001-04)

GSF 600 S Bandit (2001-04)

GSF 650 Bandit (2005-06)

GSF 650 Bandit S (2005-06)

GSF 650 Bandit (2007-)

GSF 650 Bandit S (2007-)

Gladius 650 (2009-) 517 c.c. 150 c.c. 367 c.c.

GSR 600 (2006-) 512 c.c. 120 c.c. 392 c.c.

XT 660 X (2004-) 600 c.c. 130 c.c. 470 c.c.

FZ6 Fazer (2004-06)

FZ6 N (2004-06)

FZ6 Fazer S2 (2007-)

FZ6 S2 (2007-)

Z-750 (2003-06) [ Nota 3 ] 115 c.c. [ Nota 3 ]

ER6n (2005-) sin ABS

ER6f (2006-) sin ABS

ER6n (2005-) con ABS

ER6f (2006-) con ABS

[ Nota 4 ] 125 c.c. [ Nota 4 ]

[ Nota 5 ] 125 c.c. [ Nota 5 ]

467 c.c. 110 c.c. 357 c.c.

467 c.c. 110 c.c. 357 c.c.

508 c.c. 100 c.c. 408 c.c.

458 c.c. 100 c.c. 358 c.c.

490 c.c. 110 c.c. 380 c.c.

510 c.c. 110 c.c. 400 c.c.

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ANNEX: FORK OIL VOLUME TO ADD WITH HFS SYSTEM, BY MODEL

THRUXTON (2004-) 466 c.c. 125 c.c. 341 c.c.

SCRAMBLER (2007-) 517 c.c. 150 c.c. 367 c.c.

BONNEVILLE (2007-) 517 c.c. 125 c.c. 392 c.c.

XL 883L / XL 1200N 401 c.c. 50 c.c. 351 c.c.

XL 1200L 364 c.c. 50 c.c. 314 c.c.

Rest of XL models 343 c.c. 50 c.c. 293 c.c.

CASE 2: FORK OIT QUANTITY IS DEFINED BY AIR GAP

[Note 3] : According to manufacurer manual, original oil volume is 452 c.c. (dry fork) and

385 c.c. (oil change):

- In case of dry fork, for HFS volume is 327 c.c.- In case of oil change, for HFS volume is 260 c.c.

[Nota 4] : According to manufacurer manual, original oil volume is 489 c.c. (dry fork) and

415 c.c. (oil change):

- In case of dry fork, for HFS volume is 354 c.c.

- In case of oil change, for HFS volume is 280 c.c.

[Nota 5] : According to manufacurer manual, original oil volume is 498 c.c. (dry fork) and

420 c.c. (oil change):

- In case of dry fork, for HFS volume is 363 c.c.

- In case of oil change, for HFS volume is 285 c.c.

General remark: All brands are property of OEMs.

CASE 2: FORK OIT QUANTITY IS DEFINED BY AIR GAP

AIR GAP SPECIFIED

OEM[ Note 1 ]

VOLUME TO EXTRACT[ Note 2 ]

V7 (Marzocchi) (2009-12) 150 mm 120 c.c.

V7 II (Kaifa) (2013-) 150 mm 70 c.c.

NC 700/750 X 104 mm 80 c.c.

MODEL

Note 1) To add fork oil defined by air gap follow next steps:

1.1. Take out spring and spacer/s.1.2. Totally compress stanchion.1.3. Keep fork leg perfectly vertical.1.4. Add OEM defined fork oil until reaching specified air gap (red arrow in graph). Make several strokes to release possible trapped air.Measure distance always with fork totally compressed.

Note 2) Extract with syringe (see Manual) the volume indicated in below table for each model.

Consult in case of doubt.

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HONDA NC 700/750 X

4,00

4,25

4,50

4,75

5,00

5,25

5,50

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Pre

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Recomendado/Recommended Limite superior / Upper limitLimite inferior / Lower limit

3,00

3,25

3,50

3,75

4,00

70 80 90 100 110

Pre

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Pre

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Peso piloto / Rider's weight (equipo inc. / gear included) - Kg

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