Harley Davidson Softail (FLST Only) Motorcycle

Transcription

HARLEY DAVIDSON SOFTAIL® FLST
TRIKE CONVERSION
CHAMPION TRIKES
Trike Conversion Installation Guide
for
Harley Davidson
Softail® (FLST Only) Motorcycle
1987 to Current
Revision 8
Champion Motorcycle Accessories International, Inc.
dba Champion Sidecars
11841 Monarch Street, CA 92841
(800) 875-0949 (714) 847-0949 Fax (714) 847-1539
www.championtrikes.com
CAUTION : Failure to follow these instructions can lead to serious personal injury and/or
property damage and may void the warranty.
®
Installation Guide – HD Softail FLST
Page 1 of 23
Revision 8
Tech Illustrations / Photography by Terry T. Emelio
TRIKE CONVERSION
CHAMPION TRIKES
Trike Conversion Kit for Harley Davidson Softail® FLST Motorcycles
Parts Illustration*
2
1
4
3
6
5
7
13
8
9
10
11
12
14
1987 -2006 model shown
Item #
Description
Item #
Description
1
Shock Mount Frame (1)
8
Rear Axle Assembly (1)
2
Body Frame Hanger (2)
9
Coil Over Shock Absorber (2)
3
Swing Arm Assembly (1)
10
Exhaust Extension (LHS)
4
Back Rest Mount (2)
11
Champion Exhaust Clamp (2)
5
Axle Adjuster LHS & RHS (2)
12
Muffler (2)
6
Brake Line Kit
13
Body Frame (1)
7
Exhaust Extension (RHS)
14
Trailer Hitch Receiver (1)
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TRIKE CONVERSION
CHAMPION TRIKES
Table of Contents
1
General Information............................................................................................................................................ 4
1.1 Installation Information ................................................................................................................................. 4
1.1.1
“Lowered Bikes” ................................................................................................................................... 4
1.2 For Your Safety............................................................................................................................................. 4
1.3 Important Safety Precautions ....................................................................................................................... 4
1.4 Specifications................................................................................................................................................ 5
2 Removal of Original Parts .................................................................................................................................. 6
3 INSTALLING TRIKE CONVERSION KIT........................................................................................................... 7
3.1 Sprockets and Drive Belts Specifications..................................................................................................... 7
3.2 Install Swing Arm .......................................................................................................................................... 7
3.2.1
1987-99 Model Years........................................................................................................................... 7
3.2.2
2000-2007 Model Years....................................................................................................................... 8
3.2.3
2008 Up Model Years .......................................................................................................................... 8
3.2.4
All Models ............................................................................................................................................ 8
3.3 Installing Drive Pulley ................................................................................................................................... 9
3.3.1
Aluminum Rear End Assembly ............................................................................................................ 9
3.4 Installing Aluminum Rear End Assembly to Swing Arm ............................................................................. 10
3.5 Installing Drive Pulley (“Bull-Horn” Style Rear End Assembly) .................................................................. 12
3.5.1
Install Right Axle Housing Assembly to Swing Arm (“Bull-Horn” Style Rear End Assembly)............ 13
3.5.2
Install Left Axle Housing Assembly (“Bull-Horn” Style Rear End Assembly)..................................... 13
3.6 Install Brake Lines ...................................................................................................................................... 15
3.7 Install Shock Mount to Vehicle Frame ........................................................................................................ 15
3.8 Install Body Frame Hangers ....................................................................................................................... 16
3.9 Install Body Frame to Vehicle..................................................................................................................... 16
3.10
Install Shock Absorbers ......................................................................................................................... 16
3.11
Aligning and Tensioning Rear Drive Pulley............................................................................................ 17
3.12
Install Trailer Hitch Receiver (Optional) ................................................................................................. 17
3.13
Install Exhaust Extensions ..................................................................................................................... 18
3.13.1 2006 Down......................................................................................................................................... 18
3.13.2 2007 Up.............................................................................................................................................. 18
3.14
Install Mufflers ........................................................................................................................................ 18
3.14.1 2006 Down......................................................................................................................................... 18
3.14.2 2007 and Up ...................................................................................................................................... 19
3.15
Final Check of Drive Belt Tension.......................................................................................................... 20
3.16
Install Left and Right Back Rest Mounts ................................................................................................ 20
3.17
Install Trike Body to vehicle ................................................................................................................... 20
3.18
Install Wheels ......................................................................................................................................... 20
3.19
Install Seat & Back Rest......................................................................................................................... 21
3.19.1 2007 and Up ...................................................................................................................................... 21
4 PARTS LISTS................................................................................................................................................... 22
4.1 Assembly Kits ............................................................................................................................................. 22
4.2 Hardware Kits ............................................................................................................................................. 23
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TRIKE CONVERSION
1
CHAMPION TRIKES
General Information
The Champion Sidecars Trike Conversion Kit is designed with the utmost consideration for safety, quality and
ease of installation. The kit comes complete with all necessary hardware and fasteners. However, it is assumed
that the installer has advanced/professional skills in motorcycle servicing. It is recommended that installer obtain
an OEM service manual for the vehicle on which the Trike kit is to be installed.
1.1
Installation Information
The information contained in this Installation Guide is intended for use by technicians of advanced to professional
skill levels. Attempting installation without the proper training, tools and equipment could cause injury to you or
others. It could also damage the vehicle or cause an unsafe condition.
1.1.1
“Lowered Bikes”
CAUTION: Champion's Softail® trike kits are designed for installation on motorcycles that have not been
"lowered." If the kit is installed on a lowered bike, the rear wheels are likely to rub on the underside of the
trike body.
Champion’s Softail® kit reuses the two OEM "internal" (horizontal) shock absorbers and adds two coil-over
helper shocks. The seat-height of a lowered Softail® bike will be less than the normal 25-26 inches.
In some cases a "lowering kit," has been installed, in which the kit hardware pre-loads (by compressing) the
OEM shocks. This kit hardware will have to be removed in order to properly install the Champion kit.
In other cases, the bike may come from the factory already lowered (example: the Softail® Deluxe) using
shocks that are about 1.5 inches shorter than the "standard" shocks. A set of standard-length shocks will
have to be purchased in order for proper installation of the Champion kit.
1.2
For Your Safety
Because this guide in intended for technicians of advanced to professional skill levels, we do not provide warnings
about many basic shop safety practices. If you have not received shop safety training or do not feel confident
about your knowledge of safety practices, we recommend that you do not attempt to perform the procedures
described in this guide.
Some of the most important general safety precautions are given below. Champion Sidecars cannot warn you of
every conceivable hazard that can arise. Only you can decide whether or not you should perform a given task.
1.3
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.
•
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.
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TRIKE CONVERSION
•
CHAMPION TRIKES
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 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.
1.4
Specifications
Overall Length:
66”
Body Length:
92”
Wheel Base:
53”
Load Capacity:
620 Lb
Tire Size (15”):
205 / 70 / R15
Wheel Size (15”) (4 lug)
Offset +35 mm 15x7JJ 4x4.5 – (Current Installations – Alum Rear End)
Offset +35 mm 15x7JJ 5x4.5 – (Later Installations – Black Rear End)
Tire Size (16”)
215 / 60 / R16
Offset +40 mm 16x7JJ 5x4.5 – (First Installations – Black Rear End)
Tire Pressure:
20 PSI
Suspension:
Internal Swing Arm utilizing OEM shocks
Rear Differential:
Custom-built rear differential utilizing OEM drive belt.
Brakes:
Original front plus 2 high performance disc brakes at rear.
Storage Capacity:
3.75 cubic feet. 2 full-face helmets and additional storage.
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TRIKE CONVERSION
2
CHAMPION TRIKES
Removal of Original Parts
Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift.
Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted.
•
Seat (to be re-installed without modification).
•
Left and right saddle bags (if so equipped).
•
Left and right rear crash bars, saddlebag rails (if so equipped).
•
Left and right passenger foot rests (to be re-installed without modification)
•
Complete exhaust system (to be replaced with new system).
•
Rear wheel
NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor
board). This will prevent fluid flow when rear brake caliper is removed
•
Remove Rear Caliper (disconnect brake line at caliper)
NOTE: Cap line to prevent introduction of dust / debris into line. Remove caliper.
•
Rear Drive Pulley (1987-99 models to be re-installed without modification).
•
Rear Fender (2000 and newer models, fender mount plates to be reused).
•
Swing Arm
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TRIKE CONVERSION
CHAMPION TRIKES
INSTALLING TRIKE CONVERSION KIT
3
3.1
Sprockets and Drive Belts Specifications
See following table for belt installation (1987-99 will use a 4 tooth
longer belt)
Cross Assembly
Note: See OEM manual for belt replacement procedure.
1987-92
Drive
Sprocket
70 T
OEM
Belt
132 T
New Belt /
Sprocket
136
1993-94
61 T
128 T
132
1995-99
65 T
Champion
Sprocket, 70 T
Champion
Sprocket, 66 T
130 T
136/70T OEM
135 T
Use OEM
Year
2000-06
2007
Up
Use OEM
Figure 1
3.2
Install Swing Arm
Noting size and location of bolts, remove Cross Assembly
from Champion Swing Arm. Do not discard hardware.
Figure 1
3.2.1
•
OEM Spacer Tube
1987-99 Model Years
Remove bearings from OEM Swing Arm using OEM shop
tools and hydraulic press.
Note: Although original bearings can be re-used, it is
HIGHLY recommended that NEW bearings be installed to
Champion Swing Arm
Supplied Washers (1 per
Supplied Washers (1 per
OEM Washer (1 per
Figure 2
a. Press bearings into Champion Swing Arm in the same way as
the OEM Swing Arm.
b. Using OEM Spacer Tube and supplied washers (four ¾” flat
washers), install Champion Swing Arm using OEM bolt,
outside washers and nut. Do not torque pivot bolt nut at this
time. Figure 2
Note: Insure belt path is over and under Swing Arm pivot.
c. Replace cross assembly and hardware (previously removed
in step 3.2) to Champion Swing Arm. Note that the 2 upper
left hand side bolts are countersunk.
d. Torque pivot bolt to OEM specification.
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TRIKE CONVERSION
3.2.2
CHAMPION TRIKES
2000-2007 Model Years
a. Remove OEM bearings from OEM Swing Arm using OEM
shop tools and hydraulic press.
Note: Although original bearings can be re-used, it is
HIGHLY recommended that NEW bearings be installed to
Champion Swing Arm
OEM Spacer (1 per side)
OEM Washer (1 per
b. Press bearings into Champion Swing Arm with C-clip to
outside of Swing Arm.
OEM Washer (1 per
c. Install Champion Swing Arm using OEM bolt, spacers and
nut. Do not torque pivot bolt nut at this time. Figure 3
Figure 3
Note: Insure belt path is over and under Swing Arm pivot
e. Replace cross assembly and hardware (previously removed
3.2.3
RH
LHS
2008 Up Model Years
a. Remove OEM bearings from OEM Swing Arm using OEM
shop tools and hydraulic press.
b. Press bearings into Champion Swing Arm with C-clip to
outside of Swing Arm.
c. Install Champion Swing Arm using OEM bolt and supplied
spacers. Install right hand side as per OEM (as removed).
Install left hand side as shown using supplied spacers.
Figure 4
Champion Spacer
Install as per OEM
Champion Sleeve
Champion Spacer
OEM Washer
Figure 4
(Front View)
e. Replace cross assembly and hardware (previously removed
3.2.4
•
All Models
Install OEM shock absorbers to Champion Swing Arm using
OEM hardware. Figure 17
Figure 5
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CHAMPION TRIKES
Connector tube
3.3
3.3.1
Installing Drive Pulley
Aluminum Rear End Assembly
CAUTION: Do not use air driven impact tools to assemble
the Champion Aluminum Rear End Assembly.
a. Remove the three ¾” bolts securing the left half of the rear
end assembly to the connector tubes. Figure 6
b. Separate the two halves of the rear end assembly, leaving
the differential on the right half. Figure 6
Figure 6
c. Install pulley to differential using the supplied hardware and
red Loctite. Figure 7
d. Torque bolts to 55 ft. lbs.
Figure 7
e. Install carrier bearing to differential. Ensure bearing is
properly and fully seated on the differential. Figure 8
f. Reunite the left and right halves of the differential assembly.
Ensure proper engagement of the axle into the differential
and that the carrier bearing is true in the bearing flange of the
left axle assembly. Figure 9
Figure 8
g. Re-install the three ¾” bolts, flat washers and split washers.
Snug but do not tighten hardware as adjustments will be
made later. Figure 9
Figure 9
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TRIKE CONVERSION
3.4
CHAMPION TRIKES
Installing Aluminum Rear End Assembly to
Swing Arm
a. Install the supplied M10 Adjuster Bolts and Jam Nuts to
Adjuster Plates (one bolt and nut per plate). Figure 10
Figure 10
b. Install adjuster plates to the rear end assembly using the
supplied hardware. Install plates to the rear end with the
adjuster bolt to the outboard side. Snug but do not tighten
hardware as adjustments will be made later. Figure 11
Qty per
side
4
4
4
Adjuster bolt to
outboard side
Description
3/8”-24 x 2-1/2”L socket head cap
screw (no washer on head)
3/8”SAE flat washers
3/8”-24 NyLoc nuts
Figure 11
(view of left side from rear)
c. Passing the left end through the drive belt, install the rear end
assembly (with adjuster plates) to the swing arm using the
supplied hardware. Snug but do not tighten hardware as
adjustments will be made later. Figure 12 & Figure 13
Qty per
side
4
8
4
Description
3/8”-24 x 1-1/2” hex head bolt
3/8” flat washers
Figure 12
Figure 13
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d. Remove the upper and lower rear connector tubes and
position drive belt onto the rear pulley. Figure 14
Figure 14
e. Reinstall the upper and lower rear connector tubes. Apply 2-3
drops of oil to the connector tube bolts, install and torque to
150 lb. ft. Figure 15
Figure 15
f. Remove the lower front connector tube bolts, apply 2-3 drops
of oil to the bolts, re-install and torque to 150 lb. ft. Figure 16
Figure 16
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TRIKE CONVERSION
3.5
CHAMPION TRIKES
Installing Drive Pulley (“Bull-Horn” Style Rear
End Assembly)
Note: 1999 and older models use the stock pulley from
motorcycle Follow the instructions below to install the pulley.
Note: 2000 and newer model kits are shipped with the drive
pulley preinstalled.
It is only necessary to loosen the two ¾” bolts - Figure 3.4 and rotate the “horns” to slip the drive belt in. Replace the
two ¾” bolts and install the complete Rear End to the swing
arm using the instructions below for the attachment of the
Rear End to the adjustment plates.
Figure 17
a. Remove the two 3/4” x 1 1/2” L Socket head cap screws (5/8”
Allen wrench) from the Bullhorns connecting the left side of
the Axle Housing to the right. Figure 17
b. Separate the left side Axle Housing from the right, leaving the
Differential attached to the right side assembly. Figure 18
Figure 18
c. Install rear drive pulley to CS Rear Differential using supplied
hardware. Apply blue Loctite No. 242 to bolts. Figure 19
Note: Use only the Champion-supplied hardware when installing
drive pulley to Differential.
Qty
5
5
Description
7/16”-14 x 1.1/4” L hex bolts
7/16” flat washers.
d. Torque bolts to 55 ft. lbs.
Figure 19
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3.5.1 Install Right Axle Housing Assembly to Swing Arm
(“Bull-Horn” Style Rear End Assembly)
a. Install M10 Adjuster Bolt and Jam Nut to Adjuster Plate.
Figure 20
b. Install one Axle Adjuster to right side mounting plate of Swing
Arm using supplied hardware. Loosely tighten hardware, as
adjustments will be made later. Figure 20
Qty
4
8
4
Description
3/8”-24 x 1 1/2” L hex bolts
3/8” SAE flat washers
3/8” NyLoc nuts
Adjuster Bolt
&
Jam Nut
Figure 20
c. Install right Axle Housing (with drive pulley installed to
Differential) to the Axle Adjuster mounted to the Swing Arm.
Figure 21
d. Install supplied hardware to the Pinch Block. Loosely tighten
hardware, as adjustments will be made later. Figure 21
Qty
3
1
7
4
Description
3/8”-24 x 2-3/4”L hex bolts
Figure 21
Note: Install bolts to Pinch Block from inside pointing outward
e. Place drive belt around rear pulley. Figure 21
3.5.2 Install Left Axle Housing Assembly (“Bull-Horn”
Style Rear End Assembly)
a. Install 10 mm Adjuster Bolt and Jam Nut to Adjuster Plate.
Head of bolt must be facing backwards
b. Install Axle Adjuster to left Axle Housing Pinch Block with
supplied hardware. Loosely tighten hardware, as adjustments
will be made later. Figure 22
Qty
3
1
7
4
Description
3/8”-24 x 2-3/4”L hex bolts
Figure 22
Note: Install bolts to Pinch Block from inside pointing outward
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CHAMPION TRIKES
c. Install left Axle Housing to right axle housing. Ensure proper
engagement of axle and Differential spline. Figure 23
Figure 23
d. Install Axle Adjuster to Swing Arm using the supplied
hardware listed. Loosely tighten hardware, as adjustments
will be made later. Figure 24
Qty
4
8
4
Description
3/8”-24 x 1 1/2” L hex bolts
3/8” flat washers
3/8”-24 NyLoc
Figure 24
e. Install the two 3/4” x 1 1/2” L Allen socket bolts with lock
washers to the Bullhorns, connecting the left side of the Axle
Housing to the right. Coat bolts with Loctite ANTI-SEIZE prior
to installation. Torque to 65 ft. lbs. Figure 25
Figure 25
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TRIKE CONVERSION
3.6
CHAMPION TRIKES
Install Brake Lines
a. Connect OEM brake line to tee fitting using supplied banjo
bolt and crush washers. Figure 26
b. Install braided brake lines to brake tee-block on Champion
Swing Arm. Connect non-swivel end of line to brake tee.
Figure 26
Figure 26
c. Routing line over the Swing Arm, connect swivel end of
braided brake lines to brake calipers. Figure 27
d. Secure brake lines to Swing Arm with supplied zip-ties.
e. Ensure T-Block is secure and nut is tight.
Figure 27
3.7
Install Shock Mount to Vehicle Frame
a. Install Shock Mount to vehicle frame using the supplied
hardware. Figure 28
Qty
4
8
4
Description
3/8”-16 x 1 1/2” L hex bolts
3/8” flat washers
3/8”-16 NyLoc
Note: For newer models with ½” holes in frame for fender
mounting, use threaded inserts from OEM fender instead of
Nyloc Nuts and washers. Install bolts with red Loctite.
Figure 28
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TRIKE CONVERSION
3.8
CHAMPION TRIKES
Install Body Frame Hangers
a. Install Body Frame Hangers (left & right) to Shock Mount
using the supplied hardware. Figure 29
Qty
4
8
8
4
3.9
Description
Four 3/8"-24 x 1 1/2" hex bolts
3/8” star lock washers
5/16" USS flat washers
3/8"-24 NyLoc nuts
Install Body Frame to Vehicle
Figure 29
a. Install Body Frame to vehicle frame and frame hangers using
the supplied hardware. Figure 30
To vehicle frame:
Qty
4
4
4
4
Description
3/8"-16 x 1 3/4" hex bolts (2007 Up)
3/8"-16 x 1 1/4" hex bolts (2006
Down)
3/8” flat washers
To hanger plates:
Qty
4
8
8
4
Description
Four 3/8"-24 x 1 1/2" hex bolts
5/16" USS flat washers
3/8"-24 NyLoc nuts
Figure 30
3.10 Install Shock Absorbers
a. Install supplied coil over shock absorbers using the supplied
hardware: Figure 31
Qty
4
8
4
8
Description
1/2"-20 x 2 ¾” Hex Head Bolt Gr8
1/2" Flat Washer
1/2"-20 NyLoc Nut
Hiem Spacers
Figure 31
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CHAMPION TRIKES
3.11 Aligning and Tensioning Rear Drive Pulley
a. Square Axle Adjusters with Swing Arm mount plates and
tighten hardware.
b. Set belt tension by moving axle assembly forward or rearward
with adjuster bolts as necessary. Total belt movement to be
about 1-1/2”. Figure 32
Note: Consult OEM manual for belt tension specification.
c. When proper tension has been achieved, lock Adjuster Bolt
with jam nuts
d. Tighten Pinch Block hardware.
e. Measure distance between forward face of Pinch Block and
plate of Axle Adjuster. Ensure left and right sides of Axle
Housing are equal distant.
Figure 32
Note: Belt tension should be checked prior to final
assembly (mounting body) of trike kit. Check with vehicle
secure, on jack stands, engine running and transmission
in gear. Note position and tension of belt while running.
Stop engine and adjust accordingly.
3.12 Install Trailer Hitch Receiver (Optional)
a. Install hitch receiver to Trike Body Frame with supplied
hardware. Figure 33
Qty
8
8
Description
5/16"-18 x 1 hex bolts
5/16” SAE flat washers.
b. Electrical connectors not supplied. Mounting tab for connector
socket is located on hitch receiver.
Figure 33
c. Color code for wiring as follows: (Confirm by testing)
Old Harness
Running lights
Brake lights
Turn signal, right
Turn signal, left
Accessory
Ground
Confirm by testing
RED
GREEN
YELLOW
BLUE
Confirm by testing
(White or Black)
®
New Universal
Harness
(From Mid 2007)
BROWN
RED
GREEN
YELLOW
BLUE
BLACK
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CHAMPION TRIKES
Right Exhaust
Vehicl
e
3.13 Install Exhaust Extensions
3.13.1 2007 Down
a. Sampson Headers are required for your Champion Sidecars
Trike Conversion Kit to convert the exhaust to a True Dual.
These can be purchased as an option from Champion. See
OEM instructions included with the header kit for installation
of exhaust pipes.
b. Install Champion Extensions to Sampson Headers
•
Install straight Extension to left header pipe using one of
the two Exhaust Clamps supplied with Sampson kit. Do
not tighten clamp at this point. Figure 34
•
Install bent Extension to right header pipe using one of
the two Exhaust Clamps supplied with Sampson kit. Do
not tighten clamp at this point. Figure 34
Left Exhaust
Figure 34
3.13.2 2008 Up
c. 2007 and up model years require the use of the OEM
mufflers with your Champion Sidecars Trike Conversion Kit
d. Install the Extension to the header pipes using the two
Champion supplied Exhaust Clamps. Do not tighten clamp at
this point. Figure 35
Front
Figure 35
3.14 Install Mufflers
3.14.1 2007 Down
a. Install muffler inlets to Extension tubes using supplied
exhaust Clamps. Figure 36
Figure 36
b. Install exhaust end of mufflers to the muffler mount tabs at
rear of Body Frame. Install hardware as follows: Install 5/16"18 x 2" L hex head bolts and flat washers from top to bottom,
1 rubber spacer at top and bottom of muffler bracket, one
dome washer under rubber spacer and one 5/16"-18 NyLoc
nut. Figure 37
c. Ensure proper alignment of exhaust tubing and mufflers.
d. Tighten exhaust Extension and muffler inlet clamps
(Champion Exhaust Clamps).
e. Tighten Nyloc nuts securing exhaust end of mufflers until one
thread of bolt is visible. Figure 37 (Inset)
Figure 37
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CHAMPION TRIKES
3.14.2 2008 and Up
a. Install Champion bracket to mufflers as shown using OEM
hardware. Figure 38
Figure 38
Use supplied
clamps
b. Install muffler assembly with OEM exhaust tube clamps to
body frame and exhaust extension tubes. Figure 39
c. Install hardware as follows: Figure 40
•
5/16"-18 x 2" L hex head bolts and one dome washer
from top,
•
One rubber spacer between muffler bracket and body
frame tab.
•
One flat washer and one 5/16"-18 NyLoc nut.
Figure 39
d. Align mufflers and exhaust tubes, and then tighten all
hardware and clamps.
Body Frame
Tab
Muffler Bracket
Figure 40
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CHAMPION TRIKES
3.15 Final Check of Drive Belt Tension
a. Re-check and adjust belt tension and alignment as outlined in
section 3.11. Feathering rear brakes during engine running
check will help identify any problems with belt alignment and
tracking on pulleys.
3.16 Install Left and Right Back Rest Mounts
a. Install the left and right seat braces to the Shock Mount frame
using the supplied hardware listed. Figure 41
Qty
4
8
4
Description
3/8"-24 x 1" hex bolts
3/8" flat washers
3/8" NyLoc nuts
3.17 Install Trike Body to vehicle
Note: The installation/alignment of the body is an iterative
process to find the correct position of body in relation to
the wheels The four holes already in the body are primarily
for shipping purposes. These holes might line up with the
pre-drilled body frame holes when the body is fitted. Follow
instructions below to re-drill holes if required.
Figure 41
a. Place Trike Body into position over vehicle and onto Body
Frame.
b. Locate the four holes pre drilled into Trike Body and install
one 3/8"-24 x 1-1/4" L hex bolt and one 3/8"–1 ½” fender
washer from inside of body at each hole. Install 3/8" SAE flat
washer and 3/8”-24 NyLoc nut to each bolt.
Note: The pre-drilled holes are for securing the body in the
crate and can be used to mount the body but may need to be
elongated to align body.
c. Locate left and right center body-mount tabs. Drill a 3/8" hole
up through tab and body (tab is predrilled) Install bolts.
d. Connect trike wire loom to OEM tail light harness connector.
e. Connect accessory wire (blue single wire) to 12V power
source on vehicle.
3.18 Install Wheels
Install wheels to rear axle assembly using the supplied 10
lug nuts.
®
Page 20 of 23
Revision 8
TRIKE CONVERSION
CHAMPION TRIKES
3.19 Install Seat & Back Rest
a. Install seat to Shock Mount using OEM seat hardware.
b. Install backrest to back rest mounts using OEM hardware.
3.19.1 2007 and Up
c. Remove the stud plate from the OEM rear fender. Figure 42
d. Carefully remove the studs from the stud plate ensuring not to
damage or bend the plate
Figure 42
e. Cut off the bent end (harness guide) of the stud plate. Figure
43
f. Install the supplied clinch studs as shown. When pressing in
the studs make sure not to bend or distort the stud plate.
Figure 43
Figure 43
g. Install modified stud plate to seat loop of the Champion
seat/shock mount frame using the OEM plastic retainers.
Figure 44
Figure 44
h. Install seats as normal using OEM hardware. Figure 45
Figure 45
®
Page 21 of 23
Revision 8
TRIKE CONVERSION
4
PARTS LISTS
4.1
Assembly Kits
CHAMPION TRIKES
b. 2008 Up
a. 1987 to 2007
Qty
Part No.
1
HWK-F00-006
2
CH-F00-006
1
CH-F00-017
1
CH-F00-018
2
CH-EF0-004
2
SU-F00-005
1
CH-F00-028
2
SU-F00-008
8
SU-DE0-001
2
CH-F00-019
1
SU-G00-002
2
BR-F00-001
1
CH-F00-025
1
UP-F00-001
1
CH-F00-032
1
WS-G01-002
1
HW-F00-001
4
CH-K00-010
®
Description
Qty
hardware pack, 87-07
SOF
muffler, polished, HAR
ext, exhaust, bent, ss,
+2.50", RH, 07 Down,
SOF
ext, exhaust, straight, ss,
LH, 07 Down, SOF
clamp, muffler, t-bolt,
HAR/GL5
plate, adjustment, w/ pins,
swing arm, black, HAR
mount, shock tower, 87
Up, black, SOF
shock absorber, each,
SOF
bushing, shock absorber,
GL8/TRA/SOF
bracket, hanger, body
frame, black, SOF
wrench, shock absorbers,
coil-over
line, brake, braided, 20",
rear, RH/LH, HAR/YMA
bracket, backrest, set, LH
& RH, polished, SOF
cover, backrest bracket,
black, SOF
mount, exhaust pipe,
front, black, SOF
kit, license plate,
HAR/YMA
clamp, hose, 2", SOF
kit, muffler, vibration
mount, TRI
1
HWK-F00-007
1
CH-F00-071
1
CH-F00-077
1
CH-F00-075
1
CH-F00-076
2
CH-EF0-004
2
SU-F00-005
1
CH-F01-028
2
SU-F00-008
8
SU-DE0-001
2
CH-F00-019
1
SU-G00-002
2
BR-F00-001
1
CH-F00-025
1
UP-F00-001
1
2
WS-G01-002
HW-F00-001
3
CH-K00-010
1
CH-F00-072
1
CH-F00-073
1
CH-F00-074
Page 22 of 23
Part No.
Description
hardware pack, 08 Up, SOF
mount, bracket, muffler, 08
Up, black, SO
cover, exhaust, chrome, 08
up SOF
ext, exhaust, ss, RH, short,
08 Up, SOF
ext, exhaust, ss, LH, long, 08
Up, SOF
clamp, muffler, t-bolt,
HAR/GL5
plate, adjustment, w/ pins,
swing arm, black, HAR
mount, shock tower, assy,
87-Up, black, SOF
shock absorber, each, SOF
bushing, shock absorber,
GL8/TRA/SOF
bracket, hanger, body frame,
black, SOF
wrench, shock absorbers,
coil-over
line, brake, braided, 20", rear,
RH/LH, HAR/YMA
bracket, backrest, set, LH &
RH, polished, SOF
cover, backrest bracket,
black, SOF
kit, license plate, HAR/YMA
clamp, hose, 2", SOF
kit, muffler, vibration mount,
TRI
spacer, bushing, LHS, 08 Up,
clear zinc, SOF
spacer,bearing to frame,LHS,
08 Up, cl zinc, SOF
spacer,swingarm to
trans,LHS,08 Up,cl zinc, SOF
Revision 8
TRIKE CONVERSION
4.2
CHAMPION TRIKES
Hardware Kits
b. 2008 Up
a. 1987 – 2007
Qty
Part #
Description
A. SWING ARM & REAR END
4
HW-750-010
3/4 sae f/w
2
HW-375-060
3/8-24x2-1/2 shcs
6
HW-375-056
3/8-24x2-3/4 hhcs gr8
8
HW-375-006
3/8-24x1-1/2 hhcs gr8
M10x1.25x70 hhcs full
thread
2
HW-M10-001
16
HW-375-011
3/8-24 nylock nut
2
HW-M10-009
M10x1.25 hex nut
30
HW-375-016
3/8 sae f/w
B. SHOCK TOWER & SHOCKS
4
HW-375-019
3/8-16x1-1/2 hhcs gr8
4
HW-375-012
3/8-16 nylock nut
8
HW-375-016
3/8 sae f/w
4
HW-500-005
1/2-20x2-1/2 hhcs gr8
4
HW-500-013
1/2-20 nylock nut
8
HW-500-020
1/2 sae f/w
C. HANGER BRACKETS
8
HW-375-006
3/8-24x1-1/2 hhcs gr8
4
HW-375-059
3/8-16x1-1/4 hhcs gr8
16
HW-312-040
5/16 uss f/w
20
HW-375-050
3/8 combination tooth l/w
4
HW-375-016
3/8 sae f/w
8
HW-375-011
3/8-24 nylock nut
D. SEAT BACKREST BRACKET
4
HW-375-042
3/8-24x1 hhcs gr8
8
HW-375-016
3/8 sae f/w
4
HW-375-011
3/8-24 nylock nut
1
HW-185-002
10-32x3/4 m/s thps ss
1
HW-185-004
10-32 nylock nut
E. BODY
6
HW-375-043
6
HW-375-016
6
HW-375-007
6
HW-375-011
3/8-24x1-1/4 hhcs gr8
3/8 sae f/w
3/8x1-1/2 fender washer
3/8-24 nylock nut
Qty
Part #
Description
A. SWING ARM & REAR END
4
HW-750-010 3/4 sae f/w
2
HW-375-060 3/8-24x2-1/2 shcs
6
HW-375-056 3/8-24x2-3/4 hhcs gr8
8
HW-375-006 3/8-24x1-1/2 hhcs gr8
HW-M10M10x1.25x70 hhcs full
001
thread
2
16
HW-375-011 3/8-24 nylock nut
HW-M10009
2
M10x1.25 hex nut
30
HW-375-016 3/8 sae f/w
B. SHOCK TOWER & SHOCKS
4
HW-375-019 3/8-16x1-1/2 hhcs gr8
4
HW-375-012 3/8-16 nylock nut
8
HW-375-016 3/8 sae f/w
4
HW-500-005 1/2-20x2-1/2 hhcs gr8
4
HW-500-013 1/2-20 nylock nut
8
HW-500-020 1/2 sae f/w
C. HANGER BRACKETS
8
HW-375-006 3/8-24x1-1/2 hhcs gr8
4
HW-375-072 3/8-16x1-3/4 hhcs gr8
16
HW-312-040 5/16 uss f/w
20
HW-375-050 3/8 combination tooth l/w
4
HW-375-016 3/8 sae f/w
8
HW-375-011 3/8-24 nylock nut
D. SEAT BACKREST BRACKET
4
HW-375-042 3/8-24x1 hhcs gr8
8
HW-375-016 3/8 sae f/w
4
HW-375-011 3/8-24 nylock nut
1
HW-185-002 10-32x3/4 m/s thps ss
1
HW-185-004 10-32 nylock nut
E. BODY
6
HW-375-043
6
HW-375-016
6
HW-375-007
6
HW-375-011
3/8-24x1-1/4 hhcs gr8
3/8 sae f/w
3/8x1-1/2 fender washer
3/8-24 nylock nut
F. SEAT MOUNT BRACKET
2
HW-250-036 1/4-20x1-1/8 clinch stud
®
Page 23 of 23
Revision 8

Harley Davidson Softail (FLST Only) Motorcycle

Transcription

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