Harley Davidson Softail (FLST Only) Motorcycle · HARLEY DAVIDSON SOFTAIL® FLST TRIKE CONVERSION...

HARLEY DAVIDSON SOFTAIL® FLST TRIKE CONVERSION

CHAMPION TRIKES

Installation Guide – HD Softail® FLST of 23 Revision 8 Tech Illustrations / Photography by Terry T. Emelio

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.

http://www.championtrikes.com/


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Trike Conversion Kit for Harley Davidson Softail® FLST Motorcycles Parts Illustration*

1 2

4 3

5

6

8

10

9

12

14

13

11

7

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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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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1 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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• 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.

c.

d.

e.

f.

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.

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.

Use only nonflammable solvent, not gasoline, to clean parts

Never drain or store gasoline in an open container.

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)

Wheel Size (15”) (5 lug) Offset +35 mm 15x7JJ 5x4.5 – (Later Installations – Black Rear End)

Tire Size (16”) 215 / 60 / R16

Wheel Size (16”) (5 lug) 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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2 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 re-installation 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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3 INSTALLING TRIKE CONVERSION KIT

3.1 Sprockets and Drive Belts Specifications See following table for belt installation (1987-99 will use a 4 tooth longer belt) Note: See OEM manual for belt replacement procedure.

Year Drive Sprocket

OEM Belt

New Belt / Sprocket

1987-92 70 T 132 T 136 1993-94 61 T 128 T 132 1995-99 65 T 130 T 136/70T OEM

2000-06 Champion Sprocket, 70 T 135 T Use OEM

2007 Up

Champion Sprocket, 66 T Use OEM

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 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

a.

b.

Press bearings into Champion Swing Arm in the same way as the OEM Swing Arm.

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.

d.

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.

Torque pivot bolt to OEM specification.

Cross Assembly

Figure 1

OEM Spacer Tube

Supplied Washers (1 per

Supplied Washers (1 per

OEM Washer (1 per

Figure 2


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3.2.2 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

b.

c.

Press bearings into Champion Swing Arm with C-clip to outside of Swing Arm.

Install Champion Swing Arm using OEM bolt, spacers and nut. Do not torque pivot bolt nut at this time. Figure 3

Note: Insure belt path is over and under Swing Arm pivot

d.

e.

a.

b.

c.

d.

e.

•



3.2.3 2008 Up Model Years

Remove OEM bearings from OEM Swing Arm using OEM shop tools and hydraulic press.

Press bearings into Champion Swing Arm with C-clip to outside of Swing Arm.

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



3.2.4 All Models

Install OEM shock absorbers to Champion Swing Arm using OEM hardware. Figure 17

OEM Spacer (1 per side)

OEM Washer (1 per

OEM Washer (1 per

Figure 3

Figure 4

(Front View)

Figure 5

Install as per OEM

Champion Spacer

Champion Sleeve

Champion Spacer

RH LHS

OEM Washer


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3.3 Installing Drive Pulley 3.3.1 Aluminum Rear End Assembly CAUTION: Do not use air driven impact tools to assemble the Champion Aluminum Rear End Assembly.

a.

b.

c.

d.

e.

f.

g.

Remove the three ¾” bolts securing the left half of the rear end assembly to the connector tubes. Figure 6

Separate the two halves of the rear end assembly, leaving the differential on the right half. Figure 6

Install pulley to differential using the supplied hardware and red Loctite. Figure 7

Torque bolts to 55 ft. lbs.

Install carrier bearing to differential. Ensure bearing is properly and fully seated on the differential. Figure 8

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

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

Connector tube

Figure 6

Figure 7

Figure 8

Figure 9


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3.4 Installing Aluminum Rear End Assembly to Swing Arm

a.

b.

Install the supplied M10 Adjuster Bolts and Jam Nuts to Adjuster Plates (one bolt and nut per plate). Figure 10

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 Description

4 3/8”-24 x 2-1/2”L socket head cap screw (no washer on head)

4 3/8”SAE flat washers 4 3/8”-24 NyLoc nuts

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 Description

4 3/8”-24 x 1-1/2” hex head bolt 8 3/8” flat washers 4 3/8”-24 NyLoc nuts

Figure 10

Adjuster bolt to outboard side

Figure 11

(view of left side from rear)

Figure 12

Figure 13


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d.

e.

f.

Remove the upper and lower rear connector tubes and position drive belt onto the rear pulley. Figure 14

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

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 14

Figure 15

Figure 16


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3.5 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.

a.

b.

c.

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

Separate the left side Axle Housing from the right, leaving the Differential attached to the right side assembly. Figure 18

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 Description 5 7/16”-14 x 1.1/4” L hex bolts 5 7/16” flat washers.

d. Torque bolts to 55 ft. lbs.

Figure 17

Figure 18

Figure 19


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3.5.1 Install Right Axle Housing Assembly to Swing Arm

(“Bull-Horn” Style Rear End Assembly)

a.

b.

Install M10 Adjuster Bolt and Jam Nut to Adjuster Plate. Figure 20

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 Description 4 3/8”-24 x 1 1/2” L hex bolts 8 3/8” SAE flat washers 4 3/8” NyLoc nuts

c.

d.

Install right Axle Housing (with drive pulley installed to Differential) to the Axle Adjuster mounted to the Swing Arm. Figure 21

Install supplied hardware to the Pinch Block. Loosely tighten hardware, as adjustments will be made later. Figure 21

Qty Description 3 3/8”-24 x 2-3/4”L hex bolts 1 3/8”-24 x 2-1/2”L socket head cap

screw (no washer on head) 7 3/8”SAE flat washers 4 3/8”-24 NyLoc nuts

Note: Install bolts to Pinch Block from inside pointing outward

e.

a.

b.

Place drive belt around rear pulley. Figure 21 3.5.2 Install Left Axle Housing Assembly (“Bull-Horn”

Style Rear End Assembly)

Install 10 mm Adjuster Bolt and Jam Nut to Adjuster Plate. Head of bolt must be facing backwards

Install Axle Adjuster to left Axle Housing Pinch Block with supplied hardware. Loosely tighten hardware, as adjustments will be made later. Figure 22

Qty Description 3 3/8”-24 x 2-3/4”L hex bolts 1 3/8”-24 x 2-1/2”L socket head cap

screw (no washer on head) 7 3/8”SAE flat washers 4 3/8”-24 NyLoc nuts

Note: Install bolts to Pinch Block from inside pointing outward

Adjuster Bolt&

Jam Nut

Figure 20

Figure 21

Figure 22


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c.

d.

Install left Axle Housing to right axle housing. Ensure proper engagement of axle and Differential spline. Figure 23

Install Axle Adjuster to Swing Arm using the supplied hardware listed. Loosely tighten hardware, as adjustments will be made later. Figure 24

Qty Description 4 3/8”-24 x 1 1/2” L hex bolts 8 3/8” flat washers 4 3/8”-24 NyLoc

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 23

Figure 24

Figure 25


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3.6 Install Brake Lines

a.

b.

c.

d.

e.

a.

Connect OEM brake line to tee fitting using supplied banjo bolt and crush washers. Figure 26

Install braided brake lines to brake tee-block on Champion Swing Arm. Connect non-swivel end of line to brake tee. Figure 26

Routing line over the Swing Arm, connect swivel end of braided brake lines to brake calipers. Figure 27

Secure brake lines to Swing Arm with supplied zip-ties.

Ensure T-Block is secure and nut is tight.

3.7 Install Shock Mount to Vehicle Frame Install Shock Mount to vehicle frame using the supplied hardware. Figure 28

Qty Description 4 3/8”-16 x 1 1/2” L hex bolts 8 3/8” flat washers 4 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 26

Figure 27

Figure 28


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3.8 Install Body Frame Hangers a. Install Body Frame Hangers (left & right) to Shock Mount

using the supplied hardware. Figure 29

Qty Description 4 Four 3/8"-24 x 1 1/2" hex bolts 8 3/8” star lock washers 8 5/16" USS flat washers 4 3/8"-24 NyLoc nuts

3.9 Install Body Frame to Vehicle a. Install Body Frame to vehicle frame and frame hangers using

the supplied hardware. Figure 30 To vehicle frame:

Qty Description 4 3/8"-16 x 1 3/4" hex bolts (2007 Up)

4 3/8"-16 x 1 1/4" hex bolts (2006 Down)

4 3/8” star lock washers 4 3/8” flat washers

To hanger plates:

Qty Description 4 Four 3/8"-24 x 1 1/2" hex bolts 8 3/8” star lock washers 8 5/16" USS flat washers 4 3/8"-24 NyLoc nuts

3.10 Install Shock Absorbers a. Install supplied coil over shock absorbers using the supplied

hardware: Figure 31

Qty Description 4 1/2"-20 x 2 ¾” Hex Head Bolt Gr8

8 1/2" Flat Washer

4 1/2"-20 NyLoc Nut

8 Hiem Spacers

Figure 29

Figure 30

Figure 31


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3.11 Aligning and Tensioning Rear Drive Pulley a.

b.

Square Axle Adjusters with Swing Arm mount plates and tighten hardware.

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.

d.

e.

When proper tension has been achieved, lock Adjuster Bolt with jam nuts

Tighten Pinch Block hardware.

Measure distance between forward face of Pinch Block and plate of Axle Adjuster. Ensure left and right sides of Axle Housing are equal distant.

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 Description 8 5/16"-18 x 1 hex bolts 8 5/16” SAE flat washers.

b.

c.

Electrical connectors not supplied. Mounting tab for connector socket is located on hitch receiver.

Color code for wiring as follows: (Confirm by testing)

Old Harness New Universal

Harness (From Mid 2007)

Running lights Confirm by testing BROWN Brake lights RED RED

Turn signal, right GREEN GREEN Turn signal, left YELLOW YELLOW

Accessory BLUE BLUE

Ground Confirm by testing (White or Black) BLACK

Figure 32

Figure 33


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3.13 Install Exhaust Extensions

3.13.1 2007 Down

a.

b.

c.

d.

a.

b.

c.

d.

e.

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.

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

3.13.2 2008 Up

2007 and up model years require the use of the OEM mufflers with your Champion Sidecars Trike Conversion Kit

Install the Extension to the header pipes using the two Champion supplied Exhaust Clamps. Do not tighten clamp at this point. Figure 35

3.14 Install Mufflers

3.14.1 2007 Down

Install muffler inlets to Extension tubes using supplied exhaust Clamps. Figure 36

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

Ensure proper alignment of exhaust tubing and mufflers.

Tighten exhaust Extension and muffler inlet clamps (Champion Exhaust Clamps).

Tighten Nyloc nuts securing exhaust end of mufflers until one thread of bolt is visible. Figure 37 (Inset)

Figure 34

Figure 35

Figure 36

Figure 37

Left Exhaust

Right Exhaust Vehicle

Front


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3.14.2 2008 and Up

a.

b.

c.

d.

Install Champion bracket to mufflers as shown using OEM hardware. Figure 38

Install muffler assembly with OEM exhaust tube clamps to body frame and exhaust extension tubes. Figure 39

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.

Align mufflers and exhaust tubes, and then tighten all hardware and clamps.

Figure 38

Figure 39

Use supplied clamps

Body Frame Tab

Muffler Bracket

Figure 40


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3.15 Final Check of Drive Belt Tension a.

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 Install the left and right seat braces to the Shock Mount frame using the supplied hardware listed. Figure 41

Qty Description 4 3/8"-24 x 1" hex bolts 8 3/8" flat washers 4 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.

a.

b.

Place Trike Body into position over vehicle and onto Body Frame.

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.

d.

e.

Locate left and right center body-mount tabs. Drill a 3/8" hole up through tab and body (tab is predrilled) Install bolts.

Connect trike wire loom to OEM tail light harness connector.

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.

Figure 41


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3.19 Install Seat & Back Rest a.

b.

c.

d.

e.

f.

g.

h.

Install seat to Shock Mount using OEM seat hardware.

Install backrest to back rest mounts using OEM hardware.

3.19.1 2007 and Up

Remove the stud plate from the OEM rear fender. Figure 42

Carefully remove the studs from the stud plate ensuring not to damage or bend the plate

Cut off the bent end (harness guide) of the stud plate. Figure 43

Install the supplied clinch studs as shown. When pressing in the studs make sure not to bend or distort the stud plate. Figure 43

Install modified stud plate to seat loop of the Champion seat/shock mount frame using the OEM plastic retainers. Figure 44

Install seats as normal using OEM hardware. Figure 45

Figure 42

Figure 43

Figure 44

Figure 45


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4 PARTS LISTS

4.1 Assembly Kits a. 1987 to 2007

Qty Part No. Description

1 HWK-F00-006 hardware pack, 87-07 SOF

2 CH-F00-006 muffler, polished, HAR

1 CH-F00-017 ext, exhaust, bent, ss, +2.50", RH, 07 Down, SOF

1 CH-F00-018 ext, exhaust, straight, ss, LH, 07 Down, SOF

2 CH-EF0-004 clamp, muffler, t-bolt, HAR/GL5

2 SU-F00-005 plate, adjustment, w/ pins, swing arm, black, HAR

1 CH-F00-028 mount, shock tower, 87 Up, black, SOF

2 SU-F00-008 shock absorber, each, SOF

8 SU-DE0-001 bushing, shock absorber, GL8/TRA/SOF

2 CH-F00-019 bracket, hanger, body frame, black, SOF

1 SU-G00-002 wrench, shock absorbers, coil-over

2 BR-F00-001 line, brake, braided, 20", rear, RH/LH, HAR/YMA

1 CH-F00-025 bracket, backrest, set, LH & RH, polished, SOF

1 UP-F00-001 cover, backrest bracket, black, SOF

1 CH-F00-032 mount, exhaust pipe, front, black, SOF

1 WS-G01-002 kit, license plate, HAR/YMA

1 HW-F00-001 clamp, hose, 2", SOF

4 CH-K00-010 kit, muffler, vibration mount, TRI

b. 2008 Up Qty Part No. Description 1 HWK-F00-007 hardware pack, 08 Up, SOF

1 CH-F00-071 mount, bracket, muffler, 08 Up, black, SO

1 CH-F00-077 cover, exhaust, chrome, 08 up SOF

1 CH-F00-075 ext, exhaust, ss, RH, short, 08 Up, SOF

1 CH-F00-076 ext, exhaust, ss, LH, long, 08 Up, SOF

2 CH-EF0-004 clamp, muffler, t-bolt, HAR/GL5

2 SU-F00-005 plate, adjustment, w/ pins, swing arm, black, HAR

1 CH-F01-028 mount, shock tower, assy, 87-Up, black, SOF

2 SU-F00-008 shock absorber, each, SOF

8 SU-DE0-001 bushing, shock absorber, GL8/TRA/SOF

2 CH-F00-019 bracket, hanger, body frame, black, SOF

1 SU-G00-002 wrench, shock absorbers, coil-over

2 BR-F00-001 line, brake, braided, 20", rear, RH/LH, HAR/YMA

1 CH-F00-025 bracket, backrest, set, LH & RH, polished, SOF

1 UP-F00-001 cover, backrest bracket, black, SOF

1 WS-G01-002 kit, license plate, HAR/YMA 2 HW-F00-001 clamp, hose, 2", SOF

3 CH-K00-010 kit, muffler, vibration mount, TRI

1 CH-F00-072 spacer, bushing, LHS, 08 Up, clear zinc, SOF

1 CH-F00-073 spacer,bearing to frame,LHS, 08 Up, cl zinc, SOF

1 CH-F00-074 spacer,swingarm to trans,LHS,08 Up,cl zinc, SOF


CHAMPION TRIKES


4.2 Hardware Kits 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

2 HW-M10-001 M10x1.25x70 hhcs full thread

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 3/8-24x1-1/4 hhcs gr8 6 HW-375-016 3/8 sae f/w 6 HW-375-007 3/8x1-1/2 fender washer 6 HW-375-011 3/8-24 nylock nut

b. 2008 Up

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

2 HW-M10-

001 M10x1.25x70 hhcs full thread

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-375-072 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 3/8-24x1-1/4 hhcs gr8 6 HW-375-016 3/8 sae f/w 6 HW-375-007 3/8x1-1/2 fender washer 6 HW-375-011 3/8-24 nylock nut

F. SEAT MOUNT BRACKET 2 HW-250-036 1/4-20x1-1/8 clinch stud

Harley Davidson Softail (FLST Only) Motorcycle · HARLEY DAVIDSON SOFTAIL® FLST TRIKE CONVERSION...

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Transcript of Harley Davidson Softail (FLST Only) Motorcycle · HARLEY DAVIDSON SOFTAIL® FLST TRIKE CONVERSION...