Section A. GENERAL INFORMATION

I. Description The information and instructions for attachingthe sidecar to the right-hand side of themotorcycle are contained in this handbook andmust be carefully observed. Deviating fromthese instructions may create a dangerouscondition which may contribute to an accident;under such circumstances American Jawa Ltdwill not be responsible for personal injury and

property damage.

The Velorex Sidecar consists of a tubular steelframe on which the sidecar body Is mounted.The body is made of rugged fiberglass,reinforced with sheet steel at vulnerable andstressed areas, and rests on the frame on rubberblocks at the front and rear. The wheel axle Issupported by a hydraulic shock absorber andcoil spring system mounted on a swingarm forsmooth and comfortable riding. The wheel isprovided with a single-cam, twin-shoe, internalexpanding drum brake.

An Attachment Kit (Part No.562-08-800), shownin figure 1, is supplied with each Velorex Sidecarand is packed in the luggage compartment. Thekeys to the luggage compartment, and themolded windshield, are placed inside the sidecar.

Required assembly time is approximately four tofive hours, involving four simple operations:

1. Attaching the frame of the sidecar tothe frame of the motorcycle.

2. Adjusting toe-in and lean-out of themotorcycle in relation to the sidecar.

3. Connecting the electrical wires fromthe sidecar to the electrical circuits ofthe motorcycle.

4. Connecting the brake cable from thesidecar to the foot brake pedal of themotorcycle and adjusting its operation.Note: Because of the variety of brakepedal systems used on motorcycles,this operation is best performed by aqualified dealer.

The Attachment Kit makes it possible to attachthe sidecar to virtually any current motorcyclewith round tube frame, but the motorcycle shouldbe powerful enough (not less than 25bhp) toaccept the weight of the sidecar, passenger, andextra luggage.

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FIGURE 1. Attachment Kit, Part No.562-08-800, showing Struts, U-Clamps, Sliding Clamp, Shims,Cotter Pins. Bolts and Nuts shown fitted to assemblies.

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II. SpecificationsThese four operations are given in easy-to-understand step-by-step procedures, which re-quire no special tools other than regular shopwrenches, several wooden blocks or bricks forpropping up the sidecar and the motorcycle, twostraight strips of wood for toe-in measurements,and an angle bracket for measuring lean-out.

Standard Safety Features

Single-cam, twin-shoe, internalexpanding drum brake

Swingarm with Hydraulic ShockAbsorber and Coil Spring

Stop. Light

Tail and Side Clearance Lights

Provision for attaching DirectionalSignal Lights {Lights not included)

Standard Convenience Features

Molded Aerodynamic Windshield

Lockable Luggage Compartment

Vinyl-covered Foam Rubber Uphostery

Sturdy Hand Grabrail

Rugged Footrest

Snap-on Tonneau Cover

, ...16 inch

.7.5 inches

154 pounds

230 pounds

Measurements

Wheel size Ground clearance .

Unit weight. Maximum payload .

III. Preliminary Checks

After uncrating the Velorex Sidecar and carefullyexamining it, report any concealed damage ormissing parts directly to American Jawa Ltd.Perform the following checks:

1. To prevent damage to the windshieldduring assembly procedures, removethe windshield carefully from thesidecar Interior and set it in a safe

place.2. CAUTION When handling the sidecar,

take care not to damage the electricalwiring harness and the wheel brakecable through pulling or kinking.

3. The recommended tire pressure is 28

psi.4. Working in a clear area, prop up the

frame of the sidecar with blocks ofwood or bricks to hold it level. Removethe Attachment Kit from the luggagecompartment and check all partsagainst those shown in figure 1. Adetailed Parts List and Exploded Viewis shown in Section D, along with therelated Part Numbers.

Note: For BMW models a special mounting

bracket may be needed.

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ATTACHING SIDECAR TO MOTORCYCLESection B.

For safety reasons and for best performance andriding comfort, the Velorex Sidecar must beattached to the motorcycle and all adjustmentsmade in accordance with the instructions givenin this handbook. As already explained, de-viations may create dangerous conditions, forwhich American Jawa Ltd. will not be

responsible.

consist of the U.Clamp, Spacer Block, Bolts,Lockwashers, and Nuts. Large and small Shimsare provided for use on frame tubes which aretoo thin for the U-Clamps. To attach theU.Clamps to the motorcycle frame, proceed as

follows:1. Fit the U.Clamp to the top front of the

motorcycle frame, insert the SpacerBlock, and fasten in place with the twoBolts, Lockwashers, and Nuts.

2. Thread the Eyebolt through the SpacerBlock and tighten it against the frametube. If the frame tube is too thin for afirm grip, insert the Large Shim ahead ofthe Eyebolt. If the U.Clamp is still tooloose, insert the Small Shim at the rear.See figure 3. Tighten the Eyebolt firmlyto hold the U.Clamp in place.

3. Fasten the other three U-Clampssimilarly to their attachment points asindicated in figure 2. It is important to fitthe top U-Clamps as high as possible onthe motorcycle frame, and the bottomU-Clamps as low as possible.

Before proceeding, layout the Attachment Kitand remove the Nuts, Bolts, and Lockwashersfrom the four U.Clamps, the,n remove tIle SpacerBlock from Inside each U-Clamp. On the Strutassemblies, remove the Bolts from the Eyebolts.Have two long straight strips of wood abouteight feet long (such as 2x4's), and an anglebr:acket, at hand for toe-in and lean-out

measurements later.

Assembly

Figure 2 indicates the four attachment points on

the motorcycle to which the U-Clamps must be

fastened. The four U.Clamps are identical and

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FIGURE 2. Attachment points Indicated on four basic frames. X marks indicate alternate attachment points.

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FIGURE 4. Clevis Adjusting Bolts must line up withEyebolts. Note bottom front U-Clamp attached to cross tubeof frame.

FIGURE 3. U-Clamp at top front of frame, showing largeShim in place. Small Shim in rear not needed in this case.Exhaust pipes removed for picture clarity.

4. Note The front bottom U-Clamp mayhave to be attached to the crossmember of the motorcycle frame incertain cases. See figure 4.

CAUTION Before attaching anyU-Clamp, make sure it is notobstructing any operating control onthe motorcycle, such as levers, rods,switches, and not rubbing against anywire.

The Curved Bar and the Sliding Clamp areattached to the sidecar frame as follows:

5. First loosen the two holding bolts whichare fitted to the front end of the sidecarframe, then insert the Curved Bar intothe frame. Do not tighten the twoholding bolts at this time. Note that theCurved Bar can be swung in an arc tosimplify later assembly whenconnecting the Eyebolt of the U-Clampto the Clevis Adjusting Bolt of theCurved Bar. In figure 4 one of the twoholding bolts on the sidecar frame isvisible, as well as the two Locknuts onthe Clevis Adjusting Bolt.

FIGURE 5. Rear short Strut assembled to Sliding Clamp.Eyebolts of rear long Strut assembled to sidecar frame. In allcases at least 2 inches of Clevis Adjusting Bolt must beinside Strut.

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FIGURE 7. Struts and Curved Bar are shown attached with

Eyebolts to frame of sidecar.

6. Attach the Sliding Clamp to the rearpart of the sidecar frame with Bolts,Lockwashers, and Nuts. Tighten theBolts only enough to hold the SlidingClamp in place at this time.

7. Insert the Eyebolt with the SpacerSleeve into the Sliding Clamp, andfasten with Nut, as shown in figure 5.Figure 6 shows the Eyebolt and Strutinverted for cases when such anassembly is required.

8. First remove the bottom Nuts from theEyebolts on the two long Struts, theninsert the Eyebolts into the front andrear holes provided on the sidecarframe, as shown in figure 7. At this timereattach the Nuts to the Eyebolts

loosely.Note Do not insert any Cotter Pins atthis time, as the bolts will have to betightened securely after toe-in and lean-out adjustments have been completed.

9. Set the motorcycle on level ground onits wheels so it stands upright. This canbe done with wooden blocks or bricksplaced under the frame. Position thesidecar at the right-hand side of themotorcycle so that the distance fromthe motorcycle frame edge to thesidecar frame edge does not exceed 1-2inches. Prop up the sidecar frame tohold it level.

10. IMPORTANT In final assembly, theshort Strut at the bottom rear of thesidecar frame must be at an exact rightangle (90°) to the sidecar andmotorcycle frames, thus placing thesidecar wheel ahead of the rear wheelof the motorcycle by 8 to 10 inches. Thiswheel offset distance is important (see

figure 13).

FIGURE 8. Bolts fitted to front Clevis Adjusting Bolts hold

Struts in place during adjustment procedures.FIGURE 6. If necessary, short Strut can be inverted.

Compare to figure 5. Short Strut must always be exactly at90 o to the frames.

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11. Fit the Clevis Adjusting Bolts of theStruts and of the Curved Bar to theEyebolts of each U.Clamp, and insertthe Bolts to hold the Struts in place. Seefigures 8 and 9. During alignmentoperations these Bolts must beremoved to allow the Clevis AdjustingBolt to be turned in or out, asnecessary. The Locknuts on all ClevisAdjusting Bolts are left loose at thistime, but will be tightened securelyafter toe.in and lean-out adjustmentsare completed.

12. CAUTION The long Struts connectedto the top U.Clamps on the motorcycleframe must not be parallel to eachother. When viewed from the top, theStruts must be angled outward from thesidecar frame to the motorcycle frame,as shown in figure 10. This angling ofthe Struts provides stability and lessensstress on the motorcycle and sidecar.From the standpoint of safety, eachClevis Adjusting Bolt must be threadedinto its Strut at least two inches deep.

13. With all Struts connected, remove thesupports from under the sidecar and

motorcycle.

FIGURE 9. Rear short and long Struts being lined up withbottom and top U-C:amps.II. Toe.in and lean.out Adjustments

When riding a motorcycle with a sidecarattached, stability and control depend on propertoe.in alignment of the wheels in relation to theline of travel, and the correct amount of lean.outof the motorcycle from the exact vertical.

FIGURE 10. Top long Struts must be angled outward from the sidecar.

FIGURE 11. Take Toe-in measurement about one foot ahead of the front tire. Distance must be between112 inch to 314 inches less than at rear.

FIGURE 12. Note clearance between tire and angle bracket at ground surface. Lean-out, with empty sidecar,is 118 of an inch.

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Under certain conditions it may be advisable tohave your dealer stiffen the front and rearsuspension of your motorcycle by installing airpressure cups or other devices, and insertingcotter pins into the wheel axles (or using axle

locknuts)j.

be loosened (or tightened, as the needmay be) in order to achieve proper toe-in. Counter-clockwise turning of theClevis Adjusting Bolts reduces toe-in.

Lean.out adjustment is as follows:

1. Place an angle bracket against theoutside edges of the front wheel tire, asshown in figure 12. Note the clearancebetween the tire and the angle bracketat the ground surface. The correct lean.out distance is 118 of an inch.

2. If the lean-out is not correct, remove theNuts and Bolts from the ClevisAdjusting Bolts at the upper ends of thefront and rear Struts, then turn theClevis Adjusting Bolts inward to lessenlean-out, and outward to increase lean-out.

3. After making all adjustments, replacethe Bolts and Nuts into the ClevisAdjusting Bolts, tighten securely, andinsert all Cotter Pins.

4. Test ride the machine, with a passengerin the sidecar. Note that the weight of apassenger in the sidecar brings thelean-out adjustment back to zero, whichis correct. For this reason it issuggested that when riding solo an

Toe.in adjustment is as follows:

1. Place one of the long straight strips ofwood against the outside edges of bothmotorcycle tires, with the front wheelfacing straight ahead. Place the otherstrip of wood against the outside edgesof the sidecar tire. See figure 11.

2. Measure the distance between thewood edges at the front and rear. Foraccuracy and consistency, take themeasurements at one foot ahead of thefront wheel, and one foot behind therear wheel.Toe.in difference at the front must bebetween a 1/2 inch to 3/4 of an inch lessthan at the rear. See figure 11. If thedistance difference at the front isgreater, turn the front top and bottomClevis Adjusting Bolts clockwise

(tightening).Note The top and bottom ClevisAdjusting Bolts at the rear may have to

FIGURE 13. Correct wheel offset shows sidecar wheel axle 8 to 10 inches ahead of motorcycle wheel axle.

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The sidecar Wheel Offset, Fittings, and Brakemust be checked periodically.

1. Refer to Section B for informationregarding adjustments. See figures 11,12, 13, 14 and 15.

2. If the sidecar wheel must be removed,the fittings come off as shown in figure14 (Cotter Pin not shown). Replace insame order, and insert Cotter Pin. .

3. The hydraulic Shock Absorber and CoilSpring, mounted on the Swingarm, areshown in figure 15. Note the single-cam,twin-shoe Brake, on which the liningsare easy to replace.

appropriate weight be carried in thesidecar for better stability.Ride the machine a short distance in astraight line and also in circles to bothsides. From the standpoint of safety,bear in mind that when turning to theright centrifugal force will tend to liftthe sidecar wheel off the ground. At fastspeed this is dangerous!After the test ride, check the toe.in andlean.out adjustments, and if necessarymake minor changes. Thereafter, checkthese adjustments after every 500 milesof travel. Whenever strong vibrations orshaking are noticed, it means the toe.inadjustment is out of line.

5. Normal riding stresses and vibrationsmay loosen the bolts and nuts. Checkall attachment points periodically toensure that nothing has loosened!

A = Frame-to-Frame distance 12 inches.

B = Wheel Offset 8 to 10 inches.

C = Toe-in less than at D by ~ to % inch.

E = Lean-out 1/8 inch.

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