Hello, I'm putting an '02 Harley Ultra-classic sidecar on an '05 Police Road King w/ABS. I have all the brackets that came off the Ultra-classic Rig. I have a few questions, and any help would be greatly appreciated.
1. Oil pressure sending unit interference.
2. Rear master cylinder interference.
3. Rear brake pedal interference.
4. Rear brake hose connection (i have the three-way block connector).
5. Where does the steering dampener mount to the bike?
Any part numbers would be very helpful as well; my local dealer hired a bunch of clowns in the parts department. Thanks in advance.
midnightrider1966 - 5/16/2010 6:22 PM
Hello, I'm putting an '02 Harley Ultra-classic sidecar on an '05 Police Road King w/ABS. I have all the brackets that came off the Ultra-classic Rig. I have a few questions, and any help would be greatly appreciated.
1. Oil pressure sending unit interference.
2. Rear master cylinder interference.
3. Rear brake pedal interference.
4. Rear brake hose connection (i have the three-way block connector).
5. Where does the steering dampener mount to the bike?Any part numbers would be very helpful as well; my local dealer hired a bunch of clowns in the parts department. Thanks in advance.
The connecting kit supplied with a new sidecar has the following items to address. I have tried to guve you most of the part numbers. There are a few small screws and hose clamps here and there that I haven't listed. .
I'll give you part numbers as I have them from my 2004 parts book but you must verify them independently since HD changes part numbers frequently.
1. Oil Pressure Sending Unit Relocation: There is a 90 degree brass elbow. (26337-99) The elbow screws into the crankcase and the oil pressure sending unit screws into the elbow, pointing downward and inward towards the oil filter base. This clears other items installed for the sidecar.
2. Rear Master Cylinder: There is a remote brake reservoir kit that is installed. It has a cover for the existing brake cylinder that replaces the reservoir with a sleeve. (42457-95 Kit) The sleeve has a hose ( 42365-02) coming off that goes to a remote reservoir which mounts to the frame under the front mount. The brake reservoir and kit is the same as the earlier FXR. (Reservoir 41804-84A, Bracket 42354-99, Cover 45057-82. There are additional small screws that you will need.....All are listed in the motorcycye parts book. Mine is 99456-04A and the sidecar manual which you are going to need. 99485-05, 06, etc.
3. Brake Lever: The 2002 and later brake lever is the "lay down type" which would strike the lower sidecar frame horm where it connects to the frame. It's necessary to replace it with a different one which is vertical. It's similar to the 2001 and earlier, IIRC. It's a simple swap but it permits the brake to clear the sidecar frame. It's 42407-02.
4. Rear Brake Tee: The rear brake hose connection is straightforward. The existing brake connection is loosened at the end of the tube under the transmission where the brake light swith is mounted. The tee (87113-83) is installed after bending the brake tube slightly to gain some clearance. In my case, I connected a 12" extension to the new brake teee and moved the sidecar connection upwards above the front of the transmission but if you are agile (LOL) that won't be necessary.
5.Steering Damper: The steering damper has a special bracket (87143-83) that replaces the existing air dam on the rear of the lower triple tree on FL's. In any case, there are three small bolt holes that takes three screws to retain this. I think they are 1/4-20. By the way, the HD damper is the same as the one used on the VW Bugs on the front end.......Harley gets $129 for them but you can buy the VW version, also made in Brazil for as little as $20.
There is also a longer clutch cable (38649-98) which goes underneath tne engine crankcase since the lower sidecar mount will interfere with the existing clutch cable.
IIRC, HD may have changed to DOT 4 on the 2005 and later motorcycles. If the 2002 sidecar was run with Dot 5, you will need to flush the sidecar caliper in order to use Dot 4 since Dot 4 and 5 are not compatible.
I wish could help you with the ABS issue but I have never owned a Harley with ABS. I presume it will work with the sidecar but you may wish to speak to the dealer....hopeful they will know.
I hope this is helpful. I enjoy working with the Harley sidecars but i'm only good up to 2007. . Unless you get all of the parts with the purchase, you will have to order the ones you need.
Good luck.
thanks GMN109,your advice was very helpful.all the part #s you cited were correct except for the "stand up" rear brake pedal.I only mention this to help others in the future.the old style pedal is #42407-87C,also the remote reservoir gasket is #42455-80.everything went well,the only issue with ABS was brake line clearance with reservoir hose @ rear master cylinder and at front lower mount.just had to bend a little out of the way.did not have to replace clutch cable.once again,thanks so much.
midnightrider1966 - 6/7/2010 4:55 PM
thanks GMN109,your advice was very helpful.all the part #s you cited were correct except for the "stand up" rear brake pedal.I only mention this to help others in the future.the old style pedal is #42407-87C,also the remote reservoir gasket is #42455-80.everything went well,the only issue with ABS was brake line clearance with reservoir hose @ rear master cylinder and at front lower mount.just had to bend a little out of the way.did not have to replace clutch cable.once again,thanks so much.
The $42407-02 number is correct. Zanotti's has them for $67.25. I just looked it up. It's probably similar to the -87C. The -87C was for an EVO. The one on my bike that came with the sidecar is a 42407-02 on the connection kit that I received from HD. It's also shown in my 2004 Touring Parts Manual. I presume that the -87C will fit also but I'm not certain.
The number you have for the reservoir gasket is correct.
I'm glad it's working out for you.
I ordered the 42440-02 and it was identical to the one already on the bike so I continued with the connections.while attempting to bleed rear brakes,lever (42407-02) hit rig,so I went back to dealer and got #42407-87C.its shorter and sets up higher and does'nt hit.just got back from maiden voyage.rig goes straight down road,just a little shaky on handlebars at 60mph.I don't know if thats to be expected,as I'm a novice sidecarist
midnightrider1966 - 6/7/2010 6:41 PM
I ordered the 42440-02 and it was identical to the one already on the bike so I continued with the connections.while attempting to bleed rear brakes,lever (42407-02) hit rig,so I went back to dealer and got #42407-87C.its shorter and sets up higher and does'nt hit.just got back from maiden voyage.rig goes straight down road,just a little shaky on handlebars at 60mph.I don't know if thats to be expected,as I'm a novice sidecarist
Well, that's strange. If the one you got works, then I'd go with it. The -02 lever is also shorter b about 3" and sits almost vertical. There was probably some minor change.
Do you have the steering damper installed? Also, you might need to check the steering "fall off" adjustment for the fork head bearings. How is the front tire?
There shouldn't be any shake at higher speeds.
