Installation Instructions 422 Series shocks with RAP for 89-99 Harley Davidson Softails Important Notice ATTENTION Statements in these instructions that are preceded by Caution: Please read the following instructions completely the following words are of special significance: before starting installation! Removing and reinstalling the shock absorbers must be performed by a qualified mechanic according to steps outlined in an authorized shop manual that Warning relates to your particular make, model and year motorcycle. Process may require special tools, fixtures, and/or a press. This means there is the possibility of injury to yourself or others. The vehicle must be securely blocked to prevent it from dropping or tipping when the shock absorbers are removed. Failure to do so can cause serious damage and/or injury! C a u t i o n This means there is the possibility of damage Progressive Suspension Softail shocks are designed to work to the vehicle. with the OEM (Original Equipment) chassis components. Use of this product on any chassis components other than OEM Note may produce an unsatisfactory ride and void the warranty. Information of particular importance Transmission bolts must be installed in the OEM position to has been placed in italics. insure proper clearances for the shocks. Consult your factory shop manual for proper installation. Warranty Progressive Suspension warrants to the original purchaser this Make sure that proper bushings/sleeves are installed in the Part to be free of manufacturing defects in materials and shocks. Improper bushings/sleeves can cause unsatisfactory workmanship for a period of one (1) year from the date of and/or unsafe operation. purchase. In the event warranty service is required, you must call Progressive Suspension immediately with a description of the problem.
If it is deemed necessary for Progressive Suspension to make an evaluation to determine whether the part is defective, a return Installation authorization number will be given by Progressive Suspension. Progressive Suspension shocks for your Softail are designed as a The parts must be packaged properly so as to not cause further direct bolt on replacement for your stock shocks. Although they damage and returned prepaid to Progressive Suspension with a are very similar in appearance, they have vastly improved copy of the original invoice of purchase and a detailed letter damping and spring rates. outlining the nature of the problem. If after the evaluation by Progressive Suspension the part was found to be defective it will nPlace motorcycle securely on stand or blocks so the rear be repaired or replaced at no cost to you. If we replace it, we may wheel is slightly off the ground. replace it with a reconditioned one of the same design. nPer instructions in a authorized shop manual, remove your Progressive Suspension shall not be held liable for any old shocks. Note location of the mounting hardware. consequential or incidental damages resulting from the failure of a Progressive Suspension part. Progressive Suspension shall have nWhile the shocks are off the bike either lower the bike no obligation if a part becomes defective as a result of improper or raise the rear wheel until the swingarm bottoms into installation or abuse. the bumper on the frame. Take a measurement from the axle to a point on the fender or frame directly above it, and write that measurement here ______, as well as Warning in the “Comp.” (compressed) space on the “Rider Sag Changing the chassis and/or suspension on any vehicle will Worksheet” on page three. You will need this later to change the handling characteristics of that vehicle. Care should properly adjust your rider sag / preload. be taken when operating the vehicle with such modifications n while getting accustomed to the new handling characteristics. Before installing your 422 RAP shocks, check the shock-eye length, this determines the mechanical ride height (see Ride Height Adjustment on page three) n nInstall the Progressive Suspension 422 shock without the Route the line up and then to the left side of the bike. As you RAP on the left side using the stock mounting bolts and do so, you should tie off the line to the swingarm pivot as washers. illustrated. nTighten all shock mounting bolts to the proper torque specifications (see shop manual for specs). nBefore mounting the 422 shock with RAP on the right hand side, remove the knob from the RAP adjuster to allow it to be routed through the frame and back to it’s final mounting point. To do this simply remove the screw in the center of the knob and pull it straight off. nRoute the line out the left side in front of the fender and above the lower belt-guard as illustrated. nAs you mount the RAP equipped shock, feed the RAP adjuster through the shock-eye frame window then up and to the left side of the bike as shown.
nMount the RAP adjuster to the bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Also reinstall the adjuster knob, apply a drop of thread-locking agent to the center screw, and torque it to 50 in/lbs (5.65 N-m). nWhen mounting the RAP shock make sure the adjuster line nThe RAP adjuster bracket is designed to mount to the tab on is lined up towards the center of the bike and slightly up so the frame for the left passenger peg by sandwiching it it has as much clearance as possible going through the between the bolt head and the inside of the frame. aforementioned frame window. Then mount the shock using the stock mounting bolts and washers, and tighten all shock mounting bolts to the proper torque specifications (see shop manual for specs).
Line/Fitting must NOT contact Frame
nProceed to Ride height and Preload adjustment. C a u t i o n nYour new 422 series with RAP Softail suspension NOTE: The internal fluid levels of your 422 with RAP shocks are set from the system actually has two methods of adjusting your factory and NOT to be adjusted by the customer. Do NOT attempt to preload. The most convenient is by simply turning the add/remove any fluid from any fill/bleed ports on the shocks (see below) as RAP adjuster knob – clockwise to increase preload damage and/or injury will result and the warranty will be voided. (reducing sag) and counterclockwise to reduce preload DO NOT REMOVE (increase sag). nIf you reach either end of the RAP hydraulic adjustment, then you can shift the “range” of adjustment by adjusting the preload on the shock that does not have the hydraulic adjuster. This is done by using the supplied SW-784 wrench to first loosen the lock nut and back it off a few turns, then flip the Ride Height Adjustment wrench over and rotate the round spring-plate either counterclockwise to increase preload or clockwise to Your new 422 Series shocks with RAP have adjustable ride reduce preload – it may seem backward but the less height and are capable of Stock to 2" lower ride height. The threads showing the higher the preload, and the more shocks come pre-assembled set at approximately 1.0" lower threads that are showing the lower the preload. Once than stock height. The shock with the hydraulic line cannot be you've set the preload range, retighten the locknut. rotated once installed, thus the ride height adjustment must be done with the shocks off the bike.
nTo adjust the ride height simply loosen the lock nut on the LockNut eye, and holding the hex on the shaft rotate the eye to the desired height.
nMeasuring from the locknut to the end of the threads on HarleyDavidson Adjustmentwrench the eye (see below) the ratio of adjustment is about 3.5 to (HD #94455-89) 1, the more threads that are exposed the lower the ride height – no threads showing is stock height and 9/16” of the threads showing is 2” inches lower which is the LessPreload MorePreload maximum lowered setting. Adjust both shocks to the same length.
nWhen you reach the desired height, tighten the locknut on nUse your RAP hydraulic adjuster to fine tune your rider the eye down securely (14ft/lb.) on both shocks. sag. Often a small adjustment can make a big difference in ride quality. If it feels a little too stiff, reduce the Warning preload a bit – if it bottoms, increase it.
Do not go further than this - damage or injury may result. nTest ride the bike and make further adjustments if necessary. Note: Adjusting the preload does not change 9/16" Maximum the shock length. Lock Nut nFor a balanced suspension, we highly recommend installing a pair of Progressive Suspension fork springs or Monotube Fork Kit.
nRide and enjoy. Preload Adjustment Preload adjustment greatly affects ride quality. When the preload is adjusted properly, the suspension should “sag” or compress Rider Sag Worksheet about one third of the total available travel with rider(s) & gear Ext. ______on the bike ready to ride – this is referred to as “rider sag”. To Comp. - ______accurately know your total available wheel travel you'll need to Travel = ______X.33 = Target Sag ______extend the suspension until it's completely topped out then measure from the axle to a point on the chassis directly above it, the same two measuring points used in the third step on page Ext. ______one of this instruction - this is “Ext.” (or extended) in rider sag With Rider(s) & gear - ______worksheet. Subtract the compressed measurement you wrote Actual Sag = ______down on the third step on page one from the extended measurement you just took, and that is your true wheel travel. Adjust preload until Actual Sag matches Target Sag. Your target rider sag should be about one third of that measurement (see “Rider Sag Worksheet” at right). Installation Instructions 422 Series shocks with RAP for 00-Later* Harley Davidson Softails
ATTENTION Important Notice Statements in these instructions that are preceded by Caution: Please read the following instructions completely the following words are of special significance: before starting installation! Removing and reinstalling the shock absorbers must be performed by a qualified mechanic Warning according to steps outlined in an authorized shop manual that relates to your particular make, model and year motorcycle. This means there is the possibility of injury Process may require special tools, fixtures, and/or a press. to yourself or others. The vehicle must be securely blocked to prevent it from dropping or tipping when the shock absorbers are removed. C a u t i o n Failure to do so can cause serious damage and/or injury! This means there is the possibility of damage to the vehicle. Progressive Suspension Softail shocks are designed to work with the OEM (Original Equipment) chassis components. Use of this product on any chassis components other than OEM Note may produce an unsatisfactory ride and void the warranty. Information of particular importance has been placed in italics. Transmission bolts must be installed in the OEM position to insure proper clearances for the shocks. Consult your factory Warranty shop manual for proper installation. Progressive Suspension warrants to the original purchaser this Make sure that proper bushings/sleeves are installed in the Part to be free of manufacturing defects in materials and shocks. Improper bushings/sleeves can cause unsatisfactory workmanship for a period of one (1) year from the date of and/or unsafe operation. purchase. In the event warranty service is required, you must call Progressive Suspension immediately with a description of the problem.
If it is deemed necessary for Progressive Suspension to make an evaluation to determine whether the part is defective, a return authorization number will be given by Progressive Suspension. Installation The parts must be packaged properly so as to not cause further Progressive Suspension shocks for your Softail are designed as a damage and returned prepaid to Progressive Suspension with a direct bolt on replacement for your stock shocks. Although they copy of the original invoice of purchase and a detailed letter are very similar in appearance, they have vastly improved outlining the nature of the problem. If after the evaluation by damping and spring rates. Progressive Suspension the part was found to be defective it will be repaired or replaced at no cost to you. If we replace it, we may n Place motorcycle securely on stand or blocks so the rear replace it with a reconditioned one of the same design. wheel is slightly off the ground. Progressive Suspension shall not be held liable for any n Per instructions in a authorized shop manual, remove your consequential or incidental damages resulting from the failure of old shocks. Note location of the mounting hardware. a Progressive Suspension part. Progressive Suspension shall have no obligation if a part becomes defective as a result of improper n installation or abuse. While the shocks are off the bike either lower the bike or raise the rear wheel until the swingarm bottoms into the bumper on the frame. Take a measurement from the axle to a point on the fender or frame directly above it, Warning and write that measurement here ______, as well as Changing the chassis and/or suspension on any vehicle will in the “Comp.” (compressed) space on the “Rider Sag change the handling characteristics of that vehicle. Care should Worksheet” on page three. You will need this later to be taken when operating the vehicle with such modifications properly adjust your rider sag / preload. while getting accustomed to the new handling characteristics. n n Before mounting the 422 shock with RAP on the left hand Once you have installed the other bushing, bushing-cup, and side, remove the flanged nut you can now install the safety E-clip. This E-clip knob from the RAP is snapped into the groove near the end of the stud mount adjuster to allow it where the threads stop. This is to serve as a reference point Figure 1 – to be routed through ONLY when the flanged-nut reaches it you have lowered the frame and back your ride height the maximum 2 inches. DO NOT torque the to it’s final mounting flange-nut against the E-clip (fig.4). point. To do this simply remove the screw in the center Frame of the knob and pull Lock nut Adjust- it straight off (fig.1). able Range n Prepare both shocks for mounting by threading the supplied non-flanged nuts all the way onto the stud mounts, followed by a supplied bushing-cup, bushing, and sleeve (fig.4).
E-Clip n As you mount the RAP equipped shock, feed the RAP Flange Nut adjuster up and out the left side of the bike through the Non-flange Nut space between the swing-arm and fender of the bike as Cups (bushings shown (fig.2). Figure 4 inside)
n Mount the rear eyes of the shocks using the stock bolts and washers, and tighten all shock mounting hardware to the proper torque specifications (see shop manual for specs). Route the adjuster line in a seeping arc above the right shock and toward the rear (fig.5).
Figure 2 n When mounting the RAP shock make sure the adjuster line is pointing to the right and slightly up as illustrated (fig.3). Figure 5 Figure 3
n Route the line up and then to the left side of the bike. As you do so, make sure the line will not be pinched, kinked, or exposed to excessive heat and use the included zip-ties to secure it in place. Route the line out the left side in front of the fender and above the lower belt-guard (fig.6).
Figure 6
n Then install shocks as you would a stock unit, following an authorized shop manual - noting to route the adjuster line in a sweeping arc above the right non-RAP shock and towards the rear of the bike. With the non-flanged nut spun all the way onto the stud, the stock ride height is achieved (ride height adjustment will be addressed later). n n Mount the RAP adjuster to the bracket using the supplied To lower your ride height, simply loosen the flange-nuts M6-1.0X8mm SHCS fasteners and torque them to 80-90 in equal amounts and when the desired height is reached in/lbs (9-10 N-m). Also reinstall the adjuster knob, apply a tighten the non-flanged nuts back against the bushings drop of thread-locking agent to the center screw, and (torque to factory recommended specifications). torque it to 50 in/lbs (5.65 N-m). Warning Do not tighten the flange nut against the E-clip, it is for n The RAP adjuster bracket is designed to mount on the reference only. backside of the tab on the frame for the left passenger peg. This is done by sandwiching it between the frame and the n To raise the ride height, reverse the process. Start by supplied 3/8-16 nylock-nut. To do this you’ll first have to loosening the non-flanged nuts away from the bushings, replace your stock left passenger peg bolt with one of the then start tightening the flanged nuts against the supplied 3/8-16 bolts that is approximately ½ inch longer bushings (towards the rear of the bike). When the than stock - so that it sticks out the back of the frame far desired ride height is achieved, make sure the non- enough to mount the bracket and fully engage the supplied flanged nuts are re-tightened against the bushings. nylock-nut. n It will help to hold the stud with a 3/4" wrench on the n Rotate the adjuster bracket assembly down until the hex portion of the stud to prevent it from turning while indexing tab engages the frame and torque the supplied adjusting. 3/8-16 nylock-nut to 25 ft/lbs. When mounted, it should n NOTE: The amount the nuts move on the stud may not look as illustrated in figure 7 (note foot-peg assembly not seem like much, but every 5/16" of an inch of shown for clarity). adjustment equals approximately 1" of ride height.
Preload Adjustment Preload adjustment greatly affects ride quality. When the preload is adjusted properly, the suspension should “sag” or compress about one third of the total available travel with rider(s) & gear on the bike ready to ride – this is referred to as “rider sag”. To accurately know your total available wheel travel you'll need to extend the suspension until it's completely topped out then measure from the axle to a point on the chassis directly above it, the same two measuring points used in the third step on page one of this instruction - this is “Ext.” (or extended) in rider sag worksheet below. Figure 7 Subtract the compressed measurement you wrote down on the third step on page one from the extended measurement you just took, and that is your true wheel travel. Your target rider sag should be about one third of that measurement n Proceed to Ride height and Preload adjustment. (see “Rider Sag Worksheet” below).
C a u t i o n Rider Sag Worksheet NOTE: The internal fluid levels of your 422 with RAP shocks are set from the Ext. ______factory and NOT to be adjusted by the customer. Do NOT attempt to add/remove any fluid from any fill/bleed ports on the shocks (see below) as Comp. - ______damage and/or injury will result and the warranty will be voided. Travel = ______ X.33 = Target Sag ______DO NOT REMOVE Ext. ______With Rider(s) & gear - ______Actual Sag = ______
Adjust preload until Actual Sagmatches Target Sag.
Ride Height Adjustment n Your new 422 Series shocks with RAP have adjustable ride height Note that by adjusting your Ride Height (as described in the previous section “Ride Height Adjustment”) you and are capable of Stock to 2" lower ride height. Per the “ ” installation instructions, your shocks should be at stock ride height change your Ext. (extended) measurement on the Rider initially. The ride height adjustment can be done with the shocks Sag Worksheet. Thus you must set your ride height first to on the bike, and removal is not necessary. It is important that the accurately be able to calculate a target sag measurement. locknut on the preload adjusting plate is securely tightened (refer back to fig.4). Preload Adjustment (cont.) n Your new 422 series with RAP Softail suspension system actually has two methods of adjusting your preload. The most convenient is by simply turning the RAP adjuster knob – clockwise to increase preload (reducing sag) and counterclockwise to reduce preload (increase sag). n If you reach either end of the RAP hydraulic adjustment, then you can shift the “range” of adjustment by adjusting the preload on the shock that does not have the hydraulic adjuster (on the right). This is done by using the supplied SW-784 wrench to first loosen the lock nut and back it off a few turns, then flip the wrench over and rotate the round spring- plate either counterclockwise to increase preload or clockwise to reduce preload – it may seem backward but the less threads showing the higher the preload, and the more threads that are showing the lower the preload. Once you've set the preload range, retighten the locknut.
LockNut
HarleyDavidson Adjustmentwrench (HarleyDavidson #94455-89)
LessPreload MorePreload
n Use your RAP hydraulic adjuster to fine tune your rider sag. Often a small adjustment can make a big difference in ride quality. If it feels a little too stiff, reduce the preload a bit – if it bottoms, increase it. n It’s best to target having the RAP adjuster at or near the minimum preload setting for your lightest riding load - such as rider only with no baggage. That way as you add weight such as a passenger and/or baggage you will have plenty of range to adjust for it using only the RAP adjuster. n Test ride the bike and make further adjustments if necessary. Note: Adjusting the preload does not change the shock length. n For a balanced suspension, we highly recommend installing a pair of Progressive Suspension fork springs or Monotube Fork Kit. n Ride and enjoy. Installation Instructions 422 Series Shocks 2000 & Later* Harley Davidson Softails
ATTENTION Important Notice Statements in these instructions that are preceded by Caution: Please read the following instructions completely the following words are of special significance: before starting installation! Removing and reinstalling the shock absorber, and the spring on said shock absorber, must Warning be performed by a qualified mechanic or according to steps outlined in an authorized shop manual that relates to your This means there is the possibility of injury particular make, model and year motorcycle. Process may to yourself or others. require special tools, fixtures, and/or a press.
The vehicle must be securely blocked to prevent it from C a u t i o n dropping or tipping when the shock absorber is removed. This means there is the possibility of damage Failure to do so can cause serious damage and/or injury! to the vehicle. Progressive Suspension Softail shocks are designed to work with the OEM (Original Equipment) chassis components. Use Note of this product on any chassis components other than OEM Information of particular importance may produce an unsatisfactory ride and void the warranty. has been placed in italics. Transmission bolts must be installed in the OEM position to Warranty insure proper clearances for the shocks. Consult your factory shop manual for proper installation. Progressive Suspension warrants to the original purchaser this Part to be free of manufacturing defects in materials and Make sure that proper bushings/sleeves are installed in the workmanship for a period of one (1) year from the date of shocks. Improper bushings/sleeves can cause unsatisfactory purchase. In the event warranty service is required, you must call and/or unsafe operation. Progressive Suspension immediately with a description of the problem.
If it is deemed necessary for Progressive Suspension to make an evaluation to determine whether the part is defective, a return Installation Progressive Suspension shocks for your 2000 & later Softail authorization number will be given by Progressive Suspension. are designed as a direct bolt on replacement for your stock The parts must be packaged properly so as to not cause further units. Although they are very similar in appearance, along with damage and returned prepaid to Progressive Suspension with a offering adjustable ride height they also have improved copy of the original invoice of purchase and a detailed letter damping and spring rates. outlining the nature of the problem. If after the evaluation by Progressive Suspension the part was found to be defective it will be repaired or replaced at no cost to you. If we replace it, we may n replace it with a reconditioned one of the same design. Place motorcycle securely on stand or blocks so the rear wheel is slightly off the ground. Progressive Suspension shall not be held liable for any n consequential or incidental damages resulting from the failure of Per instructions in a authorized shop manual, remove your a Progressive Suspension part. Progressive Suspension shall have old shocks. Note location of the mounting hardware. no obligation if a part becomes defective as a result of improper installation or abuse. n Before reinstalling a Progressive Suspension adjustable ride height shock, spin the non-flanged nut all the way onto the stud mount, followed by a bushing-cup, bushing, and sleeve. Then install shocks as you would a stock unit, Warning following an authorized shop manual. With the non- Changing the chassis and/or suspension on any vehicle will flanged nut spun all the way onto the stud, the stock ride change the handling characteristics of that vehicle. Care should height is achieved. Once you have installed the other be taken when operating the vehicle with such modifications bushing, bushing-cup, and flanged nut you can now install while getting accustomed to the new handling characteristics. the safety E-clip. This E-clip is snapped into the groove near the end of the stud mount where the threads stop. This is to serve as a reference point ONLY – when the flanged- nut reaches it you have lowered your ride height the maximum 2 inches. DO NOT torque the flange-nut against the E-clip (see Figure 1 figure 1). Frame
Lock nut Adjust- n Tighten all shock mounting bolts to the proper torque able specifications (see shop manual for specs). Range n Progressive Suspension shocks have adjustable pre-load to compensate for varying weights. The included wrench or a Harley Davidson pre-load adjustment wrench is necessary to E-Clip adjust the pre-load setting. Replacement Progressive Suspension Flange Nut wrenches are available as Part # SW-784 from most Dealers and Nut Accessory Stores and the Harley Davidson wrench is available Cups (bushings as part #94455-89 from any Harley Davidson Dealer. inside) n Spring preload is set by us to the lightest setting. To increase preload for heavier riders/loads/passengers, loosen locknut with the inside portion of the supplied wrench or a 1-1/16” wrench and back it off several turns. Use the supplied wrench Figure 2 or a Harley adjustment wrench to turn the adjustment nut counterclockwise to the desired preload setting. Then tighten LockNut the 1-1/16” lock nut. Both shocks must be adjusted to the same, equal setting (See Figure 2).
Note: Maximum preload is reached when the locknut and adjusting plate are turned to the end of the threads (no threads showing). ” HarleyDavidson This distance is approximately ¼ . Do not turn the locknut past the Adjustmentwrench last thread! (HarleyDavidson #94455-89) n Test ride the bike and make further adjustments if necessary. Note: Adjusting the preload does not change the shock length. LessPreload MorePreload Your new Progressive Suspension adjustable ride height shocks are capable of lowering your ride height up to 2". To lower your ride height, simply loosen the flange-nuts in equal amounts and when the desired height is reached tighten the non-flanged nuts back against the bushings (torque to factory recommended specifications). Do not tighten the flange nut against the E-clip, it is for reference only. To raise the ride height, reverse the process. Start by loosening the non-flanged nuts away from the bushings, then start tightening the flanged nuts against the bushings (towards the rear of the bike). When the desired ride height is achieved, make sure the non-flanged nuts are re-tightened against the bushings. It will help to hold the stud with a 3/4" wrench on the hex portion of the stud to prevent it from turning while adjusting. NOTE: The amount the nuts move on the stud may not seem like much, but every 5/16" of an inch of adjustment equals approximately 1" of ride height. It is important that the locknut on the preload adjusting plate is securely tightened (see figure 1). n For a balanced suspension, we highly recommend installing a pair of Progressive Suspension fork springs. n Ride and enjoy.
Learn more about other motorcycle suspension parts by Progressive Suspension on our website.