1. Introduction
Thank you for choosing Ohlins HD 159 Shocks. These high-performance shocks are specifically designed to enhance the ride quality and handling of your Harley Davidson FLH/FLT Touring Motorcycle manufactured from 1998 onwards. This manual provides essential information for the correct installation, adjustment, and maintenance of your new suspension components to ensure optimal performance and longevity.
For any questions or assistance, please refer to the support section or contact an authorized Ohlins dealer.
2. Safety Information
Always prioritize safety when working on your motorcycle. Improper installation or adjustment of suspension components can lead to serious injury or damage to the motorcycle. Please read and understand all instructions before proceeding.
- It is highly recommended that installation and initial setup be performed by a qualified motorcycle technician.
- Always use appropriate tools and follow all torque specifications.
- Ensure the motorcycle is securely supported on a stable stand before beginning any work.
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Do not modify the shocks or use them for purposes other than their intended design.
- Regularly inspect the shocks for any signs of wear, damage, or leaks.
3. Setup and Installation
The Ohlins HD 159 shocks are designed for direct replacement on compatible Harley Davidson FLH/FLT Touring Motorcycles (1998-Newer). Your shocks may come with free preload settings pre-adjusted based on your specifications at the time of purchase. Verify these settings before installation.
Image: A pair of Ohlins HD 159 shocks, featuring black springs and silver bodies, designed for Harley Davidson FLH/FLT Touring Motorcycles. These shocks are engineered for improved ride quality and handling.
3.1. Pre-Installation Checks
- Confirm the shocks are the correct model (HD 159) for your motorcycle.
- Inspect the shocks for any shipping damage.
- Gather all necessary tools, including a torque wrench, appropriate sockets, and a motorcycle lift or stand.
3.2. Removal of Old Shocks
- Secure the motorcycle on a lift or stand, ensuring the rear wheel is off the ground and the swingarm is supported.
- Locate the upper and lower shock mounting bolts.
- Carefully remove the lower mounting bolts first, then the upper mounting bolts. Support the swingarm to prevent it from dropping.
- Remove the old shocks from the motorcycle.
3.3. Installation of New Ohlins HD 159 Shocks
- Position the new Ohlins shocks, ensuring the correct orientation (usually the reservoir end is at the top).
- Install the upper mounting bolts first, but do not fully tighten them.
- Align the lower mounting points and install the lower bolts.
- With the motorcycle's weight on the wheels (or simulating ride height), torque both upper and lower mounting bolts to the motorcycle manufacturer's specifications. Refer to your Harley Davidson service manual for exact torque values.
- Double-check all fasteners for proper tightness.
3.4. Preload Adjustment (if necessary)
The HD 159 shocks feature adjustable preload. While your shocks may be pre-set, fine-tuning might be required based on rider weight, passenger weight, and luggage. Adjusting preload changes the initial sag of the suspension.
- To increase preload (stiffen), turn the preload adjuster collar clockwise.
- To decrease preload (soften), turn the preload adjuster collar counter-clockwise.
- Always adjust both shocks equally.
- Consult an Ohlins service manual or a qualified technician for detailed sag measurement and adjustment procedures.
4. Operating and Adjustment
Once installed, the Ohlins HD 159 shocks are designed to provide superior ride comfort and handling. While primary adjustments are typically preload, some models may offer additional damping adjustments. Refer to your specific shock model's detailed manual for advanced tuning.
4.1. Initial Ride Impressions
After installation, take a short, cautious ride to familiarize yourself with the new suspension feel. Pay attention to:
- Overall comfort over various road surfaces.
- Stability during cornering and braking.
- How the motorcycle reacts to bumps and dips.
4.2. Fine-Tuning
Minor adjustments to preload can significantly impact ride characteristics. Experiment with small increments to find your preferred setting. Always make adjustments to both shocks equally and re-evaluate after each change.
5. Maintenance
Proper maintenance ensures the longevity and performance of your Ohlins shocks.
- Cleaning: Regularly clean the shocks with mild soap and water to remove dirt, grime, and road debris. Avoid high-pressure washers directly on seals.
- Inspection: Periodically inspect the shock bodies, springs, and mounting points for any signs of damage, corrosion, or leaks. Check for loose bolts.
- Service Intervals: Ohlins shocks are precision components that require periodic servicing. Consult an authorized Ohlins service center for recommended service intervals, which typically involve oil changes and seal replacements. Do not attempt to disassemble the shocks yourself.
- Storage: If storing the motorcycle for an extended period, ensure the shocks are clean and dry.
6. Troubleshooting
This section addresses common issues you might encounter with your Ohlins HD 159 shocks.
| Symptom | Possible Cause | Solution |
|---|---|---|
| Harsh ride / Too stiff | Too much preload; incorrect spring rate for rider weight. | Decrease preload; consult Ohlins for correct spring rate. |
| Bottoming out / Too soft | Insufficient preload; incorrect spring rate for rider weight/load. | Increase preload; consult Ohlins for correct spring rate. |
| Oil leakage from shock body | Damaged seal; internal component failure. | Contact an authorized Ohlins service center for repair. Do not ride with leaking shocks. |
| Unusual noises (clunking, squeaking) | Loose mounting bolts; worn bushings; internal damage. | Check all mounting bolts for tightness; inspect bushings; if noise persists, seek professional inspection. |
If you experience issues not listed here or if solutions do not resolve the problem, contact an authorized Ohlins service center or dealer.
7. Specifications
Key specifications for the Ohlins HD 159 Shocks:
- Model Number: HD 159
- Brand: Ohlins
- Vehicle Service Type: Motorcycle (Harley Davidson FLH/FLT Touring, 1998-Newer)
- Exterior Finish: Black (Springs), Silver (Body)
- Item Weight: Approximately 19.1 pounds (for the pair)
- Product Dimensions: Approximately 23 x 9 x 7 inches (packaging dimensions)
- UPC: 800150101110
- Features: Adjustable Preload
8. Warranty and Support
Ohlins products are manufactured to the highest standards and are backed by a manufacturer's warranty. For specific warranty terms and conditions, please refer to the warranty card included with your product or visit the official Ohlins website. Keep your proof of purchase for warranty claims.
For technical support, service, or genuine Ohlins spare parts, please contact your authorized Ohlins dealer or visit the official Ohlins website for contact information. Professional servicing is recommended for all internal shock maintenance.
Ohlins Official Website: www.ohlins.com
