Ohlins HD 039 Shocks Instruction Manual

1. Introduction

This manual provides essential information for the proper installation, adjustment, and maintenance of your Ohlins HD 039 Shocks. These shocks are designed to enhance the suspension performance of Harley-Davidson FLHX Street Glide motorcycles from 2006 and newer models. Please read this manual thoroughly before proceeding with installation or adjustments.

2. Safety Information

Warning: Improper installation or adjustment of suspension components can lead to loss of control and serious injury or death. If you are not confident in your mechanical abilities, seek assistance from a qualified motorcycle technician.

• Always wear appropriate personal protective equipment (PPE) when working on your motorcycle.
• Ensure the motorcycle is securely supported on a stable stand before beginning any work.
• Refer to your motorcycle's service manual for specific torque specifications and procedures.
• Do not attempt to disassemble the shock absorber. It contains high-pressure gas and oil.
• Keep children and pets away from the work area.

3. Package Contents

Verify that all components are present before beginning installation:

• 2 x Ohlins HD 039 Shock Absorbers
• Instruction Manual (this document)
• Any specific tools or accessories (check packaging)

Image 1: Two Ohlins HD 039 shock absorbers. These are high-performance motorcycle suspension units, featuring black coil springs, silver-colored main bodies, and silver mounting eyes at both ends. The upper section shows the threaded preload adjusters.

4. Setup and Installation

This section outlines the general procedure for installing the Ohlins HD 039 shocks. Specific steps may vary slightly depending on your motorcycle's model year. Always consult your Harley-Davidson service manual for detailed instructions regarding rear shock removal and installation.

1. Prepare the Motorcycle: Park the motorcycle on a level, firm surface. Secure it on a suitable motorcycle lift or stand to ensure the rear wheel is off the ground and the swingarm is supported.
2. Remove Original Shocks: Carefully unbolt the upper and lower mounting bolts of the existing shock absorbers. Support the swingarm to prevent it from dropping suddenly. Remove the old shocks.
3. Install Ohlins Shocks: Position the new Ohlins HD 039 shocks. Ensure the orientation is correct (usually, the reservoir is at the top). Install the upper mounting bolts first, then the lower mounting bolts. Do not fully tighten yet.
4. Torque Bolts: Refer to your Harley-Davidson service manual for the correct torque specifications for the upper and lower shock mounting bolts. Tighten all bolts to the specified torque.
5. Final Check: Lower the motorcycle carefully. Check all fasteners for tightness. Ensure there is no interference with other components.

5. Operating and Adjustment

The Ohlins HD 039 shocks are equipped with adjustable preload. Proper preload adjustment is crucial for optimal ride comfort and handling.

5.1 Preload Adjustment

Preload adjusts the initial compression of the spring, affecting ride height and sag. It should be set according to rider weight, passenger weight, and luggage.

1. Measure Sag: With the motorcycle on its wheels, measure the distance from a fixed point on the rear fender to the center of the rear axle (Measurement A). Then, with the rider (and passenger/luggage, if applicable) seated on the motorcycle in riding position, measure the same distance (Measurement B). The difference (A - B) is the static sag.
2. Adjust Preload Rings: Use the appropriate spanner wrench (not included, typically) to turn the threaded preload rings on the shock body. Turning the rings clockwise increases preload (compresses the spring more), reducing sag. Turning counter-clockwise decreases preload (decompresses the spring), increasing sag.
3. Target Sag: Consult Ohlins documentation or a qualified technician for recommended sag settings for your specific application. A common starting point for street motorcycles is typically 25-35mm of sag.
4. Equal Adjustment: Always adjust both shocks equally to maintain balanced handling.
5. Test Ride: After adjustment, perform a short test ride in a safe area to evaluate the feel and make further fine-tuning if necessary.

6. Maintenance

Regular maintenance ensures the longevity and performance of your Ohlins HD 039 shocks.

• Cleaning: Keep the shocks clean from dirt, dust, and road grime. Use mild soap and water, then rinse thoroughly. Avoid high-pressure washers directly on seals.
• Inspection: Periodically inspect the shocks for any signs of oil leaks, damaged seals, bent shafts, or loose fasteners.
• Bushings/Bearings: Check the mounting bushings/bearings for wear. Replace if excessive play is detected.
• Professional Service: Ohlins shocks are precision components. For internal service, re-valving, or rebuilding, always consult an authorized Ohlins service center.

7. Troubleshooting

8. Specifications

• Model: Ohlins HD 039
• Application: Harley-Davidson FLHX Street Glide (2006-Newer)
• Type: Twin Shock Absorber
• Adjustments: Preload (Spring)
• Manufacturer Part Number: HD 039 Ohlins
• UPC: 800150101134

9. Warranty Information

Ohlins products typically come with a limited warranty covering defects in materials and workmanship. For specific warranty terms, duration, and claim procedures, please refer to the official Ohlins warranty documentation provided with your purchase or visit the official Ohlins website. Keep your proof of purchase for warranty claims.

10. Support

For technical assistance, service, or parts inquiries, please contact your authorized Ohlins dealer or visit the official Ohlins website for contact information and support resources.

Ohlins is a registered trademark. All rights reserved.