Hyperpro Spring Mounting Manual ENG - Your Suspension Shop

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HYPERPRO SPRING MOUNTING MANUAL

HYPERPRO SPRING MOUNTING MANUALHYPERPRO Spring Mounting Manual ContentFront Fork SpringsTelelever front suspension is disassembled as a mono shock (rear supension)F1F2F3F4Fork typeRight side upRight side upUpside downUpside downWith internal damper rod* (cartridge)With internal damper rod* (cartridge)With internal seperate damperPage14711* Special tools are usedRear Suspension MountingDescriptionM1M2M3Mono shockTwin shockLink systemPage141516Rear Shock SpringsThe shocks with and without damping adjustment are disassembled similarly. Note that shock absorberscan not be opened, as this depressurizes the damper.S1S2S3S4Preload adjustment typeCam collar adjustmentThreaded ring adjustmentHydraulic adjustmentPull shockPage18202224Motorcycle SetupSetup12345Maintenance, things to check firstStatic Sag measurement and adjustmentDamping adjustmentHandling troubleshouting chartStandard torque settings for boltsPage2627283233Note the pictures in this manual are used to indicate the working procedure. Your situation may look different from the picturesshown.

HYPERPRO SPRING MOUNTING MANUALFront fork 1: Right side up1Measure the distance from the top of the tubes to thetop fork clamp (1)Loosen the top fork clamp bolts. Loosen but notremove the fork screwcaps (4)Tip: Use a piece of paper to help protect the caps fromdamaging.If this is not possible in the normal position, move theforks down in the clamps (the wheel has to be removedfor this), retain the tubes in the bottom clamp, at about30 mm distance. Loosen the caps.Removing the fork first and later unscrew the caps is difficult, it is virtually impossible to counterholdthe fork. Always use the fork clamp to hold the fork; never place the fork in a vice as this causesdamage to the tubes. It is possible to counter hold the fork by hand when a compressed air wrenchis used.2Place the bike stable with the front wheel off the ground. Remove the frontfork from the bike. View the bike manual for details.3Remove the screwcaps (4) from the fork.Note: The caps are under tension from the preload on the spring, becareful when removing.4Remove the parts from the fork: preload bush (5), ring(s) and spring. Notehow the parts fit, sometimes there is a tapered end on one side of thespring.Pour the old oil into a tank. Hold the fork upside down and compress anddecompress the fork to pump all the oil out off the fork ( 10 to 20 times,until there is no damping felt)Old oil is harmful for the environment, dispose of it properly.5Inspect the parts for their condition. Broken parts and/or leaking seals should be replaced. If an oilseal is replaced, be sure to also check the inner tube for damage.Clean all the parts before reassembly.6Fully compress the fork and fill it with HYPERPRO fork oil of the right viscosity (see frontpage:HYPERPRO OIL) until about 200 mm under the edge.Pump all the air out of the fork by compressingand decompressing the fork ( 10 to 20times)1

HYPERPRO SPRING MOUNTING MANUAL7Measure the oil level (air chamber): Compress the forkfully, with the loose parts (ring(s), preload bush andspring) removed. Make sure the fork is compressed inthe hydraulic lock; when the compressing becomesheavier, push further until steel to steel contact is felt.The oil level is the distance between the top of the tubeand the oil inside. Hold the fork straight up. Use a tapemeasure; slide it in until it just lightly touches the oil inthe fork. Hold it against the upper edge of the tube.Add or remove oil until the setting on the frontpage isreached (see: OIL LEVEL) Make sure there is no air inthe fork (see step 6)8Mount the HYPERPRO spring in the fork. View the frontpagefor the mounting direction, usually the progressive side(circle) is mounted up. Sometimes there is a sticker markingwhich side up. Fit the spring without the sticker.Fit the ring(s) and the preload bush if present. The mountingorder of the parts is the same as original.Unless there is a remark on the frontpage9Mount the screwcaps (4) in the fork. Hold the inner tube andcompress the spring using the cap. Screw it in the innertube; make sure the cap is screwed a few turns in beforereleasing the pressure as the spring preload pushes the capout, it could jump out when released.For screwcaps with rebound adjustment rod:Make sure the adjustment rod fits correctly in the cartridge.The adjustment rod should fit in the middle of the cartridge; itfalls over an adjustment mechanism inside the fork andusually fits one way because of the flat side on theadjustment rod. The rod slides smoothly over theadjuster inside, don’t push on the cap as thisdamages the adjustment rod. If there is a gapbetween the preload bush or spring and the cap,the adjustment rod is not fitted in the cartridgecorrectly, take it out and fit it again until it is placedcorrectly.Screwcap with rebound adjustment rodWhen the cap is placed correctly, the bottom ofthe cap lies on the preload bush or spring, with (almost) no room in between. Push on the cap,directly compressing the spring so the cap can be screwed in the fork.Be careful when mounting, the spring preload pushes the cap out. Be sure the cap is a few turns inbefore the pressure is released; else the cap could jump out.10Set the spring preload (3, if available) as specified on the frontpage (see: SPRING PRELOAD) Lessrings showing indicates more preload, the preload can be adjusted to set the static sag, view setupchapter 2.The forks with reversed preload (check the frontpage for a remark)have a bush (11) which slides up and down in the cap (4) usingscrew (3) More rings (10) showing indicates more preload; normallymore rings indicate less preload. The turning direction is the same;clockwise for more preload.Set the rebound damping (2, if available) as specified on thefrontpage (view REBOUND) The rebound adjustment screw is locatedon the top of the fork. The positions are counted from the longer clickoutwards. Turn counter clockwise until one click feels longer; that isposition one. Start counting the clicks from there.Fork cap with reversed preload2

HYPERPRO SPRING MOUNTING MANUAL11HYPERPRO fork lubricant reduces the friction of the front fork.Carefully prise off the dust seals from the outer tube of the forkwith a small flat screwdriver. Put the grease on the inner tube ofthe fork. Move the fork in and out. Repeat this.Put some grease on the dust seals to make them slide in moreeasily. Refit the dust seals and remove the excess grease.12Mount everything on the bike. Fit the fork at the distance asmeasured at step 1; Unless there is a remark on the frontpageMake sure everything is tightened to the correct torque setting.13Loosen the clamping bolt(s) of the front axle.Push the front fork a few times as deep as possible to let the forksettle itself in the position with the least friction.Tighten the front axle bolt(s)3

HYPERPRO SPRING MOUNTING MANUALFront fork 2: Right side up, with cartridge1Measure the distance from the top of the tubes to thetop fork clamp (1)Loosen the top fork clamp bolts. Loosen but notremove the fork screwcaps (4)Tip: Use a piece of paper to help protect the caps fromdamaging.If this is not possible in the normal position, move theforks down in the clamps (the wheel has to be removedfor this), retain the tubes in the bottom clamp, at about30 mm distance. Loosen the caps.Removing the fork first and later unscrew the caps is difficult, it is virtually impossible to counterholdthe fork. Always use the fork clamp to hold the fork; never place the fork in a vice as this causesdamage to the tubes. It is possible to counter hold the fork by hand when a compressed air wrenchis used.2Place the bike stable with the front wheel off the ground.Remove the front fork from the bike. View the bike manual fordetails.3Turn the rebound screw (2, if available) clockwise, until thedamping is fully closed; else the adjustment mechanism will beupset when disassembling the fork. The position of thecompression adjustment (if available) is not important.Unscrew the fork screwcaps (4) from the fork.Move the inner tube down.4Place tool A through the holes in the preload bush (5) Press thebush and spring down using tool A. If there are no holes in thebush, clamp the bush between the bolts in tool A, not too tightas this can cause damage.Special tool kitLet a second person pull the damper rod out with the screwcap(4) and place plate B between the nut (6) and the bush (5)For front forks with reversed preload adjustment (look on the frontpage for aremark) the preload has to be set to the minimum (1 ring showing) beforethis can be done.5Counterhold the nut (6) and remove the cap (4) Remove the reboundadjustment rod; sometimes it’s attached to the screwcap. Note how theadjustment rod fits the fork.6Place tool C on the damper rod. Press down on tool A, let the second personpull out the damper rod and remove plate B.7Remove tool A, then remove all the internal parts from the fork: the preloadbush, ring(s) and the spring.Note how the parts fit. There is sometimes a tapered end on one side of thespring.4

HYPERPRO SPRING MOUNTING MANUAL8Pour the old oil into a tank. Pump the fork: move the damper rod and innertube up and down slowly a few times to pump all the oil out off the dampingcartridge. Hold the fork upside down and pour the oil out of the fork. Thenpump the fork again. Repeat this procedure a few times to remove all the oilfrom the fork ( 5 times, until there is no damping felt)Old oil is harmful for the environment, dispose of it properly.9Inspect the parts for their condition. Broken parts and/or leaking seals shouldbe replaced. If an oil seal is replaced, be sure to also check the inner tube fordamage.Clean all the parts before reassembly.10Fully compress the fork and fill it with HYPERPRO fork oil of the right viscosity(see frontpage: HYPERPRO OIL) until about 200 mm under the edge.Pump out all the air of the fork by slowly compressing anddecompressing the fork ( 10 to 20 times)11Measure the oil level (air chamber): Compress the fork fully, with the looseparts (ring(s), preload bush and spring) removed. Make sure the fork iscompressed in the hydraulic lock; when the compressing becomesheavier, push further until steel to steel contact is felt.The oil level is the distance between the top of the tube and the oilinside. Hold the fork straight up. Use a tape measure; slide itin until it just lightly touches the oil inside the fork. Hold itagainst the upper edge of the tube.Add or remove oil until the setting on the frontpage isreached (see: OIL LEVEL)Make sure there is no air in the fork (view step 10)12Mount the HYPERPRO spring in the fork. View the frontpage forthe mounting direction, usually the progressive side (circle) ismounted up. Sometimes there is a sticker marking which side up.Fit the spring without the sticker.Fit the ring(s) and the preload bush if present. Themounting order of the parts is the same as original.Unless there is a remark on the frontpage13Place tool A on the bush (5) Compress the bush andspring. Let the second person pull out the damper rod andplace plate B between the nut and the bush.14Screw the nut (6) down. Remove tool C. Fit the reboundadjustment rod in the damper rod. Screw the screwcap (4)onto the damper rod until it stops, don’t overtighten as thisupsets the adjustment mechanism. Counterhold the cap (4)and tighten the nut (6) against the cap.15Hold down tool A. Let the second person remove plate B.Slowly decompress the spring, making sure everything fallscorrectly into place.16Mount the screwcaps (4) in the fork.5

HYPERPRO SPRING MOUNTING MANUAL17Set the spring preload (3, if available) as specified on the frontpage(view SPRING PRELOAD) Less rings showing indicates more preload, thepreload can be adjusted to set the static sag, view setup chapter 2.The forks with reversed preload (check the frontpage for a remark)have a bush (11) which slides up and down in the cap (4) using screw(3) More rings (10) showing indicates more preload; normally morerings indicate less preload. The turning direction is the same; clockwisefor more preload.Set the damping settings (ifavailable) as specified onthe frontpage.The rebound screw (2) islocated on the top of thefork. The compressionadjustment screw is usuallylocated on the bottom of thefork.Clicks or turns are countedfrom the maximum settingout. Turn the screw in(clockwise) to the maximumsetting. Now turn the screwout (counter clockwise) thenumber of clicks or turnsspecified on the frontpage(view REBOUND &COMPRESSION)18HYPERPRO fork lubricant reduces the friction of the front fork.Carefully prise off the dust seals from the outer tube of the fork witha small flat screwdriver. Put the grease on the inner tube of thefork. Move the fork in and out. Repeat this.Put some grease on the dust seals to make them slide in moreeasily. Refit the dust seals and remove the excess grease.19Mount everything on the bike. Fit the fork at the distance asmeasured at step 1; Unless there is a remark on the frontpageMake sure everything is tightened to the correct torque setting.20Loosen the clamping bolt(s) of the front axle.Fork cap with reversed preloadPush the front fork a few times as deep aspossible to let the fork settle itself in the positionwith the least friction.Tighten the front axle bolt(s)6

HYPERPRO SPRING MOUNTING MANUALFront fork 3: Upside down, with cartridge1Measure the distance from the top of the forktubes to the top of fork clamp (1)Loosen the top clamp screws (5) Loosen thefork screw caps (4), but not yet removethem.Tip: Put a piece of paper on the caps to helpprotect them from damaging.If this is not possible in the normal position,move the fork down in the clamps; retain thetubes in the bottom clamp, at about 30 mmdistance. Loosen the caps.Removing the fork first and later unscrew thecaps is difficult, it is virtually impossible tocounter hold the fork. Always use the forkclamp to hold the fork; Never place the forkin a vice as this causes damage to the tubes. It is possible tocounter hold the fork by hand when a compressed air wrench isused.2Place the bike stable with the front wheel off the ground.Remove the front fork from the bike. View the bike manual fordetails.3Turn the rebound screw (2, if available) clockwise, until thedamping is fully closed; else the adjustment mechanism will beupset when disassembling the fork. The position of thecompression adjustment (if available) is not important.Unscrew the screwcaps (4) from the fork.Press down the outer tube.Special tool kit4Place special tool A on the preload bush (6), throughthe holes in the bush. If there are no holes in the bush,clamp the bush between the bolts on tool A, not tootight as this can cause damage.7

HYPERPRO SPRING MOUNTING MANUAL5Use tool A to press the bush (6) and spring fully down.Let somebody else put the plate B between the bush (6) and thenut (7) by pulling the damper rod up with the screwcap (4)For forks with reversed preload adjustment (check for a remark onthe frontpage) the preload has to be set to the minimum (1 ringshowing) before this can be done.6Remove the screwcap (4) by counterholding the nut (7) and turningthe screwcap (4)Remove the rebound adjustment rod (9) out of the damper rod (8)Note how it fits the fork.Sometimes the rebound adjustment rod is attached to thescrewcap.7Screw tool C on the damper rod (8) Use it to remove tool B frombetween the nut (7) and the preload bush (6) the second personpulls the damper rod out with C and removes theplate B while the first person presses down on A.8Remove tool A, then remove all the parts from thefork: the preload bush (6), ring(s) and the spring.Note how the parts fit in the fork. Sometimes thespring has a tapered end on one side.9Pour the old oil into a tank. Pump the fork: move thedamper rod and outer tube up and down slowly afew times to pump all the old oil out off thedampingcartridge. Hold the fork upside down andpour the oil out of the fork. Pump the fork again.Repeat the procedure to remove all the oil from thefork ( 5 times, until there is no damping felt)Note: Do not remove the outer tube from the innertube.Fork with reversed preloadOld oil is harmful for theenvironment, dispose ofit properly.10Inspect the parts fortheir condition. Brokenparts and/or leakingseals should bereplaced. If an oil seal isreplaced, be sure toalso check the innertube for damage.Clean all the partsbefore reassembly.8

HYPERPRO SPRING MOUNTING MANUAL11Compress the fork fully and fill it with HYPERPRO oil of the right viscosity (seefrontpage: HYPERPRO OIL) until about 200 mm under the edge of the fork tube.Remove all the air from the fork by moving the outer tube and the damperrod slowly up and down ( 10 to 20 times)12Fill the fork to the specified oil level (see frontpage: OIL LEVEL)The oil level (air chamber) is measured with the fork fully compressed and all theloose parts (preload bush, ring(s) and spring) removed. Make sure the fork iscompressed in the hydraulic lock; when the compressing becomes heavier,push further until steel to steel contact is felt.The air chamber is the length between the topof the tube and the oil inside the fork. The forkmust be held straight up. Slide a tapemeasure in until it just lightly touches the oil.Hold it against the upper edge of the tube.Add or remove oil until the correct setting isreached.Be sure there is no air in the dampingcartridge (view step 11)13Mount the HYPERPRO spring in the fork. Viewthe frontpage for the mounting direction,usually the progressive side (circle) is mounted up. Sometimes thereis a sticker marking which side up. Fit the spring without the sticker.Fit the ring(s) and the preload bush if present. Themounting order of the parts is the same as original.Unless there is a remark on the frontpage14Place the plate B between the nut (7) and the bush (6)using tool A to press the bush and spring down.15Screw down the nut (7) Remove tool C from the damperrod (8) Fit the rebound adjustment rod (9) and then screwthe cap (4) on until it stops, don’t overtighten as this upsetsthe adjustment mechanism. Counter hold the screwcap (4)and tighten the nut (7) against the cap, be careful not toovertighten it.16Press down on tool A, let a second person pull out thedamper rod (8) with the screwcap (4) Remove the plate B.Make sure everything falls into place correctly when thepressure on tool A is slowly released.17Tighten the screwcap (4) in the fork.18Set the preload (3, if available) to the setting specified on thefrontpage (view: SPRING PRELOAD) Less rings showing indicatesmore preload, the preload can be adjusted to set the static sag, viewsetup chapter 2.The forks with reversed preload (check the frontpage for a remark)have a bush (11) which slides up and down in the cap (4) usingscrew (3) More rings (10) showing indicates more preload; normallymore rings indicate less preload. The turning direction is the same;clockwise for more preload.Fork cap with reversed preload9

HYPERPRO SPRING MOUNTING MANUALSet the damping settings (if available) according to thesettings on the frontpage.The rebound is adjusted with the screw (2) on the top of thefork. The compression setting screw is usually located on thebottom of the fork (picture)Clicks or turns are counted from the maximum setting out.Turn the screw in (clockwise) to the maximum setting. Nowturn the screw out (counter clockwise) the number of clicks orturns specified on the frontpage (view: REBOUND &COMPRESSION)19HYPERPRO fork lubricant reduces the friction of the front fork.Carefully prise off the dust seals from the outer tube of thefork with a small flat screwdriver. Put the grease on the innertube of the fork. Move the fork in and out as far as possible.Repeat this.Put a small amount of grease on the dustseals to make them slide in easily. Refit thedust seals and remove the excess grease.20Mount everything on the bike. Fit the fork atthe distance (1) as mea

the fork. Always use the fork clamp to hold the fork; never place the fork in a vice as this causes damage to the tubes. It is possible to counter hold the fork by hand when a compressed air wrench is used. 2 Place the bike stable with the front wheel off the ground. Remove the front fork from the bike. View the bike manual for details.

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