I am in mid stream of installing the mounting hdw I have a 2005 ultra and a 2001 tle tub, I understand HD makes a rear brakemaster cyc relocating kit and an engine oil pres reloc kit. can any body steer me to the part #s
Originally written by chesapeake on 5/14/2007 6:04 AM
I am in mid stream of installing the mounting hdw I have a 2005 ultra and a 2001 tle tub, I understand HD makes a rear brakemaster cyc relocating kit and an engine oil pres reloc kit. can any body steer me to the part #s
Hi, there are a lot of parts involved. I assume that you already have the mounts. Beyond that, I suggest that you pick up the pertinent parts book for your bike, P/N 99456-05 or 05A, and the sidecar book, probably 99485-06. Some of the parts needed to make the changeover are listed in those two books with part numbers and some are not since they are part of the sidecar kit, which is handled separately from the normal parts book.
Generally, the extra parts needed are:
1. X-Long clutch cable (goes under frame to miss sidecar brackets) 38649-98.
2. Sidecar/standard rear brake lever. Probably the same as pre-2002 bike. I don't have P/N for this. Part of connection kit. 87166-99B. It's the earlier stand-up lever. They changed back to the earlier lever so that the pedal would miss the lower sidecar mount.
3. FXR style remote master cylinder with hose and remote reservoir:
42457-95 Kit, brake master cyllnder Adapter w/O-rings
42365-03 Hose, brake reservoir.
10038A clamp (2)
41804-84A master cyl. reservoir
42354-99 reservoir bracket (need 1/4-20 bolts and washers, too)
42455-80 Gasket, reservoir
45057-82 reservoir cover.42534-90 screw, res. cover (2)
4. Brass oil pressure 90 degree right angle with short pipe nipple to relocate oil pressure switch. (1/4" pipe?) Auto stores have these.
5. Brass Tee for rear brake to sidecar. (1/8" pipe on two sides with 3/16" tube on the center tee opening) Auto stores have these.
6. Hinge changeover kit for right saddlebag. No part number for this. Part of connection kit 87166-99B. This makes the right saddlebag cover removeable so that it won't bang into the back of the tub.
The reason I don't have all of the part numbers is that they are not listed in one place. They come with the installation kit with the mounts and some of them don't even have parts numbers since they only appear as part of the intsallation kit.
Sorry to say, you're sort of doing this the hard way. When I got my sidecar in the crate, all of that stuff was already in there.
There's also a rollover change kit for the bank angle sensor, 88115-03. This is a safety issue to change so that the bank angle sensor doesn't cut off your engine in a hard turn. This could be saved for last, I guess. Once installed, it has to be programmed by the dealer with a Digital Technician unit.
Hope this helps..........
lots of folks get a used HD sidecar thinking its a really great deal
and lots of folks think they can make a bunch of bux splitting a bike and sidecar to sell them seperate..
but most of the time about 1k+ worth of parts got left on the bike the sidecar was mounted to. the bike owner has a terrible time getting the right parts for the brakes etc when its time for service & the new sidecar owner is missing all the little expensive bits that come in the crate....
i actually knew what i was doing but busted a important math bit and would have saved cash to have traded in my bike and sidecar together rather than move the sidecar i had to the new bike....
live and learn...
to
Originally written by timo482 on 5/15/2007 6:20 PM
lots of folks get a used HD sidecar thinking its a really great deal
and lots of folks think they can make a bunch of bux splitting a bike and sidecar to sell them seperate..
but most of the time about 1k+ worth of parts got left on the bike the sidecar was mounted to. the bike owner has a terrible time getting the right parts for the brakes etc when its time for service & the new sidecar owner is missing all the little expensive bits that come in the crate....
i actually knew what i was doing but busted a important math bit and would have saved cash to have traded in my bike and sidecar together rather than move the sidecar i had to the new bike....
live and learn...
to
It's all too true!
I also learned the hard way on my two previous Harley sidecars. When I got to this point, I determined that I'm too old to be chasing parts with some parts man who is not familiar with sidecar items.
That's why, more out of fear than anything else, I bought a new sidecar in the crate. It came with every last single piece part that you could possibly imagine. I mean, they outdid themselves and didn't miss a trick.
That's why when someone asks for a part number, if I can find it, I'll certainly pass it along. I've been in that spot and it's not much fun.
Thanks you have me on the right track, Bo
gnm109, Big thanks I just left HD of Maryland, got all the parts I needed for a little over $220.00 all I have to think is what was the motor company thinking???
Originally written by chesapeake on 5/17/2007 10:37 AM
gnm109, Big thanks I just left HD of Maryland, got all the parts I needed for a little over $220.00 all I have to think is what was the motor company thinking???
Good luck. The Motor Company was only thinking about their bottom line and their liability when they designed the sidecars. Hahahaha. It sounds like you got off easy! I hope you have fun installing all of that stuff. I'll be thinking of you. If you get stuck, drop another message or PM me. Get some blue loctite and some torque wrenches and go easy tightening things up.
To be continuned, I'm sure!
Happy Trails! LOL
lets see, I am still waiting on the old style rear brake pedal to arrive, I have relocated the master cylinder, installed the brake tee fitting, got the new clutch cable mounted to the trans Pulling of the fairing iver the next day or so, then refill the oil trans and rehang the right side exhaust, then drop her off the lift and see what I have,,,,, to do then,, what a job!
Originally written by chesapeake on 5/29/2007 11:11 AM
lets see, I am still waiting on the old style rear brake pedal to arrive, I have relocated the master cylinder, installed the brake tee fitting, got the new clutch cable mounted to the trans Pulling of the fairing iver the next day or so, then refill the oil trans and rehang the right side exhaust, then drop her off the lift and see what I have,,,,, to do then,, what a job!
Hi,
It sounds like you are on your way.
If I were you, I would avoid removing the front outer fairing cover unless absoutely necessary. I think you are talking about running the longer clutch cable through that area, correct? If so, you can push a piece of 10 gauge insulated house wire thrugh that area and then use it to pull the clutch cable through. It worked for me. I later removed the fairing for another reason and the clutch cable was doing fine in front of all of the other wires inside the area.
I have had to pull the fairing off a number of times, heated grips, chrome lowers oil temp/ air temp gauge swap,, but how in the world to you install / removel the oil filter with all this pile of new parts? I have to take the remote master cyclinder loose again,,
My oil filter will come off. I use the Harley wrench that fits on the end and have managed to turn it so that it comes out......there may be slight differences in each motorcycle.
I tried snaking out my oil filter and it just won't come out without dropping the reservoir on the '05. I have also been looking for an oil filter relocation kit but it doesn't look like anyone makes one for the twincam.
if the filter wont come out you have the lower bracket mounted too high
it has to be EXACTLY 1/16" above the voltage regulator [and no you must NOT have a chrome cover over the regulator] if its lower the regulator bites it, if its 1/16" too high the oil filter wont come out. its all engineered so that it works at exactly 1/16". no more, no less.
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Originally written by timo482 on 6/1/2007 7:30 PM
if the filter wont come out you have the lower bracket mounted too high
it has to be EXACTLY 1/16" above the voltage regulator [and no you must NOT have a chrome cover over the regulator] if its lower the regulator bites it, if its 1/16" too high the oil filter wont come out. its all engineered so that it works at exactly 1/16". no more, no less.
to
Yeah, that's a good point. You might want to check for clearance as suggested here. When I installed my lower front mount, I used a Stanley plane blade for a spacer. It was exactly 1/16". I had other problems myself, though. I asolutely could not get the mount on without finally having to remove the oil filter adapter. It simply would not go on.
All is well not, however. Finally.
I will give this a try, I will make a couple of 1/16" spacers and rest the lower mount on them, This is all great help, Many thanks Bo
