Harley Davidson FLH EZ-Steer Installation MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2012

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Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamp of your Harley Davidson FLH Motorcycle. We recommend that you use an OEM service manual and follow the prescribed disassembly, installation and torque specifications for the upper and lower clamp assembly. Before Installing Kit (2008 & Prior) The wiring bracket of the OEM upper triple clamp needs to be modified to fit the Champion upper triple clamp. After removing / disassembling the OEM parts from your motorcycle, position the OEM wiring bracket onto the Champion upper clamp as shown. Scribe the ID of the steering stem hole onto the wiring bracket and enlarge the hole to scribe line. This will allow the wiring bracket to fit over the new Stem Lock-Nut. Install OEM handle bar mount assemblies to Champion upper clamp using Item #5 (Handle Bar Mount Spacer). The spacers are used on top of the upper clamp. Installation Notes • Be sure to use the correct fork extension. Yellow 2002 and newer (non adjustable air pressure). Black for 2001 and older (adjustable air pressure). Be sure to double check the fork cap (Fork Tube Plug) being removed. • Reinstall the OEM O-rings on Item #7 (Fork Extensions) prior to installing in the fork tubes. • On some of the Road King models with chrome headlight Nacelle, Item #9 must be mounted underneath upper clamp Item #2 to ensure enough room for air fittings. • Be sure to replace fork covers in proper order, during installation of the fork tubes. • Thoroughly clean sides of steering neck and install self adhering rubber stops where steering stop screws contact frame. • Secure wires and cables clear of steering stop bolts. • Do not torque Item # 1 (½-20 x 1-1/4″ Hex Head Bolt) until fork tubes have been installed to assembly. • Note the torque specification for the items listed in the table below.

2009 Harley-Davidson FLH Series Independent Suspension Trike Conversion Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Important Safety Precautions a. Make sure you have a clear understanding of all basic shop safety practices and that you wear appropriate clothing and use safety equipment. Be especially careful of the following: · Read all directions before you begin, and make sure you have the tools, the parts and the skills required to perform the tasks safely and completely.Harley-Davidson® FLH 2009 & Up Independent Suspension CHAMPION TRIKES Installation Guide Page 5 of 18 Revision 8 · Protect your eyes by using proper safety glasses, goggles or face shields anytime you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. · Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. · Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported. b. Make sure the engine is turned off and battery disconnected before you begin work. · Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine. · Burns from hot parts: Let the engine and exhaust system cool before working on those areas. · Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts. c. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries. d. Use only nonflammable solvent, not gasoline, to clean parts. e. Never drain or store gasoline in an open container. f. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts. 1.6 Specifications Overall Length: 103″ Overall Width: 57.25″ Wheel Base: 53″ Max Load Capacity: 600 Lb Max Tire Size (15″): 205 / 70 / R15 Wheel Size (15″) (4 lug) Offset +35 mm 15x7JJ 4 on 4.5 Tire Pressure: 24-26 PSI Suspension: Double A-arm Independent Rear Differential: Custom-built rear differential utilizing OEM drive belt. Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 5.75 cubic feet. Two full-face helmets and additional storage. *Champion does not change certain components that will affect EPA, CARB, or any laws that will change the emission characteristics of the motorcycle.

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HARLEY DAVIDSON FLH AND FLT TRAILER HITCH OR RACK LIGHTING WIRE HARNESS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Remove the seat and locate the tail light plug, this should be attached to the frame with a plastic clip where the fender meets the frame cross member. Unplug the connector and plug in the male and female ends of the supplied wire harness. Route the harness as shown following the other wire looms and then down along the main frame of the trailer hitch or your fender support to the bottom of the rear fender. Secure the harness using the supplied cable ties. Install a plug that matches that of your trailer. The wires in the harness functions/colors are as follows: Black = Ground Brown = Tail Light Red = Brake Light Orange = Left Turn signal Blue = Right Turn signal NOTE: If your trailer has only four (4) wires you will need to use a 5 to 4 wire converter. These are available at most auto parts stores or thru RIVCO Products. NOTE: If your trailer uses more than two (2) incandescent tail light bulbs the use of a trailer wiring isolator is strongly advised as this additional load is too much for the motorcycles wiring to support and may cause damage to the electrical system. Trailer wiring isolators are available although not as common in auto parts stores and are also available thru RIVCO Products. If you are installing both you must first install the 5 to 4 wire converter then the isolator then to the trailer plug.

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