Progressive Suspension Airtail I.A.S.

Transcription

1 5572 Fresca Drive, La Palma, CA , FAX Progressive Suspension Airtail I.A.S. Installation Instructions for Harley Davidson E.C.C. with Compressor Kit FLH/FLT Models with and without Cruise Control not necessary. (Where applicable) Note: Please read the following instructions completely before starting. This will aide in an easy installation and familiarize you with part names. Caution: Follow instructions in an authorized shop manual or take the motorcycle to a competent dealer. The motorcycle must be securely blocked to prevent it from tipping over when shocks are removed. Failure to do so can cause serious damage and/or injury. The use of lowering kits on Progressive Suspension shocks is not recommended. Use of a lowering kit may void the warranty or damage the shock or motorcycle. Progressive Suspension shocks are designed to work on OEM (Original Equipment) frame and swing arm. Use of these shocks on a frame or swing arm other than OEM may produce an unsatisfactory ride and void the warranty. Make sure proper bushings/sleeves are installed in the shocks. Improper bushings/sleeves can cause unsatisfactory and/or unsafe operation. Lowering your motorcycle will decrease initial ground clearance. The motorcycle will be lower to the ground and care should be taken to avoid bottoming, especially over bumps and in turns. Lowering a motorcycle can change the handling characteristics. Always use extreme caution when riding after a change is made and take time to get accustomed to any handling change. Installation: Progressive Suspensions Airtail I.A.S. suspension system is designed as a direct bolt on replacement for your stock shocks. Along with the ability to conveniently adjust both the bottoming control and the motorcycle ride height, they have vastly improved damping. The installation of the Airtail I.A.S. with E.C.C. compressor kit is a 4 step process, and it is strongly suggested to follow these instructions step by step after reading through to familiarize you with the process. Step 1 Shock installation 1. Place motorcycle securely on a stand or blocks so the rear wheel is slightly off the ground, and bike is stable. 2. Per instructions in an authorized shop manual, remove your old shocks. Note the mounting hardware. It is only necessary to disconnect the stock rear shock airlines from the OEM bracket, removal of stock bracket is 3. Install the new Airtail I.A.S shocks with the airlines at the top and facing the frame. Using the appropriate torque specifications (see shop manual for specs), tighten hardware. 4. Route the airlines (2) from each shock, between the fender and strut, to under the seat area making sure they won t be pinched, exposed to excessive heat, or contact any moving parts. It may be necessary to trim excess airline to avoid these circumstances, however, to insure sufficient lengths and clearances for all lines and fittings, it is recommended that you wait until the entire system has been connected before trimming any airlines. Note: The compressor, solenoid, and T fittings feature high pressure quick connect fittings. To connect the airlines, simply press them into the fitting until they bottom out. They bottom out about 3/16" past the first resistance you feel. If you need to trim the airline it is vital that you make a square cut with a sharp razor blade (do not use dikes or wire cutters) as failure to do so could result in a leak. If you need to disconnect a line for any reason, simply push in the outer collar on the fitting and pull out the airline. Also, if you disconnect an airline for any reason it is suggested to trim a small amount (approximately 1/8") off the end you pulled out as a freshly cut and installed airline is less likely to leak. 5. With shocks properly installed and airlines routed as stated earlier, you will now connect the airlines coming from the shocks to the first set of T fittings. There will be two airlines coming from each shock, a blue one which controls the Ride Height Chamber, and a Black one for the Bottoming Control Chamber (see Figure 1). Connect the Ride Height airline from each shock (the Blue ones) into the side valves of one T fitting. Next connect the Bottoming Control airlines from each shock (the Black ones) into the second T fitting. Page1of8

2 Figure 1 Blue Black Figure 2 Note the routing of airlines and the use of a zip-tie to secure the T fittings Step 2 - Compressor installation The following steps outline the installation of the compressor assembly in the space available directly under the battery box. NOTE: ON MODELS WITH THE EMISSIONS CANISTER IN THIS LOCATION, YOU WILL NEED TO RELOCATED THE CANISTER. NOTE: ON MODELS WITHOUT CRUISE CONTROL. SEE OPTIONAL MOUNTING LOCATION INSTRUCTIONS BEGINNING ON PAGE 4 Page2of8

3 1. Following the procedures in an authorized shop manual for your model, remove the battery and battery box. 2. Place the compressor and mount assembly into the space above the swingarm and below the space normally occupied by the battery box. See figure 3 3. Re-install the battery box through the right side opening and loosely attach top mounting bolts. Installation Under Battery Box 4. Using the hardware supplied with the compressor kit and the OEM rear fender bolt, Attach the compressor mounting bracket to the bottom of the battery box(figure 4). Install the OEM rear fender bolt through the fender, discard the threaded clip nut, through the battery box and thread it into the compressor mounting hole provided. (Figure 5) Tighten bolts. 5. With the compressor mounting bracket securely fastened to the battery box, run the orange wire up through the left front opening of the battery box. Run the lower harness from the compressor and the black wire (Battery ground connection) together through the right front battery box opening. 6. Feed the two airlines attached to the compressor to the right and along the right side of the rear fender up to the T fittings installed previously. To insure sufficient line lengths and clearances for all lines and fittings, it is recommended that you wait until the entire system has been connected before trimming these airlines and making the final connections to the T fittings. Figure 3 Figure 4 7. Tighten the battery box mounting bolts according to your authorized shop manual. Continue with ECC Control Unit Installation section on page 6. Figure 5 Page3of8

4 To use this optional installation, perform the following steps; 1. Unplug the Relay from the Relay Socket. Figure 6 Optional Installation for Models without Cruise Control 2. Remove the socket head cap screw that mounts the Relay socket to the Battery Box mount. Figure 7( Be sure to save the screw for step 4 below). 3.Rremove the Battery Box Mounting Bracket (A) from the compressor assembly. Do this by removing the two Button Head Socket Screws shown in Figure 7. Be sure to keep the shortest screw. You will need this for mounting the compressor unit. 4. Re-mount the Relay Socket in the location shown in Figure 8 using the Socket Head Screw saved from #2 above. Note the position of the Relay Socket in relation to the Compressor and Solenoid Valves. Figure 6 Figure 7 Figure 8 Page4of8

5 Optional Installation for Models without Cruise Control Continued Now that you have reconfigured the Compressor / Solenoid Valve Assembly for mounting behind the left side cover of your motorcycle, continue with the installation procedure. If you have already mounted the Compressor / Solenoid Valve Assembly under the Battery Box, you need to go to Page 6, ECC Control Unit Installation. Step 2 - Compressor installation 1. Disconnect and remove battery as per manual. 2. Remove saddlebags and left side cover. 3. Use existing holes in battery tray, the short screw removed on Page 4 and the supplied washer to mount compressor unit. Figure 9 4. Torque mounting bolt to 6 ft. lbs. Page5of8

6 Step 3 E.C.C. control unit with upper wire harness 1. Remove stock clamp from right hand control and replace with E.C.C. control, throttle side mount (see figure 11). Figure10 5. Feed the Bottoming control chamber, ride height chamber airlines and orange wire from compressor though the existing hole on the right in battery box. Route E.C.C. harness wires through opening just left of battery tray and up into the battery tray (see figure 9). 6. With orange wire from compressor now in battery box area, connect to orange fused battery connection jumper. Remove fuse from block, inserting fuse will be done later after final connection to battery. 7. The two airlines now in the battery box (from the compressor unit) should be run back to the T fittings which the shocks are connected to. Be sure that the ride height airline gets connected to the same T fitting as the ride height airline that comes from each shock. Do like wise with the bottoming control airline, appropriately connecting it to the T fitting which the bottoming control airline from each shock is connected to. 8. The E.C.C. lower wire harness which was routed to the left of the compressor unit (see figure 9) including the red fused wire, will be connected after installing the E.C.C. control unit with upper wire harness. Figure Torque the mounting screws as specified in shop manual. 3. Route the E.C.C. wire harness along the handlebars and secure with zip ties, run wire harness from E.C.C to the steering head. 4. Following the instructions as per shop manual to loosen chrome handlebar cover, then feed harness and connectors through opening, making sure to not damage the connector ends while doing so (see figure 12). Figure 12 Page6of8

7 5. Continue routing the harness along side of frame, use stock wire clamp to secure them. Make sure the harness is not pinched or in a bind through the full range of steering (see figure 13). Step 4 Final connections (see Fig. 16) 1. Making sure that no wires or airlines will be pinched or crushed, re-install battery. 2. Connect red fused wire to battery positive, checking to make sure the 2 amp fuse is good. 3. With 15 amp min-blade fuse still NOT in fuse block, connect orange fused wire to battery positive. 4. The black wire coming from the compressor unit with battery connection needs tol be connected to battery negative now. This is the systems only ground wire and a good connection to battery negative is critical. 5. Install 15 amp min-blade fuse into fuse block of orange wire. 6. System is now powered up and hot. 7. Place coiled and zip-tied extra wire in a secure area away from excessive heat, sharp edges, and moving parts. Figure Remove necessary hardware to gain access to under the fuel tank dash console. 7. Route the wire harness from the E.C.C. handlebar control under the console and connect with the harness from the compressor unit. (See figures 14 & 15) Figure 14 Figure With wire harnesses and connectors tucked under fuel tank dash console, free of binding, sharp edges or being crushed, re-install fuel tank dash console. 9. It is recommended that all excess wire is coiled, zip tied and placed in a secure area away from excessive heat, sharp edges and moving parts. Page7of8

8 Figure 16 Page8of8