The open road awaits for motorcyclists and sidecar passengers.
Sidecars offer a comfortable ride for motorcycle passengers. With features such as radios, interior lighting and comfort seating, a passenger can simply sit back and enjoy the view. Installation of sidecars requires advanced motorcycle mechanic skills. According to The Texas Sidecar Company, the difficulty of installation depends on the make and model of the motorcycle, the make and model of the sidecar, the mechanical skills of the installer and the available tools and equipment.
Instructions
Wiring the Sidecar
1. Remove the seat from the motorcycle.
2. Use test light to locate the tail light wire connection, the brake light wire connection and the battery positive terminal.
3. Connect the supplied hardware wiring kit to connect the red wire from the sidecar harness to the motorcycle brake light connection. The black wire from the sidecar harness connects with the negative battery post. Connect the green wire from the sidecar to the motorcycle tail light connection.
4. Connect any additional accessory wiring, such as interior lights or driving lights, to the positive battery terminal or motorcycle accessory lead.
Upper Front Mount
5. Place the strap clamp on the right-side of the vertical frame tube.
6. Move it as high as possible.
7. Install two 1/4 bolts from the rear forward into the clamp. The bolt heads should face the engine. Do not tighten.
Lower Front Mount
8. Remove the two socket-head screws holding the floorboard on the right side of the motorcycle.
9. Remove the bolt that holds the bottom of the crash guard to the motorcycle.
10. Install the lower front sidecar mount between the frame and the crash guard.
11. Replace the crash guard bolt.
12. Replace the floorboard, aligning the holes with the mount slots for the sidecar. Tighten all three bolts.
Lower Rear Mount
13. Remove the bolt that holds the engine ground strap to the cross member, located on the bottom of the motorcycle frame.
14. Place the lower rear mount in position, sliding the U-strap over the right side of the horizontal frame tube. Slide it forward until touching the frame gusset weld.
15. Install the outer bolt into the U-strap.
16. Clamp the mount up to the center of the cross member.
17.Use the mount for a guide to drill a 3/8 inch hole through the cross member for the second U-strap bolt. Drill two 5/16 inch holes at the far end of the mount. Add remaining bolts, using one of the 5/16 holes to secure the engine ground strap. Tighten all four bolts on the lower rear mount.
Upper Rear mount
18. Locate and remove the 7/16 inch bolt from the rear floorboard mount. It will be located at the top of the mount. Remove the seat, oil tank cover and right saddlebag.
19. Remove the upper front mounting bolt for the oil tank.
20. Position the upper rear mount and install the included new grade 8 bolts into the top floorboard mounting position and into the upper front oil tank mounting hole. Do not tighten.
21. Position the rear of the mount behind the box section of the frame using the provided spacers. Install four bolts to the rear piece of the mount.
22. Check the position of the mount and tighten all bolts.
Attaching the Sidecar
23. Support the sidecar frame at the front and rear cross members with stands so that it is level with the mounts on the motorcycle.
24. Slide the sidecar towards the motorcycle, guiding the mounting hardware into the sidecar frame.
25. Install a 45 degree boss and 45 degree clamp to the front mounting hardware.
26
Install a 70 degree clamp and 70 degree boss to the rear mounting hardware.
27
Adjust the motorcycle so that it simulates the riding position. Engage the lower rear mount insert and tighten the 5/8 inch through bolt. Repeat for the front lower mount. Tighten all half-inch fasteners with a torque of 80 ft. lbs. Torque the half-inch pinch bolts to 85 ft. lbs. Install the rear and front struts from the sidecar frame eye to the upper rear mount eye.
Tags: rear mount, from sidecar, crash guard, cross member, lower rear
