Installation Instructions
HJC Model CL Max ll Modular Helmet
First two pictures above is a standard 2012 CL Max ll HJC Modular Helmet.
Remove 3.4″ electricians tape to separate earmuff ABS washer and pad from ABS cup.
Use ABS cup to trace around inside of APS Styrofoam side padding shown below. When done tracing snap ABS cup and ABS washer back together and reinstall 3/4″ tape over seam between ABS cup and washer. Tapping seam is important in providing noise reduction quality of earmuffs,
ABS Earmuff cup placed in position against EPS Styrofoam side pad to trace location for making earmuff pocket.
Line drawn on plastic covering over EPS Styrofoam left side pad.
EPS Styrofoam cut out for earmuff pocket. Chin strap and metal chin strap connection must be relocated down and forward 2 1/4″. It is impossible to properly Velcro air bladder to inside of helmet shell until metal chin strap connection to helmet and chin strap is removed from earmuff pocket.
Metal chin strap in new location. It is attached to helmet by drilling a 3/16″ hole is the helmet and attached using a short 3/16″ pop rivet.
Side pad and what is left of EPS Styrofoam is reinstalled to left side of helmet.
With chin strap and chin strap metal connection relocated it is now possible to stick on loop Velcro piece included in the earmuff kit.
Modified foam side padding ready to install in helmet around earmuff.
Modified left side EPS Styrofoam side pad with attached vinyl and padding to accept earmuff.
Modified left side EPS Styrofoam side pad with attached vinyl installed on left side of helmet with screw reinstalled to hold EPS Styrofoam piece in place. Loop Velcro stuck to inside of helmet shell in pocket to attach to hook Velcro stuck on air bladder.
Left side bladder with hook Velcro is stuck to loop Velcroed in helmet shell. Note bladder is positioned in forward lower earmuff pocket. In all cases this makes it easier for earmuff to seal lower area around ears in area of the jaw bones which is an irregular surface versus flat head bone area above the ear using less air pressure.
Foam side padding is reinstalled on left side EPS Styrofoam padding and attached using one snap button and loop and hook Velcro attached to both ends of side pads to the helmet shell and to the EPS Styrofoam.
Air lines form bladder are ready to be cut to length and attached to air valve and earmuff Velcroed to air bladder.
Air lines from bladders are cut to length and attached to air valve and held by two small cable clamps stuck to helmet shell by 3M VHB double face tape. A larger clamp holds air intake for air valve pump bladder.
Modification of HJC CL MAX II is complete. User will enjoy over 50% reduction of wind and engine noise versus original Standard helmet before installing noise reduction earmuffs. Update electric double lens visor installed.
