Trike Conversion Installation Guide for Indian Scout Motorcycles 2016 & Up Revision 2

Transcription

1 Trike Conversion Installation Guide for Indian Scout Motorcycles 2016 & Up Revision 2 Warning - This product was not intended for more than one rider. Weight limit on this product has been set at 400 lbs. maximum and should not be exceeded. Failure to follow these warnings could result in serious injury or death. Champion Motorcycle Accessories International, Inc. dba Champion Sidecars Monarch Street, CA (800) (714) Fax (714) Installation Guide Page 1 of 20 Revision 2

2 Table of Contents 1 General Information Installation Information For Your Safety Important Safety Precautions Specifications Removal of Original Parts Pre-Installation of Trike Conversion Subframe Modification Header Pipe Modification Installation of Trike Conversion Kit Subframe Support Installation Champion Swing Arm Rear Axle Clamps Rear End Assembly Rear Brake Lines and Components Body Frame Aligning and Tensioning Drive Belt Exhaust System Exhaust Chrome Covers Body Seat Accessories Passenger Pegs Passenger Seat *Please check to see if you have all components before assembly. **After the following assembly is tested make sure to torque all fasteners to factory specifications. ***Before installation of your Champion kit we recommend that your motorcycle be serviced by a qualified mechanic. Any worn parts should be replaced before or during the installation process. Box Contents 1 Tires/Wheels 2 Hardware Kit 3 Swing Arm 4 Rear Differential with Pulley 5 Body Installation Guide Page 2 of 20 Revision 2

3 1 General Information The Champion 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 motorcycle on which the Trike kit is to be installed. Warning Failure to follow these instructions may result in serious injury or death. 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. 1.2 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. 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. Installation Guide Page 3 of 20 Revision 2

4 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: Overall Width: Wheel Base: Load Capacity: Tire Size (15 ): 400 Lb 205 / 70 / R15 Wheel Size (15 4 lug) Offset +35 mm 15x7JJ 4 x 4.5 Tire Pressure: Suspension: Rear Differential: Brakes: PSI Zero-Flex Swing Arm Utilizing OEM Coil-Over Shock Custom Built Aluminum Rear Differential Original Front plus 2 High Performance Disc Brakes in Rear Warning Failure to follow these instructions may void warranty. Installation Guide Page 4 of 20 Revision 2

5 2 Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove or perform the following listed below. See OEM manual for detailed instructions. Items to be retained for re-installation after modification are noted. Left and right saddle bags (if so equipped) Left and right rear crash bars, saddlebag rails (if so equipped) Top chrome cover from header pipe Mufflers and hanger Disconnect rear brake line at caliper and remove clamp from swing arm (Note: Prior to disconnecting line, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake line is disconnected. Cap line to prevent introduction of dust/debris into line. Rear brake line and clamp will be used later.) Loosen belt tension and remove from sprocket. Shocks Front pivot bolt with washers Swing arm assembly, a.k.a. Rear Fork (Figure 1) Passenger foot rests Warning - This product was not intended for more than one rider. Weight limit on this product has been set at 400 lbs. maximum and should not be exceeded. Failure to follow these warnings could result in serious injury or death. Pivot bolt, nut and washers from swing arm will be used later. *Champion does not recommend removing any factory original parts that may change the emission from CARB or EPA requirements. Figure 1 Installation Guide Page 5 of 20 Revision 2

6 3 Pre-Installation of Trike Conversion 3.1 Subframe Modification a. On the RHS of the OEM subframe will needed to cut for swing arm clearance. On the following page is a template that you will need to print. Note: The print needs to be set one-to-one scale. If the print is not scale correctly the template will not fit the subframe profile. b. In Figure 2, match up the printed template with the OEM subframe. Mark the subframe with a permanent marker and remove the template. Champion recommends using a reciprocating saw to cut the aluminum subframe and then grind smooth the marked profile. Figure 2 Installation Guide Page 6 of 20 Revision 2

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8 3.2 Header Pipe Modification a. The top header pipe will need to be cut. Remove 3/4 from the end of the pipe as shown in Figure 3. Figure 3 4 Installation of Trike Conversion Kit 4.1 Subframe Support Installation a. Remove the four OEM screws from the subframe. Note: DO NOT COMPLETELY REMOVE OR LEAN ON OEM SUBFRAME. THE BATTERY IS ATTACHED TO THE SUBFRAME. b. Place the support mount onto the subframe. Use the supplied M10x1.5x60mm w/washers and apply blue Loctite (medium strength) on hardware. Torque screws to 50ft-lbs. See the figure below. c. Cut the plastic cover as shown below as indicated in Figure 4. Installation Guide Page 8 of 20 Revision 2

9 Figure 4 d. Attach the cross member bracket the support mount using the M10x1.25x30mm w/washers, and nylock nuts. Keep loose. Installation Guide Page 9 of 20 Revision 2

10 4.2 Champion Swing Arm a. Verify the two ball bearings and a wave washer per side before installing the swing arm. See Figure which shows only the RHS components. Side the supplied sleeves into swing arm as indicated in Figure. b. Slide the swing arm into position. Place the supplied spacers at both outer ends of the swing arm. Re-use the OEM pivot bolt and washers. Use the supplied M16x1.5 nylock nut. Torque the pivot bolt to 90ft-lbs. c. Place one OEM shock to either LHS or RHS of the bike frame to the Champion swing arm. Re-use the OEM hardware but keep loose. d. Install the supplied 5/16-18x2-1/4 hex head adjuster bolts and jam nuts onto the swing arm. Adjuster bolt should be in the furthest forward position to allow room to place belt around rear pulley in a later step. Figure 7 Installation Guide Page 10 of 20 Revision 2

11 4.3 Rear Axle Clamps a. Tap in supplied 1/4" dowel pin into the left side axle housing. b. Install rear axle clamps onto axle housing using the supplied hardware. The left hand side clamp slot must register into dowel pin on rear end. (Note: The rear brake lines run through each clamp with a nylon protective tube.) Keep hardware loose. Qty per Description side 2 3/8-16x2-1/2 socket head bolt 2 3/8-16x3-1/2 socket head bolt 8 3/8 SAE SS flat washers 4 3/8-16 nylock nut c. For the RHS, use the same hardware listed above. Torque both RHS and LHS clamp bolts to 30 ft-lbs. Installation Guide Page 11 of 20 Revision 2

12 4.4 Rear End Assembly a. Slide the Champion rear end near the swing arm. Wrap the supplied belt to the driving pulley. b. Line-up rear pulley to the OE driving pulley. Belt adjustment will be address in a later section. CAUTION: Do not use air driven impact tools to assemble the Champion aluminum rear end assembly. c. Connect the rear end assembly to the swing arm using hardware by the axle clamps to swing arm using the supplied hardware. Snug hardware just enough to still allow the clamps to slide in the swing arm as adjustments will be made later. Repeat the this step for the RHS. 4.5 Rear Brake Lines and Components a. Attach brake line with bend as seen in Figure 4 to each caliper using the supplied banjo bolts and crush washers. (Note: Use a total of three crush washers.) Figure 4 Installation Guide Page 12 of 20 Revision 2

13 b. Install t-block using supplied ¼-20 bolt, washer, and nylock nut with the OE brake line clamp. c. Connect blue pressure residual valve to t-block using a crush washer between the two. The blue residual valve needs face towards the ground. Torque the ¼-20 nylock nut to 8ft-lbs. and the blue residual valve to 17-19lb-ft. d. Connect OE brake light pressure sensor to the master cylinder as shown in. Torque 17 to 19lb-ft e. Connect braided lines from each wheel caliper to t-block. f. Using brake fluid specified on the master cylinder, bleed rear brake system thoroughly using the upper bleeders, Figure 11, on the rear brake calipers. Once assembled replace with new factory specified brake fluid; adjust accordingly and check for leaks. You may need to adjust the rear brake push rod to get the pedal in a comfortable position due to the increased pedal throw associated with the dual rear calipers. Note: You may need to bleed the brakes using the lower bleeder also. Air may be present. 4.6 Body Frame a. Slide the body frame onto the OEM subframe by driving the top section of the frame under the OEM subframe pasting the four mounting holes. While keeping the Champion frame level rotate the body frame in a clockwise motion above the four holes. The body frame should slide onto the four mounting holes. Note: Trying to mount the Champion body frame directly onto the subframe will not work. b. Attach the rear two holes using M08x1.25x50mm w/washers and lock washers. Torque to 18ft-lbs. Installation Guide Page 13 of 20 Revision 2

14 c. The front two mountings will need to be drill. First, use the supplied M08x1.25x50mm screw on the LHS of the OEM subframe. Torque the screw to 18ft-lbs. This will hold the body frame in position while drilling the RHS. d. Use 10.5mm drill or Z drill to the RHS front hole using the bung as a pilot. Place a M10x1.25x70mm HHCS w/washer through the body frame and OEM subframe. Note: Do not attach the cross member to frame yet and make sure the cross member is away from the drilling process. e. Remove the M08x1.25x50mm screw from the LHS and drill the threaded hole using the bung as a pilot with the same 10.5mm or Z drill. Note: The M08x1.25x50mm screw will no longer be used for the trike installation. f. Attach the cross member to the OEM subframe and the Champion body frame using another M10x1.25x70mm screw w/washers, and nylock nut. Torque to 32ft-lbs. g. Secure the front hole on the LHS using a washer and M10x1.5 nylock nut. Torque to 32ft-lbs. h. Torque the loose M10x1.25x30mm screws located at the cross member s bottom to 40ft-lbs. Installation Guide Page 14 of 20 Revision 2

15 i. To Install the Champion shock insert four steel bushings into the shocks eyes. j. Attach the center shock onto the body frame to the swing arm using the 1/2x20x2-1/2 HHCS, w/washers, and nylock nuts. Toque to 64ft-lbs. 4.7 Aligning and Tensioning Drive Belt NOTE: The slots in the swing arm axle clamp mount plate allow the rear end assembly to move approximately 1.25 forward or rearward. The rear end assembly also has a total movement of approximately 1.125" side to side. This movement is accomplished by sliding the axle housing within the axle clamps; it is limited by the dowel pin and grove. The following steps are a starting point to properly align the belt. a. Center rear end assembly within the axle clamps. Ensure center by measuring from axle clamp to fender bracket on both sides until equal. b. Tighten nuts on axle clamp to 31 lb. ft. (Note: Ensure braided brake line is seated properly in saddle and does not get pinched between the two halves.) c. Adjust adjuster bolts to set belt tension and to square rear end assembly to swing arm. The belt should have approximately ¾ of total vertical movement. Tighten jam nut to lock adjuster bolt. d. Rotate rear sprocket several times by hand to register belt on sprocket. The belt should run in the center of the rear sprocket. Make small adjustments if needed and recheck alignment. e. Torque the hardware from to 64ft-lbs. Repeat for RHS. NOTE: Belt tension and alignment should be checked prior to final assembly of trike kit. Check with vehicle secured on jack stands and adjust accordingly if needed. Installation Guide Page 15 of 20 Revision 2

16 Figure Exhaust System a. Install the header pipe bracket on the trike. Use M10x1.5x50mm HHCS w/ lock washers and washers. Reusing the OE screw, attach the header pipe tab to the bracket. Use the supplied M8x1.25 nylock w/ washer. Torque the M8 bolt to 18ft-lbs. Torque the M10 screw to 40ft-lbs. b. Slide the exhaust extensions to the header pipes. Reuse the OE clamps and the supplied 2 t-bolt clamps on the mufflers and extensions. See both figures below. Installation Guide Page 16 of 20 Revision 2

17 c. Attach both exhaust hanger brackets to the body frame. d. Install both mufflers using the four supplied 4 t-bolt clamps and into the exhaust extensions. Wrap the clamps around both exhaust hanger brackets and OEM exhaust mufflers. Keep clamps loose for adjustment. NOTE: If customers purchase Scout Chrome Stage 1 Straights Slip-on Exhaust (Indian item # ), different t-bolt clamps must be installed accordingly. T-bolt clamps #can be purchased through Champion. e. Rotate the mufflers as shown in the figure below and reuse the OE muffler screw. Torque OE screw to 20 ftlbs. Torque the OEM muffler clamps to 35ft-lbs and the all t-bolt clamps to 70in-lbs. Installation Guide Page 17 of 20 Revision 2

18 4.9 Exhaust Chrome Covers a. Use three #24 hose clamps for the top chrome cover. Torque to 12in-lbs Body Note: The installation/alignment of the body may take several attempts to find the correct position of the body in relation to the wheels. The six 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. Remove the OEM shock that was installed earlier from the trike. b. Glide the body onto the body frame. Slide both OEM shocks through the body. Using the OEM hardware for the shocks torque the hardware to 70ft-lbs. c. Check the body fitment on the trike. The OEM shocks should be evenly spaced from the body. Grind/drill the holes open for the 5/16 screws. Installation Guide Page 18 of 20 Revision 2

19 d. To attach the RHS of the body open the trunk to gain access. Use two 5/16-18x1-1/4 HHCS, w/washer, fender washers, nylock nuts for the RHS channel located at the front of the body. Use two more 5/16-18x1-1/4 HHCS, w/washer, fender washers, nylock nuts at both LH and RH side of the body (near the trunk door). e. The LHS of the body there will be a plug underneath the body. Open the plug and use two 5/16-18x1-1/4 HHCS, w/washer, fender washers, nylock nuts. Torque all six 5/16 bolts to 15ft-lbs. Place plug back into position. f. Install the wheels/tires onto the trike. Torque to 75ft-lbs Seat a. Remove the seat post from the OEM subframe. b. Place the supplied black plate onto the subframe using the two M08x1.25x35mm SHCS w/washers. Reattach the seat post by using a M8x1.25x40mm screw. Torque all hardware to 18ft-lbs. c. Install seat. Installation Guide Page 19 of 20 Revision 2

20 5 Accessories 5.1 Passenger Pegs a. The Indian Scout passenger pegs can be purchased at Indian (Indian Item # ). Using the purchased passenger pegs attach the thicker peg onto the LHS of the swing arm. Attach the other peg onto the RHS. Torque hardware to Indian s Instructions. 5.2 Passenger Seat a. The passenger seat can be purchased at Indian (Either Indian Item # or # ). b. A small kit will need to be purchased through Champion (Champion Kit #CH-IN1-001). Description Qty. Threaded Insert, ¼ /4-20x3/4 PHCS ss 1 25/32 washer 1 1/4" washer 1 1/4" rubber washer 1 c. Install the passenger seat above the champion spacer plate. Place the extended reach driver backrest support on top of the passenger seat. At the seat tab use a marker to mark on the body. Drill a hole using a 6mm drill. Place the 25/32 washer under the threaded insert and thread the insert into the body. d. Place the 1/4" rubber washer between the seat and insert. With the ¼-20 pan head screw and washer attach the passenger seat to the body. Torque to 5ft-lbs. Installation Guide Page 20 of 20 Revision 2