© Öhlins Racing AB. All rights reserved. Any re-
printing or unauthorized use without the written
permission of Öhlins Racing AB is prohibited.
Printed in Sweden.
Mounting Instructions HD644_0 Issued 2006 12 13
These instructions and other documents
can be downloaded from
www.ohlins.com
Mounting Instructions
Kit Contents:
Part no. Pcs.
Shock absorber HD644 2
Sleeve 00123-13 4
Washer 03118-08 8
Öhlins Sticker 00192-01 2
Owner’s Manual 07241-02 1
Before installing this shock absorber,
check the contents of the kit listed
below. If anything is missing, please
contact your nearest Öhlins dealer.
SHOCK ABSORBER HD644
for Harley Davidson Sportster
During storage and transportation,
especially at high ambient tempera-
ture, some of the oil and grease used
for assembling may leak and stain
the packaging. This is in no way det-
rimental to the product, wipe off the
excessive oil/grease with a cloth.
Before installing this product, read the Öhlins Owner’s Manual!
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Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden.
Phone +46 8 590 025 00 Fax +46 8 590 025 80
www.ohlins.com
WITH SET-UP DATA
Set-up Data
Spring preload 15 mm
Compression damping 2 clicks
Rebound damping 18 clicks
Shock absorber length 360 (
+10
/
-0
) mm
Stroke 101 mm
HOW TO INSTALL
1
Put the motorcycle on a workstand so that the
rear wheel barely touches the ground.
WARNING!
Make sure the vehicle is securely supported so
that it will not tip.
2
Remove the original shock absorbers. Consult
your Vehicle Service Manual.
NOTE!
Recommendation! Before installing the Öhlins
shock absorber:
• clean the vehicle thoroughly
• adjust the length of the shock absorber (check
the headlight angle after adjusting the length!)
3
Install the Öhlins shock absorbers in the same
way as the original units. The shock absorber
should be installed with the cylinder head at
the top and the reservoir towards the rear. Use
the washers and sleeves provided in this kit.
NOTE!
Lower the motorcycle so that the shock
absorber is sligthly compressed, before tighten-
ing the screws.
WARNING!
It is advisable to have an Öhlins dealer install the
shock absorber.
Make sure that all screws are tightened to the
correct torque and that nothing fouls or restricts
movement of the shock absorber when the sus-
pension is fully compressed or extended.
Always ensure that the basic settings made by
Öhlins are intact.
ADJUSTMENTS
Spring Preload
Turn the knob on the hydraulic preload
adjuster. Turn clockwise to increase the
spring preload. Turn counter clockwise to
release it.
Compression Damping
Turn the wheel on top of the reservoir.
The adjustments are made in four (4)
steps.
Rebound Damping
Turn the adjuster wheel on the piston
shaft above the end eye.
1
2
03118-08
00123-13
03118-08
00123-13
1
2
3
4
3
4
WARNING!
When delivered, the Öhlins shock absorber is
dialed to the recommended settings for the spe-
cifi c brand and make of the motorcycle. Before
riding, always ensure that the basic settings
made by Öhlins are correct.
To set the adjuster:
The turn adjusters have a normal right hand
thread. Turn the damping adjusters clock-
wise to fully closed (position zero [0]). Then,
turn counter clockwise to open, and count
the clicks until you reach the recommended
number of clicks. See Set-up data.
Do not use force, delicate sealing surfaces can
be damaged. Handtighten only.
Length
Use two wrenches. Hold the upper nut
with one hand and at the same time
loosen the lock nut (lower nut). Turn the
end eye/ bracket to the desired length.
Lock the lock nut.
WARNING!
The adjustable end eye/bracket must not be
threaded out more than that the groove is fully
visible beneath the lock nut. This is maximum
length. After adjusting, make sure that the lock
nut is tightened.
/