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Honda Goldwing GL1800 Independent Rear Suspension Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm . 5.1 Explanation of OEM brake system and changes From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Trike Conversion Kit.

Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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Honda GL1500 Gold Wing Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 17-02-2011

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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 reinstallation after modification are noted. • Left and right side-covers (to be re-installed with minor modification). • Seat (to be re-installed without modification). • Trunk. • Left and right passenger foot rests (to be re-installed without modification). • Left and right side-covers above passenger foot rests. • Battery and holder (to be re-installed without modification). • Left and right saddle bags (retain side cover mounting grommets for re-use). • Left and right mufflers. • Rear wheel. • Rear brake line to master cylinder.** • Reverse resistor assembly (to be relocated). • Swing Arm (Drive shaft boot will not be used). • Bank angle sensor. • Shocks. Air shock (non coil-over) to be reused. ** Thoroughly vacuum drain rear brake system, including feed line to left front caliper PREINSTALLATION PREPARATION 3.1 Modification to Trunk / Luggage Stay Removal from vehicle frame is not necessary. a. Cut the down tubes of the trunk stay and remove the lower section as shown in Figures 1 & 2 b. Trim rear upper tube-end rounded corners just outboard of welded nut. Trim line should be parallel with center line of vehicle. This will provide clearance for body when installed. Figure 2 (Inset) c. Remove the Hazard and Turn Signal relays from the center holder; bend Relay Holder Tab up 90°. Relays will be relocated to left and right sides. Figure 3 d. Disconnect and remove Bank Angle Sensor from its mount tab (Bank Angle Sensor will not be re-used). Cut wires midway between sensor and plug. e. On plug end, splice / connect red and green wires together to close the circuit. f. Cut and remove the Bank Angle Sensor mount tab from the Trunk stay. Figure 4 3.2 Modification to Rear Inner Fender Removal of fender and attached parts is not necessary for modification. a. Place supplied template (See last page) on fender (left and right sides) as shown and mark outline. With box cutter, cut fender along template outline. Once material is removed, make a vertical cut up the side (line indicated by arrow Figure 5) of the fender. Do not continue cut across top of fender. Figure 5 b. Carefully heat underside of fender with heat gun and bend fender upward until aft end contacts frame cross member. c. Drill holes in plastic fender through cross brace at locations indicated and secure fender to cross with zip ties. Figure 6

Honda Goldwing GL1800 Independent Rear Suspension Trike Conversion Installation Guide

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Filed Under (Honda) by admin on 17-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame

Yamaha Road Star Trike Conversion Installation Manual

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Filed Under (Yamaha) by admin on 17-02-2011

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the 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. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model Installation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster

Yamaha Road Star Motorcycles Trike Conversion Removal And Installation Manual

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Filed Under (Yamaha) by admin on 09-11-2010

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Removal of Original Parts a. Disconnect the battery. b. Secure and raise the 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. • Rider’s Seat (to be re-installed without modification) • Passenger Seat (to be reinstalled without modification) NOTE: OEM front / rear seat mount bracket and rear seat mounting bolt to be retained and reused. • Passenger Back Rest w/ Mounting Rails (to be re-installed without modification) NOTE: Back rest to mounting rail hardware to be reused. Mount rail to vehicle frame not to be reused. • Left and right passenger foot rests (to be re-installed without modification) • Drive Pulley / Belt cover (to be re-installed without modification) • Mufflers (to be re-installed and relocated with minor modification) • Rear Fender (complete w/ sub frame and all attaching parts) NOTE: Upper Forward Fender Mounting Bolt to be retained and reinstalled. • Shock Absorber to Swing Arm Mounting Bolt (to be re-installed) • Swing Arm and Rear Wheel (complete w/ all attaching parts) NOTE: Swing Arm Pivot Bolt, washer and nut to be retained and reinstalled. • Brake Line to Rear Master Cylinder • Drive Belt Core Return There are NO core return parts for this model. nstallation of Champion Trike Conversion Kit 4.1 Install Drive Belt a. Install supplied drive belt to transmission output pulley. (Refer to OEM manual) Figure 1 b. Drive belt cover to be reinstalled later. 4.2 Install Champion Swing Arm a. Install Champion Swing Arm to vehicle using the OEM pivot bolt, washer and nut. Figure 2 b. Attach OEM shock absorber to swing arm using OEM hardware. c. Torque pivot bolt nut to 90 lb. ft. d. Torque lower shock hardware to 43 lb. ft. 4.3 Install Rear Drive Assembly a. Install tension bolts and jam nuts to adjuster plates. Figure 3 Qty per Assm Spec Description 2 M10 x 1.25 x 70 Hex Head Bolt 2 M10 x 1.25 Hex Nut b. Install adjuster plates to rear drive pinch blocks. Hardware installs from inboard to outboard side. Snug, but do not tighten hardware at this time. Figure 4

V-Star 1100 And Dragstar 1100 Modification V-Star Driving/ Passing Lights Factory Chrome Light Bar Cover Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Use a rotary tool to widen the fastening area of the lower backside clips on the cover. The total width between the clips should be 4 æ inches. Trim off º inch on both inside ends of the lower backside attachment clips. Trim the clips equally. The following picture shows a modified cover. Narrow the clips on both ends to fit over the welds on the bar. The cover will not attach to the bar if the width between the clips is too narrow. If the width is too wide the cover may slide sideways on the bar. Narrow both clips equally to center the cover over the welds on the lower edge of the bar. The top of the cover is modified to allow the cover to fit over the bolts on the light bar. The top edge of the cover is filed æ inch deep and 5/8 inch wide to fit over the bolts. The back top edge is filed or ground 1/8 inch to fit over the light bar fastening bracket. Use care when filing chrome covered plastic. The following picture will help to complete this step in the modification. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. The ends of the cover are modified to allow the cover to fit over the upward curved light bar. The upper openings on the ends of the cover that fit over the bar must be filed to enlarge the area. Grinding the cover ends will allow the cover to fit and clip onto the bar. The end openings are filed or ground at an angle to match the slope of the bar. This picture shows the outer end of the cover. The ends of this cover have been modified by enlarging the area on the upper edges to fit over the upward curving light bar. The ends must be enlarged 1/8 inch on the top edge. The cover edge can be slanted upward to match the curved bar. Modify the cover ends until it fits without the outer chrome cover touching the bar. Modify your factory light bar cover to fit on Yamaha brand driving/passing lights. Sometimes the modified light bar cover may touch the bottom of the headlight. Modify the cover, or adjust the bar or headlight if you notice the headlight touching the bar cover. This modification makes the V-Star motorcycle with Yamaha driving lights look better. The light bar bolts are covered and the chrome cover improves the appearance of the front of your bike. Other V-Star riders will notice how nice the front of your bike looks with the chrome light bar cover installed

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Harley Davidson Five Speed Transmissions Hydraulic Clutch Modification

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Filed Under (Harley Davidson) by admin on 31-10-2010

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Hydraulic Clutch Modification for Harley Davidson With Champion Reverse Gear 1 1.1 Install Reverse Gear Assembly to gearbox. 1.2 Remove clutch cover (left side). 1.3 Remove Release Plate (clutch adjustment) and Push Rods. 1.4 Install Hydraulic Clutch Release Cover with supplied spacer and two gaskets. 1.5 Bleed clutch system. NOTE: When bleeding clutch system, lever feel will become hard, do not force lever because piston is at end of travel.(Continue Bleeding) 2 2.1 Install Push Rod. 2.2 Push the rod into clutch assembly to force hydraulic piston to its start position. Push the rod hard until the clutch cylinder is fully compressed. This is the start position. 2.3 Install Hydraulic Clutch Throw-Out Bearing Holder and bearing to push rod. Do not install circlip at this time. 2.4 If the throw-out bearing holder does not fully seat into the Pressure Plate (Figure 2.4), proceed to step 2.5. If shaft is too short then use throw-out bearing holder from Champion Reverse Gear Kit, skip next step and proceed to 3.0 2.5 Measure distance between bearing holder and pressure plate (ensure that push rod is pushed in) Figure 2.4 2.6 Remove bearing holder and push rod, reinstall bearing holder until seated (without push rod). Measure distance from pressure plate to bearing holder. Figure 2.6 2.7 Add measurements taken in steps 2.5 and 2.6 2.8 Add 0.090″ to total of step 2.7 (allowance for clutch plate wear). Measurement should be approximately 1/8″. 2.9 Measure push rod length. 2.10 Subtract measurement of step 2.8 from measurement of step 2.9 (push rod length). This measurement represents the amount of material to be removed from ball end of push rod. (Step 2.11)

Honda GL1500 Gold Wing Motorcycles Trike Conversion Installation Guide

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Filed Under (Honda) by admin on 19-12-2011

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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 reinstallation after modification are noted. • Left and right side-covers (to be re-installed with minor modification). • Seat (to be re-installed without modification). • Trunk. • Left and right passenger foot rests (to be re-installed without modification). • Left and right side-covers above passenger foot rests. • Battery and holder (to be re-installed without modification). • Left and right saddle bags (retain side cover mounting grommets for re-use). • Left and right mufflers. • Rear wheel. • Rear brake line to master cylinder.** • Reverse resistor assembly (to be relocated). • Swing Arm (Drive shaft boot will not be used). • Bank angle sensor. • Shocks. Air shock (non coil-over) to be reused. ** Thoroughly vacuum drain rear brake system, including feed line to left front caliper Modification to Trunk / Luggage Stay Removal from vehicle frame is not necessary. a. Cut the down tubes of the trunk stay and remove the lower section as shown in Figures 1 & 2 b. Trim rear upper tube-end rounded corners just outboard of welded nut. Trim line should be parallel with center line of vehicle. This will provide clearance for body when installed. Figure 2 (Inset) c. Remove the Hazard and Turn Signal relays from the center holder; bend Relay Holder Tab up 90°. Relays will be relocated to left and right sides. Figure 3

2001-2003 YAMAHA XV16 MODELS FACTORY MODIFICATION CAMPAIGN

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Filed Under (Yamaha) by admin on 02-12-2010

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Fuel Pump and Carburetor Removal: •Disconnect the carburetor fuel line hose at the fuel pump. •Disconnect the fuel pump wire coupler. •Remove the choke cable from fuel pump bracket. •Remove the upper engine mount, leaving the fuel pump attached to the mount. •Disconnect the TPS and carburetor wire couplers. Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws. PAGE 3 of 12 HIDDEN 6mm SCREW 6mm BOLT UPPER ENGINE MOUNT/ FUEL PUMP CARBURETOR PAGE 4 of 12 Right-Hand Footrest Removal: •Disconnect and remove the brake light switch. •Remove the forward-most tie wrap around the brake hose and frame. •Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: •Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting. Air Injection System (AIS) Removal: •Remove the electric starter motor. •Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. •Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. •Remove the three Phillips head screws holding the AIS assembly on the frame. •Remove the AIS assembly from the left side. FOOTREST ASSEMBLY UPPER BANJO BOLT AIS AIR FILTER AIS ASSEMBLY PAGE 5 of 12 Transfer Case Removal: •Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. •Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. •Remove the drive pulley cover and remove the drive pulley nut. •Loosen the drive belt tension. •Remove the drive pulley, inner cover, collar, and O-ring.