INSTALLATION INSTRUCTIONS FOR THE MOTOR TRIKE GL1500 RAKE KIT

INSTALLATION INSTRUCTIONS FOR THE MOTOR TRIKE GL1500 RAKE KIT

Thank you for choosing the Motor Trike GL1500 Rake Kit. We ask that you read the directions before you start and follow them very closely. Doing so will save you time and ensure that the customer s experience with their new rake kit is a positive one. It is critical that proper eye wear, ear protection, and protective clothing is worn throughout this rake kit installation. Failure to secure this vehicle during installation could result in injury up to and including death. If you do not have the proper tools to do this installation, DO NOT ATTEMPT TO PERFORM THE INSTALLATION. When placing your order please remember to provide the bike year and model. This information is necessary for you to receive the correct parts. (Ex. 1992 GL1500 I) Determine if the bike receiving the rake kit has air forks. If the bike does not have air forks you must order an air fork plug kit, part number MTFS-0030. When you receive your kit, please check to ensure that all parts and hardware are included and/or assembled correctly. Use the supplied assembly drawing as an aid. If there are any parts missing or if you have any questions concerning the kit at this time call Motor Trike at 1-800-90TRIKE (800-908-7453) Mon-Fri 8am-5pm CST. Or you can email us at INFO@MOTORTRIKE.COM The installation process may vary for different years and/or models. Motor Trike Inc. reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation. 2 of 22

DISSASSEMBLY PROCEDURE 1. Protect the dash by covering it during the disassembly and installation process. Figure 1: Protect Dash 2. Carefully remove the center section of the dash along with the black handle bar inserts. Lift the bottom of the center section up to remove it. Turning the handle bars will help remove the inserts. See Figure 2 and Figure 3. 3 of 22

LIFT HERE INSERTS Figure 2: Remove Dash Center and Inserts Figure 3: Inserts Removed 3. Remove the handle bar center cover. It snaps off. See Figure 4 4 of 22

Figure 4: Center Handle Bar Cover 4. Remove the fork tube cap covers. These will vary with year model. See Figure 5. Figure 5: Fork Tube Cap Cover 5. Lift the front tire just off of the ground using a hydraulic floor jack under the front of the bike. 6. Loosen the two pinch bolts in the top triple tree using a 12mm wrench. See Figure 6. 5 of 22

Figure 6: Loosen Top Pinch Bolts 7. Carefully remove the front fender side covers from both sides of the front fender. See Figure 7. Figure 7: Front Fender Side Cover. Right Side Shown 8. Remove the indicated fasteners from both sides of the front fender using an 8mm socket. Each bolt will have a top hat washer underneath it. Keep track of them for reinstallation. See Figure 8. 6 of 22

Figure 8: Remove Three Bolts from Both Sides 9. Remove the chrome brake rotor covers from both sides. 10. Remove the brake caliper mounting bolts using a 5mm and 6mm Allen socket. Remove both front calipers from the down tubes, but do not disconnect the brake lines. See Figure 9. 7 of 22

Figure 9: Remove Front Brake Calipers 11. Carefully hang the front calipers so that they do not scratch the front fender or lower front fairing. Wire tying a towel to the crash bars helps protect the lower front fairing. See Figure 10. Figure 10: Carefully Hang Front Brake Calipers 12. Using a Phillips screw driver remove the front wheel speed sensor from the front wheel. With the Phillips screw removed the cable will slide out. See Figure 11 8 of 22

Figure 11: Removing Front Wheel Speed Sensor 13. Free the wheel speed sensor from the clip attaching it to the front wheel assembly. See Figure 12. Figure 12: Wheel Speed Sensor Clip 9 of 22

14. Use a 5/16 Allen socket to loosen the lower triple tree pinch bolts under the front fairing. Access to these bolts is acquired by turning the handle bars all the way to the left for the right side bolts and vise versa for the left side bolts. There are 4 bolts in all. See Figure 13 and Figure 14. Figure 13: Lower Pinch Bolts Location Figure 14: Lower Triple Tree Pinch Bolts 15. The front wheel assembly should be free from the upper and lower triple trees at this point. 16. Slowly lift the front of the bike higher using the hydraulic floor jack. The forks will start to slide out of the triple trees. You may need to shift the front wheel back and forth for it to slide out. When the fork tubes are almost free from the lower triple tree, have someone hold the fork tubes to keep them from falling. 17. Roll the front wheel assembly away from the bike and secure it in a tire clamp. See Figure 15. 10 of 22

Figure 15: Secure Front Tire Assembly 18. Remove the air deflector from the lower triple tree using a Phillips head screw driver. See Figure 16. Figure 16: Air Deflector 19. Remove the steering cancel lever, located just behind the lower triple tree, from the bike by unsnapping it from the lower triple tree and using a Phillips screw driver. See Figure 17. 11 of 22

Figure 17: Steering Cancel Lever 20. Remove the turn signal cancelation sensor from the bottom of the lower triple tree with a Phillips head screw driver. Unplug the connector and remove. See Figure 18. Figure 18: Remove the Turn Signal Cancelation Sensor 21. Remove the handle bar saddle clamp bolts with a 12 mm socket. See Figure 19. Figure 19: Handle Bar Bolts 12 of 22

22. Lift the rubber cap to expose the top triple tree nut. Remove the harness from the steering stem. See Figure 20. Figure 20: Lift Rubber Cap 23. Remove the top triple tree nut with a 30mm socket. See Figure 21 Figure 21: Remove Top Triple Tree Nut 24. Remove the top triple tree. See Figure 22. 13 of 22

Figure 22: Remove Top Triple Tree 25. Bend the vertical tabs of the lock washer down to allow removal of the top lock nut. Use a lock nut removal tool (Honda Part # 07916-3710100 or 07916-3710101) to remove the top lock nut. See Figure 23. Figure 23: Remove Lock Washer and Nut 26. Remove the bearing adjustment nut with the same Honda tool and remove the lower triple tree and steering stem from the steering neck. See Figure 24 and Figure 25. Figure 24: Steering Adjustment Nut 14 of 22

Figure 25: Stock Lower Triple Tree 27. Wipe the lower bearing race off and inspect the race to determine if it is necessary to replace it. If there are any scratches, blemishes, or scoring on the surface of the bearing race, replace the bearing race. If the bearing race surface is completely smooth, then it may be reused. 28. To replace the lower bearing race: a. Knock out the old bearing with a screwdriver from the top. b. Use a bushing driver or similar tool to tap the new supplied bearing race into the lower end of the steering neck. Make sure to evenly tap the bearing race into the steering neck with the cup facing down. It will be difficult to remove the bearing race if it is installed upside down. Use a tool that will not damage or dent the bearing race. The race is seated when the sound of tapping on the bearing becomes solid. Visually inspect the race to make sure it seated properly. 29. Inspect the upper bearing and bearing race. Replace them if necessary. The replacement procedure for the upper bearing is the same as the lower bearing. INSTALLATION PROCEDURE 1. Remove the four pinch bolts from the stock lower triple tree and install them in the rake kit lower triple tree. Use blue loctite on the bolts. Thread in the two supplied studs to a depth of 10 rotations. See Figure 26 15 of 22

Stock Pinch Bolts Stock Pinch Bolts STUDS Figure 26: Pinch Bolts and Mounting Studs 2. Grease the bearing on the lower triple tree. Spin the bearing several times and reapply grease. Every roller must be completely coated with grease. 3. Install the lower tree assembly on the bike and thread the steering adjustment nut onto the steering stem. 4. Torque the bearing adjustment nut to 30 ft-lbs using the Honda tool used earlier. Loosen the bearing adjustment nut and then re-torque it to 30 ft-lbs. Turn the lower tree from lock to lock five times and then re-torque the bearing adjustment nut to 30 ft-lbs one last time. 5. Reinstall the lock washer with two apposing fingers bent down into the grooves of the bearing adjustment nut. 6. Reinstall the lock nut and get it hand tight. Use the Honda nut tool to further tighten the lock nut, within 90 degrees or a ¼ turn, to align its grooves with the tabs of the lock nut. Bend the two tabs up to engage the lock nut. 7. Transfer both pinch bolts and cable brackets from the stock top triple tree to the rake kit top triple tree. If the bike is equipped with 7mm bolts use the supplied 8mm bolts in their place. Do not tighten. See Figure 27 and Figure 6. 16 of 22

Figure 27: Top Pinch Bolt and Cable Bracket. 8. Install the rake kit top triple tree along with the steering stem spacer. Install the steering stem nut and hand tighten. See Figure 28. STEM NUT TOP TREE SPACER Figure 28: Install Top Triple Tree 9. Rotate the top and bottom triple clamps left and right to make sure that the upper and lower bearings feel good and to check for any clearance issues. 10. Reinstall the front tire assembly by sliding the fork tubes into the lower and then upper triple trees as you lower the front of the bike. Tighten the upper and lower pinch bolts enough to hold the fork tubes in the clamps. Leave enough of the top of the fork tubes exposed to remove the fork tube caps. 11. If equipped, remove the air valve from each fork tube cap using a 10mm socket. See Figure 29. 17 of 22

Figure 29: Remove Air Valves 12. Remove the stock fork tube caps and transfer the o-rings from the stock caps to the rake kit extensions. Inspect the o-rings for damage. Apply fork tube oil to the o-rings. 13. Carefully screw the new fork tube caps into the fork tubes. Do not use a pneumatic or power tool to install the fork tube extensions. Slowly screw them in with a 3/8 drive ratchet. Taking the proper precautions during this step will eliminate the chance of cross threading the down tubes. Torque the fork tube caps to 20 ft-lbs. 14. Loosen all of the pinch bolts and adjust the fork tube extensions until the rear edge of the tube extension is flush with the top edge of the mounting hole. Do this for both tube extensions. See Figure 30. FLUSH WITH TOP TOP Figure 30: Extension Adjustment 15. Tighten all four of the lower triple tree pinch bolts on the front of the lower triple tree to 40 ft-lbs. See Figure 26. 16. Tighten both of the top triple tree pinch bolts to 20 ft-lbs. See Figure 27. 17. Screw the stock air valves into the top of the fork tube extensions if equipped. See Figure 29. If the bike does not have air valves screw the bolts supplied in MTFS- 0030 into the fork tube caps to seal the fork tubes. Torque them to 15 ft-lbs. See Figure 31. 18 of 22

Figure 31: Sealing Bolt From MTFS-0030 18. Torque the steering stem nut to 76 ft-lbs. See Figure 28. 19. Reinstall the fork tube cap covers if equipped. See Figure 5. 20. Install the handle bars using the original handle bar saddles and hardware. The dot on the left side of the handle bar should go 1/8 above the top surface of the lower saddle clamp for correct handle bar timing. Torque the handle bar bolts to 20 ftlbs Figure 32: Handle Bar Clocking 21. Apply soapy water to the rubber grommet on the steering cancel harness. Slide the rubber grommet back on the harness to provide enough length to feed the connector all the way through the steering stem. Feed the connector all the way through the steering stem so that the connector sticks out of the bottom of the steering stem. See Figure 33 19 of 22

Figure 33: Slide Grommet Back on Harness 22. Connect the harness to the turn signal cancellation sensor. Reinstall the turn signal cancellation sensor using a Phillips screw driver and the original hardware. See Figure 18. Slide the grommet back down the harness and push it on to the top nut. 23. Reinstall the turn signal cancellation arm using the supplied hardware. Use the plastic standoff to space the arm down. Put a washer on each side of the arm. Snap the end of the arm onto the turn signal cancelation sensor boss. See Figure 34. Figure 34: Steering Cancellation Arm 24. Install the front air deflector on the lower triple tree using the supplied M5 jam nuts on the M5 studs installed earlier. Remember to route the wheel speed sensor cable through the slot in the air deflector. See Figure 16. 25. Reconnect the front wheel speed sensor with a Phillips head screw driver. Reroute the cable back through the cable clip. See Figure 11 and Figure 12. 26. Reinstall the front calipers. See Figure 9. 20 of 22

27. Reinstall the left and right brake rotor chrome covers. Remember to reinstall the top hat washer under all six bolts. See Figure 8. 28. Reinstall the left and right fender side covers. See Figure 7 29. Reinstall the center handle bar cover. See Figure 4. 30. Reinstall the left and right handle bar inserts and the center dash section. See Figure 2 and Figure 3. 31. Carefully lower the front of the bike and remove the hydraulic jack from under the bike. 32. Depending on several factors including year model, accessories installed on bike, and bike model, it may be necessary to trim the chrome fork cover on the front wheel assembly of the GL1500. Check for clearance between the chrome cover and the main front faring with the handle bars turned all the way to the steering lock. Follow the procedure below. With the handle bars at the end of their travel have an assistant bounce on the trike while you watch the clearance between the main front fairing and the chrome down tube cover. Check for clearance with the handle bars turned all the way to the left and then all the way to the right. 21 of 22

a. If there is no interference, trimming is not required. If there is interference trim both sides of the cover equally following steps b and c. Failure to trim parts when interference exists may result in the chrome cover breaking while riding. b. Remove the chrome cover by removing the two 5mm bolts on the top of the cover with an Allen wrench. Carefully measure before cutting and make sure the cuts are equal, level, and straight. This part is best cut with a cut-off wheel. Use tape to protect the chrome cover while cutting. See Figure 35. 1 INCH MIN. CUT LINE CUT LINE Figure 35: Front of GL1500 Front Wheel Assembly c. Check the clearance again to ensure you have removed enough to obtain full clearance. Remove more if necessary, while removing as little as possible. 33. Verify that all of the parts are installed properly and that all of the bolts are tight, keeping in mind that customer safety is the first priority. 34. Test drive the vehicle at parking lot speeds and then highway speeds. Always remember to check that your brakes are functioning correctly before beginning a test drive. Always wear a helmet and appropriate riding gear. 35. Clean the bike thoroughly inside and out. 22 of 22