timo482 - 4/9/2010 8:14 PM
LOTS of folks buy a used sidecar without getting all the bits and pieces... - unless you can get the guy to cough up the parts you will need to take a inventory and get whats missing.. there is a complete parts list of whats in a 2003 mounting kit in the manual and a list of what parts you need to change from a 2001 kit if you have the whole kit.
the most expensive parts are the ones you CANT see - the ones that are easy to get off and send with the sidecar are the cheap ones - that 200 $ bracket is a cheap part - you should be able to get it for 120 if you dig. i got the latch on ebay for a hundred, got the roll over for 110.. purchased a 2007 mount kit that didnt have those two parts for 975, plus the special right side fairing lower for 200. oh, and a tree that is very nice but not required unless, like me, you get sore wrists for 1k
the mounting kit - all told - is about 1200 bux now. [plus a few parts that wont be in the kit....] - its a 40 lb box of totally special one off parts that convert a bike from a solo bike to a sidecar capable bike... and the whole kit just disappears into the bike. its completely invisible & only somebody who has installed the kit will really be able to look at a bike and tell if it has the kit on it or not - its very subtle and well enginered to be invisible. many many owners take the sidecar off and sell it not even aware that 1200 bux of parts for that sidecar are still on there bike.
ive done two installs and one removal - takes me about a day and a half each way - and i have all the tools.
that all said - its not that bad - fairly straight forward - follow the service manual the sidecar service manual to the t and its all good.
but to be completely honest with you. you jack up the bike, remove the exhaust system, remove the right foot board and brackets, remove the rear brake pedal & master cyl, remove the transmission cover, cable, levers, remove the seat, battery etc. remove the saddle bags, remove the fairing, remove the voltage regulator.
then - install the new latch that comes in the kit in the right saddlebag
then - install the brake kit - takes me a hour with it off the bike to get it done - stubborn O rings.
then - move the oil sender
then - install the brake tee for the sidecar brake
then - install the roll over switch etc and put the batt back in [and take to the dealer to get activated - takes 10 mins]
then - install the new clutch cable and all its fixings, the cover and adjust the clutch and put the fairing back on.
then - install the rear mount
then - install the rear master cyl and pedal
then - install the new voltage regulator bolts - its IMPOSSIBLE to remove the regulator for service if the bolts are not changed to sidecar bolts BEFORE you install the lower mount...
then - install the lower mount and adjust it
then - install the upper mount
then - install the upper steering damper mount
then - install the foot board
then - install the exhaust sys and all the gaskets etcif you want it to steer real nice - stop here and change out the front tree for a trike raked tree, liberty, HD trike, champion etc etc pick one. well worth the money if you are not very strong
then - install the sidecar
then - bleed the brakes
then - plug in all the wires
then - adjust toe in & lean out
then - install the seat & bags etc & go do a test ride
then - tweak till toe in and lean out till the result is nice easy centered steering.later
to
All very good points. Don't forget that the Harley dealer is the only place to get the Rollover switch adtivated. With a 1999 sidecar, it won't be incluided. He would have to go out and buy one. It's really optional if you don't want to pay for it, althogh it will provide some additional safety in the event of a complete rollover.
I would also check the TSSM part number to see if it is inside of the block of numbers that require the rollover switch. Up to late 2001, the sidecar mode could be set using only the turn signals and ignition switch, like the security code.
Good luck to everyone!
