For Harley Davidson Flh Series Motorcycles-Books Pdf

for Harley Davidson FLH Series Motorcycles
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Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. Champion Trikes, Trike Conversion Kit for, Harley Davidson FLH 87 08 Series Motorcycles. Installation Guide Page 2 of 33 Revision 16, Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. Table of Contents, 1 General Information 5, 1 1 Installation Information 5.
1 1 1 Lowered Bikes 5, 1 2 For Your Safety 5, 1 3 Important Safety Precautions 5. 1 4 Specifications 6, 2 Removal of Original Parts 7. 3 Installation of Trike Conversion Kit 8, 3 1 Remove Pivot Assemblies from OEM Swing Arm 8. 3 1 1 1987 2001 Models 8, 3 1 2 2002 2008 8, 3 2 Install Pivot Assemblies to Champion Swing Arm 8. 3 2 1 1987 2001 Models 8, 3 2 2 2002 2008 9, 3 3 Installing Champion Swing Arm to Vehicle All Models 9.
3 3 1 1999 And Earlier Models 9, 3 3 2 2000 to 2008 Models 10. 3 4 Installing Drive Pulley Aluminum Rear End Assembly 11. 3 5 Installing Aluminum Rear End Assembly to Swing Arm 12. 3 6 Install Drive Pulley to Differential 14, 3 7 Install Right Axle Housing Assembly to Swing Arm 15. 3 8 Install Left Axle Housing Assembly 16, 3 9 Install Shock Mount and Seat Rail Mount to Vehicle Frame 17. 3 9 1 1987 1996 Models 17, 3 9 2 1997 2007 18, 3 9 3 2008 Models 18. 3 10 Install Champion Battery Tray 1987 1992 Models Only 19. 3 11 Relocate Relays 1987 1992 Models Only 19, 3 12 Install Body Frame to Vehicle 19.
3 12 1 1987 to 1992 Only 19, 3 12 2 All Models 19, 3 12 3 Install Body Frame to Hanger Plates 1987 to 1996 Models 20. 3 12 4 Install Body Frame to Hanger Plates 1997 to 2008 Models 20. 3 13 Install Shock Absorbers 21, 3 14 Aligning and Tensioning Rear Drive Pulley 21. 3 15 Install Brake Lines 22, 3 16 Final Check of Drive Belt Tension 22. 3 17 Install Mufflers and Tail Pipes 22, 3 17 1 1999 Down Model Years 22. 3 17 2 2000 to 2008 model Years 23, 3 18 Install Trike Body to Vehicle 24.
3 19 Install Tour Box Frame 24, 3 19 1 1997 2005 24. 3 19 2 2006 2008 24, 3 19 3 1997 2005 25, 3 19 4 Install Seat Rail 1991 1996 only 25. 3 20 Install Tour Box 25, 3 20 1 1987 1996 25, 3 20 2 2006 2008 25. 3 21 Modify Side Covers 25, 3 21 1 1987 to 1992 Models 25. Installation Guide Page 3 of 33 Revision 16, Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh.
Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. 3 21 2 1993 to 1996 Models 26, 3 21 3 1997 to 2008 Models 27. 3 22 Install Seat Mount Adapter To Seat 1987 1992 Only 27. 4 Install Frame Stiffeners to Vehicle Frame 28, 4 1 1987 2002 Models 28. 4 2 2003 2007 Models 29, 4 3 2008 Models 31, 5 Radio CB Relocation Rear Mounted Units 32. 5 1 Install Radio Mount Tabs 32, 5 1 1 1993 1996 Models Only 32.
6 Trailer Hitch Receiver Optional 32, 6 1 Install Trailer Hitch Receiver 32. 7 Hardware 33, Installation Guide Page 4 of 33 Revision 16. Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. 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 FLH trike kits are designed for installation on motorcycles that have not been. lowered If the Champion kit is installed on a lowered bike the rear wheels are likely to rub on the. underside of the trike body, Champion s FLH trike kit re uses the OEM rear air shocks and does not add any new shocks The seat. height of a lowered FLH FLT bike will be less than the normal 26 27 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 FLHX Street Glide using. shocks that are about 1 5 inches shorter than the standard shocks In this case a set of standard length. shocks 13 inches 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, Installation Guide Page 5 of 33 Revision 16. Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. 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. 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. Installation Guide Page 6 of 33 Revision 16, Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION.
2 Removal of Original Parts, a Disconnect the Battery. b Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. c Remove the following from the vehicle See OEM manual for detailed instructions Items to be retained for re. installation after modification are noted, o 1987 2007 Models To be re installed after installation of engine mount stiffeners. o 2008 Models It is NOT necessary to remove fuel tank as stiffeners are not required. Seat to be re installed without modification 1993 2008 after modification 1987 1992. Left and right side covers to be re installed after modification Right side cover supplied by Champion. Sidecars 1987 1992 Models, Tour Box to be re installed without modification. Left and right saddle bags, Left and right rear crash bars saddlebag rails. Tour Box mounting frame, Left and right passenger foot rests to be re installed without modification.
Left and right mufflers, 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 2003 to be re installed without modification 2004 2008 use Champion supplied. Rear Fender, 1987 1992 Models Purchase 1995 FLH Seat Hand Rail HD Part No 91583 97 Not furnished by. Champion Sidecars, Installation Guide Page 7 of 33 Revision 16. Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. 3 Installation of Trike Conversion Kit, 3 1 Remove Pivot Assemblies from OEM Swing.
3 1 1 1987 2001 Models, a Pry the spacer and plastic retaining ring from one side of. the swing arm, OEM Swing Arm Pivot Assembly, b Place the swing arm in an arbor or hydraulic press Place. the press collar Swing Arm Assembly Tool Part No HD. 96200 80 on the outside diameter of the swing arm, c Using a long extension and socket press the clevebloc out. of the swing arm, d NOTE The clevebloc is a fluid filled bushing ALWAYS. press on the clevebloc outer sleeve, e Repeat above steps for opposite end of swing arm.
3 1 2 2002 2008, a See OEM manual for pivot assembly removal instructions. noting use of HD special tools Keep the bearings to be. installed later, b Modify Outer Spacers Figure 1, Machine or drill outer spacers to match large bore. as shown Figure 2, Ensure spacers slide freely over full length of pivot. 3 2 Install Pivot Assemblies to Champion Swing, Arm Before After. 3 2 1 1987 2001 Models, a Place a new tolerance ring on a clevebloc.
b NOTE It is strongly recommended that NEW tolerance. rings and clevebloc s be used when installing pivot. components to Champion Swing Arm Using the PRESS, PLUG press the spacer plastic ring and clevebloc into. one side of the Swing Arm Insure that the stepped surface. of the clevebloc is flush with the outer surface of the. Champion Swing Arm Figure 3, c Repeat above steps for opposite end of Swing Arm. Installation Guide Page 8 of 33 Revision 16, Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh. Harley Davidson FLH 1987 to 2008, CHAMPION TRIKES, TRIKE CONVERSION. 3 2 2 2002 2008, a Install OEM pivot bearings to Swing Arm from outside.
inwards Figure 4, CAUTION When installing bearing always press on outer. b Install inner spacer to Swing Arm from outside inwards. opposite of OEM installation Figure 4, c Install modified outer spacer to Swing Arm from inside Figure 4. outwards opposite of OEM installation Figure 4, 3 3 Installing Champion Swing Arm to Vehicle. All Models, NOTE 1993 to 2001 Models If the Swing Arm does not fit. over the transmission boss check that the clevebloc s are. approximately 4 9 16 apart Brake Line, T Block Screw.
a Coat OE pivot shaft with Loctite ANTI SEIZE, b Position Champion Swing Arm with brake line T Block. screw on cross bar pointing upward to rear of, transmission Figure 5. 3 3 1 1999 And Earlier Models, a Install rubber mount to pivot shaft small diameter of boss. facing outward with the slot at top, b From left side of vehicle install pivot shaft through. Champion Swing Arm and transmission mount, c From right side of vehicle install rubber mount washer.
and nut to pivot shaft Leave nut lose enough to allow. rubber mounts to rotate, d Install left and right Swing Arm brackets Ensure rubber Figure 6. mount index tabs fully engage bracket slots Hand tight. mounting bolts, e Torque pivot bolt nut to 45 lbs ft. f Remove left and right Swing Arm brackets, g Install supplied white stabilizer bushings on both sides. pivot shaft nuts using small amount of grease making. sure to align of center hole with pivot shaft and nut Figure. 6 Figure 7 Figure 8, h Re install left and right Swing Arm brackets Ensure rubber. mount index tabs fully engage bracket slots Torque. mounting bolts to 34 42 ft lbs, Installation Guide Page 9 of 33 Revision 16.
Harley Davidson FLH 1987 to 2008 TRIKE CONVERSION CHAMPION TRIKES Installation Guide Page 1 of 33 Revision 16 Illustrations Photography By Terry T Emelio Tech Writing By Terry T Emelio Tech Advisor Jan Myburgh Trike Conversion Installation Guide for Harley Davidson FLH Series Motorcycles Model Years 1987 to 2008

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