1. Introduction
This manual provides essential information for the installation, operation, maintenance, and troubleshooting of your Ohlins HD771 Rear Suspension. Please read this manual thoroughly before installation and use to ensure proper function and safety.
The Ohlins Black Line Series HD771 rear suspension is designed for HARLEY-DAVIDSON TOURING Family motorcycles manufactured up to 2016. It features a robust design with a focus on performance and durability, offering an upgrade to your motorcycle's handling characteristics.
2. Product Overview
Figure 2.1: A pair of Ohlins HD771 BlackLine rear shock absorbers, showcasing their all-black finish and robust construction.
Figure 2.2: Close-up detail of the Ohlins HD771 BlackLine rear shock absorber, highlighting the laser-engraved Ohlins logo on the head.
Key Features:
- Compatibility: Specifically designed for HARLEY-DAVIDSON TOURING Family motorcycles manufactured up to 2016.
- Adjustability: Equipped with a screw-type spring and pre-load adjuster for fine-tuning suspension performance.
- Piston Diameter: Features a Φ1.4 inches (36 mm) piston for consistent damping.
- Free Length: 12 inches (305 mm).
- Type: S36D, indicating a built-in free piston model.
- Aesthetics: All-black finish (BlackLine) for a sleek appearance.
3. Setup and Installation
Installation of the Ohlins HD771 rear suspension should be performed by a qualified technician. Incorrect installation can lead to serious injury or damage to the motorcycle. Always refer to your motorcycle's service manual for specific torque specifications and procedures.
3.1 Pre-Installation Checks
- Verify that the suspension model HD771 is compatible with your HARLEY-DAVIDSON TOURING Family motorcycle (model year up to 2016).
- Inspect the suspension units for any signs of damage from shipping.
- Ensure all necessary tools and safety equipment are available.
3.2 Installation Steps (General Guidelines)
- Secure the motorcycle on a suitable stand to prevent it from falling.
- Remove the original rear shock absorbers according to the motorcycle manufacturer's instructions.
- Install the Ohlins HD771 units, ensuring the mounting bolts are correctly aligned and tightened to the manufacturer's specified torque.
- Check for proper clearance with other motorcycle components throughout the suspension's travel range.
- Perform initial sag adjustment (see Section 4.1).
Note: It is highly recommended to consult a professional mechanic for installation to ensure safety and optimal performance.
4. Operation and Adjustment
The Ohlins HD771 rear suspension allows for pre-load adjustment to fine-tune the ride height and sag, which is crucial for optimal handling and comfort.
4.1 Pre-load Adjustment
Pre-load adjustment affects the initial compression of the spring and thus the ride height and sag. Correct sag is essential for the suspension to work effectively over bumps and maintain tire contact with the road.
- To adjust pre-load, use the screw-type adjuster located on the shock body.
- Turning the adjuster clockwise increases pre-load (stiffens the spring, raises ride height).
- Turning the adjuster counter-clockwise decreases pre-load (softens the spring, lowers ride height).
- Measure static sag (motorcycle's weight only) and rider sag (with rider on board) and adjust according to your preference and riding style. Consult a suspension specialist for recommended sag settings for your motorcycle and weight.
Caution: Do not over-tighten or loosen the pre-load adjuster beyond its specified limits. Refer to the Ohlins service manual for detailed adjustment procedures.
5. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Ohlins HD771 rear suspension.
5.1 Cleaning
- Clean the shock absorbers regularly with mild soap and water to remove dirt, dust, and road grime.
- Avoid using high-pressure washers directly on seals or bearings.
- Dry thoroughly with a soft cloth.
5.2 Inspection
- Periodically inspect the shock absorbers for any signs of oil leaks, damage to the body, springs, or mounting points.
- Check mounting bolts for proper torque.
- Inspect bushings and bearings for wear.
5.3 Service Intervals
Ohlins recommends periodic servicing by an authorized Ohlins service center. Service intervals depend on riding conditions and usage, but generally, a full service is recommended every 20,000 km or every 2 years, whichever comes first.
6. Troubleshooting
This section provides guidance for common issues you might encounter with your Ohlins HD771 rear suspension. For complex problems, contact an authorized Ohlins service center.
| Problem | Possible Cause | Solution |
|---|---|---|
| Excessive Sag / Bottoming Out | Insufficient spring pre-load; Worn spring. | Increase spring pre-load; Inspect spring for wear and replace if necessary. |
| Harsh Ride / Too Stiff | Excessive spring pre-load. | Decrease spring pre-load. |
| Oil Leakage | Damaged seal; Overheating. | Contact an authorized Ohlins service center for seal replacement. |
| Unusual Noises | Loose mounting bolts; Worn bushings/bearings. | Check and tighten all mounting bolts to specification; Inspect and replace worn components. |
7. Specifications
| Feature | Detail |
|---|---|
| Model Number | HD771 |
| Brand | Ohlins |
| Compatible Models | HARLEY-DAVIDSON TOURING Family (-2016) |
| Type | S36D (Built-in free piston) |
| Piston Diameter | Φ1.4 inches (36 mm) |
| Free Length | 12 inches (305 mm) |
| Adjustability | Screw-type spring pre-load adjuster |
| Position | Rear |
| Color/Exterior Finish | Black (BlackLine) |
| Item Weight | 6 kg |
| Package Dimensions | 60 x 30 x 20 cm |
8. Warranty and Support
8.1 Warranty Information
Ohlins products are manufactured to high standards and come with a limited warranty against defects in materials and workmanship. For specific warranty terms and conditions, please refer to the official Ohlins warranty documentation provided with your product or visit the official Ohlins website. Keep your proof of purchase for warranty claims.
8.2 Customer Support
For technical assistance, service, or spare parts, please contact your authorized Ohlins dealer or an official Ohlins service center. You can find contact information and a list of authorized service centers on the official Ohlins website.
Official Ohlins Website: www.ohlins.com
