Extended frames and low stances are the mark of true choppers.
A low, raked out, hard tail chopper turns heads. Sportsters provide the motorcycle enthusiast an approachable option to building a chopper due to their relative ubiquity and low price. Whether you want to build a chopper from the ground up or simply bolt on a few parts, an old sportster offers you the perfect opportunity to ride the bike of your dreams.
Instructions
1. Secure the motorcycle on a motorcycle jack. Disconnect the battery cable.
2. Remove the exhaust shields and exhaust pipes. Set these in a safe place to avoid scratching them during your work.
3. Keeping the parts organized will make reassembly much easier.
Remove the suspension system, drive belt cover, drive belt, brake assembly, swing arm, and rear wheel. Set each of these parts and their corresponding nuts and bolts in separate areas in your workspace.
4. Bolt on the hard-tail extension. Check the manual for torque specifications and make sure to follow the procedure exactly.
5. Reinstall the rear wheel. Do not tighten the wheel into place as you will have to adjust it later.
6. Wrap the extended drive belt around the front sprocket. Loop it around the back sprocket. Pull the rear wheel backwards creating tension in the drive belt. Tighten the rear wheel.
7. Reinstall the brake assembly along with the exhaust pipes and shields.
8. Remove the old seat. Disconnect the gas line running from the gas tank. Remove the old gas tank.
9. Install the new, extended gas tank. Reconnect the gas line. Install the new solo seat making sure to tighten the fasteners according to the specs in the accompanying manual.
10. Disconnect the brake lines and clutch cable from the handlebars and front wheel. Remove the turn signals, front fender, front wheel, forks, and tubes. Remove the handlebars, risers, and triple trees.
11. Install the new bottom adapter, top and bottom trees along with the extended fork tubes from the bolt on fork extension kit. Reinstall the front wheel and brake assembly with the appropriate spacers and new hardware from the fork extension kit.
12. Position the new ape hanger handlebars to accommodate the rider's height and posture; tighten the handlebars.
13. Install the new brake lines and clutch cables from the fork extension tube kit. Reinstall and reconnect the turn signals. Install the front fender. Reconnect the battery cable.
Tags: drive belt, rear wheel, brake assembly, fork extension, front wheel, along with
