Motorcycle Suspension Components
                             with other products available from Kientech Engineering

 
                        INstallation Instructions
      Fits:  2003-07 Husqvarna Four Strokes. 1" & 1.5" Lowering Links.  PN: HL1 & HL2 
        The HL1 link lowers the rear approx. 1" and the HL2 link lowers the rear approx. 1.5" on most models.
                                                       **Will not fit 08-up models. :-(

                   (HL2 Link Shown Above Lowers Rear 1.5" On Most Models.

*Note: The HL2 link will not work on at least the 07 TE450, 05-07 TE510, & 06-up TE610/SM610 unless the swingarm tunnel and/or the bottom of the spring is ground approx, 1/4" for clearance.  The HL1 link may also require some filing for clearance as it is only 3 mm's shorter than the HL2 link. The HL1 link lowers the rear only 1". 

Thanks to Lance Turnley for TRAIL ZONE Magazine/Australia  and Stefan Appelgren over at R&D Husqvarna/Australia, we have a link to a detailed installation of the HL2 link on the Husqvarna TE610:
http://www.offroadexplorer.com/ORE_Garage/Technical/KoubaLink.html

The first picture below shows the spring to swingarm clearance with the stock links on some of the Husky models, if your bike has only the clearance shown below with the swingarm fully extended then the spring and/or swingarm tunnel will have to be filed. When using the HL1 link, approx 1/8 inch more clearance is required.  When using the HL2 link, 1/4 inch more clearance is required.   *Sometimes the shock spring and spring retainer can be rotated a few degress to get maximum clearance.  If your bike has 1/2 inch plus more clearance than shown below then filing the swingarm or spring should not be required.

     Thanks Mark Compton for the picture above of his 05 TE510 with stock links.

The picture below is an 06 TE250 with the HL2 link installed showing the shock clevis hitting the rocker and not allowing the bottom shock mount eyes to align when the swingarm is fully extended.  A reply from a customer is below this picture with a description of what has to be done to gain the clearance requirements.

I finally installed the HL-2 lowering link, and as you mentioned, there was a need to machine the tunnel. Easily accomplished with a dremel and coarse sanding barrels. Also, there was a need to machine the rocker at the lower shock clevis impact point. I have not had a chance to ride the bike yet but I remain confident that I can maintain the right geometry with the front end.  Fortunately, this era of Huskys responds well to the front end being pushed out slightly to increase stability.  I will keep you posted on my impressions.

Bob S.
06 TE-250
 

                  Installation Instructions

1.  Raise the motorcycle with the center stand or milk crate, etc., so the rear wheel is slightly off the ground.  Remove the kickstand mount, lower chain roller, and the 12 or 14 mm headed bolt (head size depends on year model) from the lower shock mount. Then remove the 17 mm nut and washer from the right side of the front link mounting bolt and also the 17 mm nut and washer from the left side of the rear link mounting bolt.  Remove both plastic plugs on the sides of the swing arm and remove the 17 mm nut that is inside the left side tunnel in the swing arm.    *Be careful not to drop that nut down inside the swing arm tube. :-(   Push the bolt out the right side.  You may have to lift up on the rear wheel slightly to allow the bolt to slide out freely.

2.  Next remove both link mounting bolts, pushing the front one out the left side and the rear one out the right side. (*You will have to drop the rocker down slightly to allow the rear link mounting bolt head to clear the bottom of the swing arm.) After removing both link mounting bolts the stock link should drop out the bottom and you are ready to install the longer KoubaLink.  Before installing the new link be sure and grease all of the bearings including the ones in the KoubaLink.

3.  Now that the stock link is removed, install the KoubaLink in the reverse order, bearing end to the front with the grease fitting pointing down.  Move the rear of the link up until the mounting holes line up with the hole in the rocker.  Push the rear link mounting bolt in from the right side and install the washer and 17mm nut.  Push the rocker back up inside the swing arm and push the rocker mounting bolt in from the right side and install the 17mm nut. Rotate the front of the link up and push the front mounting bolt in from the left side.  Install the washer and 17mm nut. (You will have to raise the rear wheel until the front mounting holes line up.) Torque all three 17mm nuts to approx. 35 ft lbs.  Put the 2 plastic plugs back in the swing arm holes. You may want to check the sag and if the full 1 1/2 inches of rear lowering is desired, sag should be set at 100 mm/3.90 inches. 

4.  We recommend sliding the front fork tubes up (approx. ½ inch) until they almost touch the bottom of the handlebars.  If quicker steering is required we would recommend lessening the rear sag, which will subtract from the 1 or 1 1/2 inches of rear lowering.  These links are as long as possible for the maximum rear lowering, on some models the bottom of the shock spring may rub the swing arm tunnel when fully extended.  Grinding the tunnel or spring slightly would produce the required clearance. 

If you like what the KoubaLink does, please tell everyone, if you do not, please tell us.  We can be contacted at our email address below and are always interested in your questions or comments. 
Norm

Norm Kouba
Email:  njkouba@ix.netcom.com
Web page:  http://www.koubalink.com
 

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