HARLEY DAVIDSON RIGID MOUNT SIDEPLATE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION (2000 THROUGH 2002) Refer to the instructions included with kit 53388-03 for installation on 2000 through 2002 models. INSTALLATION (2003 AND LATER) NOTE To keep the fender aligned, completely install the sideplate on one side of the motorcycle before proceeding to the second side. The sissy bar should be installed last. 1. For models equipped with saddlebags: a. Remove the saddlebag, and retain the mounting hardware for later reinstallation. b. See Figure 1. Remove the bolt (A) and washer (4) that secures the rear fender to the fender brace. Discard the bolt and washer. Remove and retain the two saddlebag mounting studs (C) and nut plate (D) for later use. For models NOT equipped with saddlebags: a. See Figure 1. Remove the two rearmost bolts (A), washers (4) and nut plate that secure the rear fender to the fender brace. Discard the bolts and washers. b. Remove the bolt (B) and washer (4) that secure the fender and brace to the frame. Discard the bolt and washer. 2. See Figure 1. Position the correct sideplate to the outside of the fender brace. 3. With saddlebags: Apply LOCTITE 243 (blue) to the 3/8- 16 threads of the saddlebag mounting studs (C) and reinstall the studs through the sideplate, fender brace, frame and fender, and thread into the stock nut plates (D). Install one chrome 3/8-16 screw (3) and chrome washer (4) from the kit through the rear hole in the sideplate, fender brace and fender, and thread into the stock nut plate (D). Without saddlebags: Install three chrome 3/8-16 screws (3) and chrome washers (4) from the kit through the holes in the side plate, fender brace and fender, and thread into the stock nut plates (D). 4. Repeat steps 1-3 for the opposite side. 5. Install a sissy bar (not included in the kit) into the side- plates. Apply LOCTITE 262 (red) to the threads of the chrome 1/4-20 capscrews (5) and insert them into the sideplate holes. Tighten to 8-10 ft-lbs (11-14 Nm) . 6. Tighten the bolts (3) and/or saddlebag mounting studs to 21-27 ft-lbs (28.5-36.6 Nm) . 7. Reinstall the saddlebags

HARLEY DAVIDSON THROWOVER SADDLEBAGS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Installation 1. Place the saddlebags on the vehicle so the straps are positioned over the top of the passenger seat. 2. Lace saddlebags together. 3. Adjust the leather straps so the saddlebags ride high and fit snugly and evenly against the side of the seat. Top of saddlebags may be replaced to achieve snug fit. NOTE On some models, the rear turn signal lights may interfere with mounting of saddlebags. To correct this, a new directional set-back kit is available under part number 90504-82. This kit allows the rear signal lights to be mounted in the rear positions on the fender support, on 1982 and later FXR and XL models. Contact your Harley- Davidson Dealer to obtain this kit. If rear turn signal lights interfere with saddlebags, see your Harley-Davidson Dealer for a turn signal set-back kit. Proper turn signal operation and visibility is a major concern for motorcyclists. Failure to have visible, operational rear turn signals may result in death or serious injury. 4. The front securing straps must be fastened to a point on the motorcycle which is forward of the saddlebags, such as the upper shock mount or fender brace. Be certain the straps so not interfere with any moving parts. Improper positioning or fastening of these saddlebags could cause them to interfere with the operation of the vehicle, possibly causing a hazardous condition. The fastening straps and the saddlebags must be clear of the rear wheel, drive chain or belt, sprocket and rear brake components. Location of the saddlebags should not interfere with the operation of the swingarm and rear shocks and the turn signals should remain clearly visible from the rear and side of the vehicle. Improperly positioned or fastened saddlebags could interfere with the operation of the motorcycle, which could result in death or serious injury. 5. The rear securing straps must be fastened to a point which is rearward of the saddlebags such as the rear turn signal light support. 6. Check that saddlebags are mounted with ample clearance between the bags and the brake caliper and disc so they do not contact each other, even when the swingarm deflects under full load. 7. Once both saddlebags are mounted correctly, check all securing straps to be certain they are not interfering with or exposed to any moving parts. Tuck the tails of the leather straps underneath the portion of the straps that connect the two saddlebags. NOTE On some motorcycles, it will be necessary to mount the saddlebags over the outside surface of the rear shock. This is acceptable if all CAUTIONS and WARNINGS are observed

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Honda GL1100/ 1200 Saddlebag Bent Rails Installation Manual

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Filed Under (Honda) by admin on 28-02-2011

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Read instruction thoroughly before installing. DRILLING REQUIRED. 1. Place bike on center stand. 2. Place masking tape on feet of rail to prevent scratches on the saddlebags. Position saddlebag rails on saddlebag to mark for drilling. 3. When positioning the rail, carefully move the rail back and forth until proper alignment is achieved and there is no interference with the saddlebag latch. 4. Mark position for drilling holes on a piece of masking tape placed on the saddlebag under each leg. 5. Drill a 6mm hole. 6. Remove tape from rail and clean the saddlebag if necessary. 7. Attach the rail with the hardware included from the inside of the saddlebag lid. 8. Repeat on other side.

HARLEY DAVIDSON REAR BRAKE CALIPER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION Prepare the Motorcycle for Service To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Follow the Service Manual instructions to disconnect the negative (-) battery cable. Remove Rear Brake Caliper Remove the Brake Pads 1. For models equipped with saddlebags: Remove the right-side saddlebag. Refer to the SADDLEBAGS section of the Service Manual. 2. Remove the rear master cylinder reservoir cover. 3. Pry both the inside and outside pads away from the brake disc and toward the caliper assembly to push the caliper pistons back into their bores. Use steady pressure to prevent scoring the brake disc. Pry between the pads and the brake disc. 4. When the pistons are fully retracted into their bores, pull the pad pins out to allow the pads to drop from the caliper assembly. Note the pads’ original orientation for installa- tion. 5. Install the cover on the rear master cylinder reservoir. NOTE Place a container under the brake caliper to catch brake fluid released when removing the brake line from the caliper. 6. Remove the banjo bolt fastening the rear brake line to the stock rear brake caliper. Save the banjo bolt for brake caliper installation and discard the two steel/rubber gas- kets. Remove the Stock Rear Brake Caliper 1. Apply isopropyl alcohol to the rubber bumper on the brake caliper to ease removal. 2. Lift the stock rear brake caliper toward the front of the motorcycle. The notch in the caliper must clear the weldment on the swing arm. 3. Remove the caliper from anchor weldment on rear swingarm. Inspect Pad and Pins 1. Inspect the brake pads. If friction material above the backing plate on either pad is 0.040 in. (1.02 mm) thick or less, replace the set. Follow the instructions in the Service Manual. 2. Inspect pad pins for wear and grooving. If wear is more than 0.015 in. (0.38 mm), replace both pins. 3. Inspect the brake disc and, if necessary, follow the instructions in the Service Manual to replace the brake disc. Install the Rear Brake Caliper NOTE Pay close attention to all warnings, cautions, and torque specifications in this instruction sheet and in the service manual when installing this rear brake caliper. NOTE Apply isopropyl alcohol to the rubber bumper for ease of installation. 1. See Figure 1. Position the caliper (1) between the brake disc and the rear fork. The weldment on the fork should fit between the notch and rubber bumper on the caliper. Verify that the full length of the rubber bumper contacts the underside of the weldment

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HARLEY DAVIDSON SIGNATURE SERIES SOLO SEAT KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL NOTE Refer to owner’s manual or service manual for seat removal instructions for your model. 1. Remove right and left saddlebags according to the instructions in the service manual. Save saddlebag mounting brackets and hardware. 2. Remove passenger seat strap. Discard passenger seat strap. 3. Remove existing seat from vehicle. 4. See Figure 1. Remove and discard stock nuts (2) from studs (1) on rear fender (3). INSTALLATION Install Rider Seat 1. Push front seat on frame with mounting bracket at rear. 2. Firmly push front of seat downward and rearward until frame tongue engages slot in seat. 3. Push seat forward until studs are centered in slots of mounting bracket. 4. See Figure 4. Install two nuts (4) on studs to secure rear seat mounting bracket to rear fender. Alternately tighten nuts to 60-96 in-lbs (6.8-10.9 Nm). 5. If installing a new passenger seat, refer to the instructions included with the kit. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 6. If installing passenger seat, install passenger seat strap following the instructions in the service manual. 7. Install right and left side saddlebags following the instructions in the service manual. 1 2 3 2 1 is04121 1. Stud (2) 2. Nut (2) 3. Rear fender Figure 1. Rear Fender Install Rider Backrest NOTE Flaps shown removed for clarity of illustration. 1. See Figure 2. Turn backrest assembly (1) at a 45 degree angle clockwise to the seat. Slide the backrest shaft (2) through the flaps and into the receptacle in the seat. 2. While pushing down on the backrest assembly, twist the backrest counterclockwise until the shaft hits the stop. 3. Verify that the backrest assembly is locked in place by pulling up in the backrest pad

HARLEY DAVIDSON HERITAGE REAR FENDER RAIL DISASSEMBLY AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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DISASSEMBLY NOTE See Figure 1. Saddlebags must be removed to insert spacer (1). 1. Using a small flat head screw driver, remove rear fender tip light lens cover (A) by gently prying cover away from assembly. (There is a notch at top of cover to ease removal.) Remove and retain cover (A) and gasket (C). 2. Remove fender tip light assembly (B) by removing two screws, four star washers, and two nuts (not shown) using a #2 Phillips screw driver and a 3/8 inch wrench. Retain all hardware for reassembly. 3. Remove hole plugs from rearmost fender strut holes on both sides of fender. 4. Mark fender on both sides of bike using rear most fender strut hole as a template. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) 5. Carefully remove fender strut and drill a 11/32 inch hole through each side of fender in locations marked in Step 4. 6. Loosely reinstall fender strut (D), allowing enough room to slip spacer (1) between fender (E) and strut. INSTALLATION 1. Align rear fender rail (2) from kit with rearmost fender strut (D) mounting holes, making sure lower mounting tab (3) is inside fender (E). Place large chrome washer (4) from kit next to head of button head socket bolts (5) from kit. Insert bolt through fender rail (2), fender strut (D), spacer (1) and fender (E), in that order. Install large unfinished washer (6) from kit onto end of bolt (5). Secure assembly into place by threading locknuts (7) from kit onto ends of bolts (5) from inside of fender (E). Tighten loosely at this time. 2. Install truss head screw (8) from kit through fender (E) and rear fender rail mounting tab (3). Secure into place using small washer (9) and locknut (10) from kit. Use #2 Phillips screwdriver and a 3/8 inch wrench to tighten rear mounting assembly securely. 3. Tighten fender strut bolts (5) to 21-27 ft-lbs.(28-37 Nm) 4. Reinstall fender tip light assembly (B), gasket (C) and lens (A) using original hardware (not shown)

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Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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Honda Goldwing GL1800 Independent Rear Suspension Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm . 5.1 Explanation of OEM brake system and changes From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Trike Conversion Kit.

HARLEY DAVIDSON SADDLEBAG LID COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION NOTE To avoid failure, the fastening tab adhesive must be allowed to cure for 24 hours before installing these Lid Covers. NOTE Lid Cover installation may be easier with the saddlebags removed from the motorcycle. 1. See Figure 1. Open the saddlebag lid. Remove the two T-20 TORX® screws (5) attaching the check strap (3) to the lid. 2 4 2 3 1 6 7 4 4 6 5 is02962 1. Saddlebag lid cover 2. Hook and loop fastener, 1.5 inch 3. Check strap 4. Hook and loop fastener, 4.0 inch 5. Torx screws (2) 6. Hook and loop fastener, 6.0 inch 7. Anchor tab (install first) Figure 1. Saddlebag Lid Cover Installation 2. Wash the entire saddlebag lid, inside and out, with warm, soapy water. Rinse and dry thoroughly. 3. Use the alcohol prep pad provided in the kit to further clean the inside of the lid in the areas where the hook and loop strips will be attached. NOTE The Saddlebag Lid Covers are side-specific. A Bar-and-Shield logo is stitched into the rear face of each cover. NOTE DO NOT fasten the Saddlebag Lid Cover tabs to the hook and loop strips until the adhesive has cured for 24 hours. 4. Place the correct Saddlebag Lid Cover (1) over the saddlebag lid in its proper position. Bring the cover tabs over the edge of the lid to serve as a guide in positioning the hook and loop strips on the inside of the lid. Remove the protective backing from one hook and loop strip at a time. Use the corresponding tab on the cover only as a positioning guide, then fold it back out of the

HARLEY DAVIDSON SADDLEBAG GUARD RAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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Installation NOTE A Service Manual for your vehicle is available from your Harley-Davidson Dealer. 1. Remove saddlebags from motorcycle according to Service Manual instructions. 2. Remove left and right side covers (located just ahead of saddlebags) by removing Phillips head screw from bottom of side cover. Save hardware and side covers for later reassembly. 3. Remove upper and lower bolts securing left and right forward saddlebag guards to frame. Remove Phillips head screws securing saddlebag guards to muffler supports. Discard saddlebag guards, but save hardware. 4. See Figure 1. Install new left and right forward saddlebag guards (1) with upper bolts (2), lower bolts (3) and Phillips head screw (4) saved from Step 3. 5. Insert one rear guard rail mount (6) onto rounded, tubular end of one of the saddlebag side guard rails (5). 6. Insert a hex cap screw (8) through one of the front guard rail mounts (7) as shown. 7. Line up saddlebag side guard rail (5) with attached rear guard rail mount (6) from Step 5 with lower hole in forward saddlebag guard rail (1). Insert hex cap screw (8) from front guard rail mount (7) through hole in forward guard rail (1) and into side guard rail assembly. Tighten finger tight. 8. See Figure 2. Install a side guard rail (2) in lower position on rear fender support (3) with pan head screw (1). Tighten finger tight. 9. Repeat Steps 5 through 8 in upper position. 10. Repeat Steps 5 through 9 for opposite side of vehicle. NOTE Each of the four guard rail clamps vary slightly. Two fit together for the right side of the motorcycle and two fit together for the left side. The inner right and left clamps have two holes drilled through them. 11. See Figure 2. Locate four guard rail clamps (4). Match up two left side and two right side guard rail clamps. Install one piece of cushion tape to the lower inner surface of right and left inner clamps. Peel off paper from outer surface of tape. Do not apply tape to the outside clamps. NOTE Be sure that you correctly position the inner clamps on the side guard rails, as directed in Step 12, before tape on inner clamp contacts side guard rails. Tape is very sticky and will be difficult or impossible to remove once it has made contact with side guard rail surface. 12. See Figure 2. Position clamps (4) in desired position on side guard rails (2). Install clamps (4) on left and right side of vehicle side guard rails using four Torx screws (5). Torx screw heads should face inward toward motorcycle. Tighten each screw a little at a time until secure. 13. Tighten hex cap screws and pan head screws installed in Steps 7 and 8.

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