Trike Conversion Installation Guide Kawasaki Vulcan ...

KAWASAKI TRIKE CONVERSION

CHAMPION TRIKES

Installation Guide – Kawasaki Vulcan 2009-Up of 31 05/09/2012

Jan Myburgh, Kurt Larson, and Brad Vinton

Trike Conversion Installation Guide

Kawasaki Vulcan Voyager and Vaquero Motorcycles (Non ABS)

2009 and Up Independent Suspension

11/29/2012

CAUTION: Champion’s Independent Suspension was designed to enhance your riding comfort and performance. However, to achieve maximum results adjustments must be made for individual riding styles, passenger weight, and traveling with a trailer. Failure to make the proper adjustments will potentially lead to serious personal injury and/or property damage and may void the warranty. Champion does not guarantee fit form or function to any of their trike kits if altered or aftermarket components were added to the original bike design. All dealers or installers should make proper adjustments with the customer before delivery. Champion is not responsible for additional adjustments made under warranty.

Champion Motorcycle Accessories International, Inc.

dba Champion Sidecars

11841 Monarch Street, CA 92841 (800) 875-0949 (714) 847-0949 Fax (714) 847-1539

www.championtrikes.com

http://www.championtrikes.com/


CHAMPION TRIKES



Champion Trikes

Trike Conversion Kit 2009-Up

Kawasaki Vulcan Motorcycles Voyager and Vaquero Models

Independent Suspension


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Table of Contents

1 General Information .............................................................................................................................................4 1.1 Installation Information ................................................................................................................................4

1.1.1 Altered or Changed from OEM Warning .................................................................................................4 1.2 For Your Safety ...........................................................................................................................................4 1.3 Important Safety Precautions .....................................................................................................................4 1.4 Specifications ..............................................................................................................................................5

2 Removal of Original Parts ...................................................................................................................................6 2.1 Secure and raise motorcycle at least 10 inches. ........................................................................................6 2.2 Remove the following from the vehicle for installation. See OEM manual for detailed instructions. .........6

3 INSTALLING TRIKE CONVERSION KIT ............................................................................................................7 3.1 Install Champion Belt ..................................................................................................................................7 3.2 Install Top Frame ........................................................................................................................................7 3.3 Install Rear End Assembly..........................................................................................................................8 3.4 Install Swing Arm and Body Frame ............................................................................................................9 3.5 Align and Tension Drive Belt ................................................................................................................... 12 3.6 Install Anti-Roll Bar .................................................................................................................................. 13

3.6.1 Standard Anti-Roll Bar ......................................................................................................................... 13 3.6.2 Variable Sway Control (VSC) Optional ................................................................................................ 14

3.7 Install Brake Parts .................................................................................................................................... 14 3.8 Install Exhaust Parts ................................................................................................................................ 15 3.9 Vaquero Body and Side Panel Installation (Go to 3.10 for Voyager Models) ......................................... 17 3.10 Voyager Body and Side Panel Installation .............................................................................................. 22 3.11 Wheel and Tire Installation ...................................................................................................................... 30 3.12 Antenna Replacement ............................................................................................................................. 30 3.13 Install Trailer Hitch Receiver (Optional) ................................................................................................... 30

4 Shock Adjustment ............................................................................................................................................ 31 4.1 Adjusting Shock Preload.......................................................................................................................... 31


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1 General Information

The Champion Sidecars Trike Conversion Kit is designed with the utmost consideration for safety, quality and ease of installation. The kit comes complete with all necessary hardware and fasteners. It is recommended that the installer obtain an OEM service manual for the vehicle on which the Trike kit is to be installed. The Champion Independent was designed to enhance your riding performance and comfort. The independent must be adjusted per the individual riding style. Please review the installation instructions before installing the kit.

1.1 Installation Information

The information contained in this installation guide is intended for use by technicians of advanced to professional skill levels. Attempting installation without the proper training, tools and equipment may result in damage to the vehicle, cause unsafe conditions, or cause personal injury to you and/or others. 1.1.1 Altered or Changed from OEM Warning

CAUTION: Champion trike kits are designed for installation on unmodified motorcycles as from the OEM. Champion does not guarantee fit, form, or function, on any of their trike kits if installed with altered or aftermarket components on the original bike design.

1.2 For Your Safety

Because this guide is intended for technicians of advanced to professional skill levels, we do not provide warnings about many basic shop safety practices. If you have not received shop safety training or do not feel confident about your knowledge of safety practices, we recommend that you do not attempt to perform the procedures described in this guide.

Some of the most important general safety precautions are given below. Champion Sidecars cannot warn you of every conceivable hazard that can arise. Only you can decide whether or not you should perform a given task.

1.3 Important Safety Precautions

a. Make sure you have a clear understanding of all basic shop safety practices and that you wear appropriate clothing and use safety equipment. Be especially careful of the following:

Read all directions before you begin, and make sure you have the tools, the parts and the skills required to perform the tasks safely and completely.

Protect your eyes by using proper safety glasses, goggles or face shields anytime you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components.

Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts.

Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported.

b. Make sure the engine is turned off before you begin work.

Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine.

Burns from hot parts: Let the engine and exhaust system cool before working on those areas.

Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts.


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c. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries.

d. Use only nonflammable solvent, not gasoline, to clean parts

e. Never drain or store gasoline in an open container.

f. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts.

1.4 Specifications

Overall Length: 105.5”

Overall Length (w/ EZ-Steer) 109.5”

Overall Width: 57.75”

Wheel Base: 70”

Wheel Base (w/ EZ-Steer) 73”

Max Load Capacity: 500 lb

Tire Size (15”): 205 / 70 / R15

Wheel Size (15”) (4 lug) Offset +35 mm 15x7JJ 4x4.5

Tire Pressure: 20-25 PSI

Suspension: Double A-Arm Independent

Rear Differential: Custom-built rear differential utilizing OEM drive belt

Brakes: Original front plus 2 high performance disc brakes at rear

Storage Capacity: 5.75 cubic feet (2 full-face helmets and additional storage)


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2 Removal of Original Parts

Champion does not change components that will affect or change the emission characteristics of the motorcycle.

2.1 Secure and raise motorcycle at least 10 inches.

2.2 Remove the following from the vehicle for installation. See OEM manual for detailed instructions.

Disconnect battery leads

Seat (both front and rear)

Top Box (if equipped)

Saddle Bags

Mufflers (and chrome covers over muffler joints if needed)

Saddlebag Rails (if so equipped)

Top Box Frame and Chrome Covers (if equipped)

Side Body Panels

Rear Wheel

Rear Caliper

NOTE: Prior to disconnecting the line at the caliper, depress the foot brake and secure it in the down position (zip-tie to floor board). This will prevent fluid flow when the rear brake caliper is removed.

Rear Brake Line (disconnect line at master cylinder)

Rear Fender (Remove the passenger seat catch with bolts from the fender)

Shocks

Swing Arm

Drive Belt


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3 INSTALLING TRIKE CONVERSION KIT

3.1 Install Champion Belt

a. Install included longer belt onto front countershaft sprocket as per the OEM service manual.

3.2 Install Top Frame

a. Bolt Top Frame to the motorcycle sub-frame using the supplied M8x1.25x30 socket head cap screws with washers and nylock nuts. Then install the two M8x1.25x25 hex head cap screws with split lock and flat washers. Torque hardware to 19 ft-lbs.

b. Attach the passenger seat catch to the top frame with the OEM bolts.

M8x1.25x25 HHCS w/ Lock Washer and Flat Washer

M8x1.25x30 SHCS w/ Washers and Lock Nuts

M8x1.25x30 SHCS w/ Washers and Lock Nuts


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3.3 Install Rear End Assembly

a. Remove 3 of the 4 cross tubes as seen below.

b. Pass rear end assembly through the drive belt and position drive belt onto rear pulley. We recommend using a hydraulic lift table or something similar to hold the unit in position.

c. Install the 2 rear cross tubes with spacers first. Use the ¾-10x2.5 hex head bolts and washers on the side without spacers. Use the ¾-10x3 hex head bolts and washers with the spacers. Apply anti seize to the threads of the bolts and torque the ¾ hex head bolts to 150 ft-lbs. Install the front cross tube with notch toward the belt. Rotate the cross tube so that the notch is in line with the belt (provides the greatest gap) and torque the ¾ bolt to the above specification. Install the spacer and torque the ½-13x2.25 hex head cap screw with washers to 50 ft-lbs.

Front

½-13x2.25 HHCS


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d. Bolt both left and right Side Body Mount brackets to Top Frame with the supplied 3/8-24x1.25 hex head cap screws with washers and nylock nuts. Keep the bolts slightly loose for belt adjustment. Torque hardware to 45 ft-lbs after the belt tension is set. Then bolt the Rear End Assembly to side body mount brackets with the supplied ½-13x1.5 hex head cap screws with washers and nylock nuts. Do not torque hardware yet, must be slightly loose for belt tension adjustment later.

e. Remove the support or table jack holding the rear end assembly for additional room to work. The rear end can now hang from the side body mount brackets.

3.4 Install Swing Arm and Body Frame

a. You will need to bend a tab on the right hand side near the exhaust header slightly to the outside of the bike to install the swing arm.

Bend Tab to

the Outside

½-13x1.5 HHCS

3/8-24x1.25 HHCS


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b. Pass the swing arm through the belt and position into the motorcycle frame as seen below. Slide the OEM pivot bolt through the motorcycle frame and swing arm. Thread the OEM nut onto the pivot bolt, but keep loose.

c. Position body frame inside of swing arm and push the ½-13x3.75 hex head bolts with flat washer through the mounting holes from the outside until flush with inside of body frame. Swing the body frame and swing arm assembly up into the rear end assembly.


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d. Push the bolts through the rear end mounting plates and position the clamp plates over the bolts. Install the nylock nuts with washers and keep slightly loose to adjust the belt tension later.

e. Install both belt adjustment brackets using the 3/8-16x1-1/4” bolts, washers, and nylock nuts. Torque hardware to 40 ft-lbs.

Belt Adjustment

Bracket

Belt Tension

Adjuster Bolts


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3.5 Align and Tension Drive Belt

a. Set the belt tension and alignment by moving the independent drive train unit forward or rearward as necessary using the adjuster bolts. Belt tension can be measured by total vertical movement and should be approximately ¾”-1” with a new belt.

Tip: Measure from the bracket to the face of the drive train on each side to get the alignment close. Then perform the next step.

b. To check the alignment, turn the sprocket by hand in the forward direction, noting whether the belt runs in the center of the pulley. If the pulley runs on the right side plate of the pulley, use the right hand adjuster bolts to move the right wheel rearward until the belt runs in the center. If the belt runs on the left side plate of the pulley, use the left adjuster bolts to move the left wheel rearward. Make small adjustments and recheck the alignment.

c. Once the belt is aligned, torque the four front 1/2" fasteners to 70 ft-lbs and double check belt alignment. If alignment is off, please repeat alignment process.

d. Tighten all fasteners left loose for belt adjustment.

Torque the four rear ½” fasteners to 70 ft-lbs.

Torque the Side Body Mount brackets to Top Frame 3/8-24x1.25 HHCS to 45ft-lbs.

Torque the OEM pivot bolt nut to 80 ft-lbs.

e. Recheck belt tension and alignment after tightening the fasteners.


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3.6 Install Anti-Roll Bar

3.6.1 Standard Anti-Roll Bar

a. Install the four 3/8-24x1.25 bolts with washers and nuts through anti-roll bar housing onto front frame. Position the anti-roll bar on the frame so that the rod ends will be close to vertical when attached to the control arms. Torque hardware to 45 ft-lbs.

Longer Side on RHS (10.80 Approximately) Shorter Side on LHS

(10.42 Approximately)


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b. Attach rod-end to right control arm with the included hardware in the following order: 3/8-24x2.25 bolt, washer, rod-end, washer, control arm, washer, and then nut. Torque to 45 ft-lbs.

c. Adjust left side rod-end until it aligns with the left control arm mounting hole.

d. Tighten jam nut on the left side rod end assembly.

e. Attach rod end to left control arm just as was done to right control arm. Torque to 45 ft-lbs.

3.6.2 Variable Sway Control (VSC) Optional

3.7 Install Brake Parts

a. Attach brake t-block to bolt on swing arm and use the supplied ¼-20 nylock nut with washer. Torque to 140 in-lbs.

b. Connect blue brake pressure residual valve to t-block with crush washer. Torque to 18 ft-lbs.

c. Route the Champion braided brake lines from the rear calipers through the rubber grommets on the belt tension adjustment brackets to the t-block.

d. Connect included Champion braided brake line with 90 deg. bend to OEM rear master cylinder using OEM banjo bolt and crush washers. Route Champion brake line in the same location as the old OEM brake line. Connect Champion brake line to pressure residual valve using a 10mm banjo bolt and two crush washers. Torque to 18 ft-lbs. (Note: Picture below do not show the Champion brake lines.)


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e. Use brake fluid specified on the master cylinder and bleed rear brake system. Thoroughly bleed the system of any air using the upper bleeders on rear brake calipers.

3.8 Install Exhaust Parts

a. Attach the exhaust extension hanger to the swing arm as seen below.

b. Slip Champion exhaust extensions into OEM header pipe ends (longer extension is used on the LHS). Attach the LHS extension to the hanger with the two supplied hose clamps. Keep all the clamps slightly loose until the mufflers are installed.

c. Install muffler brackets to body mount frame using hardware in supplied kit. Note the orientation of the rubber vibration isolators in the illustration below. Tighten the nuts until a few threads of the bolts are visible.

Make sure rubber body mounts are installed before mounting mufflers.


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d. Cut the LHS OEM header pipe as seen in the picture below.

e. Slip the supplied exhaust t-bolt clamps over the extension ends. Then slip the OEM mufflers into the extensions and bolt to the muffler brackets using the supplied M8-1.25x25 hex head cap screws with split lock and flat washers. Torque hardware to 20 ft-lbs.

f. Adjust the extensions and mufflers until the best fit is achieved. Make sure the mufflers are at the same angle relative to the body frame otherwise the gap around the muffler to the body may differ. Now tighten the exhaust hanger hose clamps, OEM exhaust clamps, and the supplied t-bolt clamps on the exhaust extensions.

Cut At Red Line (Note: The cut is in the middle of the bends on either side.)


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3.9 Vaquero Body and Side Panel Installation (Go to 3.10 for Voyager Models)

a. Trim both LHS and RHS side panels to fit around swing arm and sway bar.

b. Remove side panels to install body later.


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c. Place the RHS side panel face down and position trunk release bracket as seen. Mark the smaller hole center and drill with a #5 drill. Trace the larger opening for reference later.

d. Cut out the trunk lock opening such that the trunk lock will fit. Place the trunk release bracket inside and attach it to the side panel using the #10-32 screw with two washers and nylock nut.

e. Place the supplied gasket on trunk lock, then insert through side panel. Attach trunk lock to trunk release bracket with the supplied nut as shown below. Champion recommends applying a medium strength thread lock compound to nut with a minimum torque of 176 in-lbs.


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Note: The installation/alignment of the body is an iterative process to find the correct position of body in relation to the wheels. The six holes already in the body are primarily for shipping purposes. These holes may line up with the pre-drilled body frame holes when the body is fitted, but may need to be elongated to align body.

f. Make sure the two rear rubber mounts are attached to the rear frame and are loose.

g. Place trike body, with front four rubber mounts attached, onto all six mounting locations.

h. Install the hardware as it came shipped and keep loose.

i. Position the trike body to best fit both the rear wheels and bike frame.

j. Only drill or slot the two rear holes in the body larger if necessary.

k. Tighten all six 3/8-16 short nylock nuts to 20 ft. lbs.

l. Connect Champion wire harness to body harness.

Connect Champion Wire

Harness to Body Harness


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m. Connect Champion wire harness to OEM motorcycle wire harness as seen below. Attach black ground wire as seen below. Connect the blue accessory wire from the Champion wire harness to a 12V power source, brown and green wire, as seen below.

Connect Black Ground Wire

Connect Blue Accessory Wire to OEM Brown and Green Wire


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n. Install the remaining parts onto the trunk lock. Route cable to trunk lock assembly as shown below.

o. Attach the LHS and RHS side panels.


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3.10 Voyager Body and Side Panel Installation

a. Trim both LHS and RHS lower side panels to fit around swing arm and sway bar then remove to install body later.


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b. Install side panel brackets on both sides of the motorcycle with the OEM bolts (LHS is shown below). You may need to adjust the rotation of the bracket slightly to line up with the side panels before tightening the bolt.

c. Position Trunk Release Assembly onto RHS side panel with slight gap between knob and panel. Mark and drill two holes then attach with the supplied 6-32 screws and nuts as seen below.

Ensure Small Gap


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Note: The installation/alignment of the body is an iterative process to find the correct position of body in relation to the wheels. The six holes already in the body are primarily for shipping purposes. These holes may line up with the pre-drilled body frame holes when the body is fitted, but may need to be elongated to align body.

d. Make sure the two rear rubber mounts are attached to the rear frame and are loose.

e. Place trike body, with front four rubber mounts attached, onto all six mounting locations.

f. Install the hardware as it came shipped and keep loose.

g. Position the trike body to best fit both the rear wheels and bike frame.

h. Only drill or slot the two rear holes in the body larger if necessary.

i. Tighten all six 3/8-16 short nylock nuts to 20 ft. lbs.

j. Connect Champion wire harness to body harness.

Connect Champion Wire

Harness to Body Harness


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k. Connect Champion wire harness to OEM motorcycle wire harness as seen below. Attach black ground wire as seen below. Connect the blue accessory wire from the Champion wire harness to a 12V power source, brown and green wire, as seen below.

Connect Black Ground Wire

Connect Blue Accessory Wire to OEM Brown and Green Wire


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l. Attach the RHS lower side panel with trunk release assembly to the motorcycle. Route and attach the trunk pull cable hook into the plastic clip on the trunk release as seen below.


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m. Attach the upper RHS side panel. Then attach the LHS lower and upper side panel. Push in the supplied black cap to cover the hole as seen below.


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n. Assemble the top box frame with the OEM chrome covers and hardware as seen below.

o. Position, by sliding from front to back under the trike body, and align the top box frame assembly to the bike subframe mounting holes. Then thread the supplied M8x1.25x45 socket head cap screws into the four mounting holes from the inside out until the head bottoms out against the sub frame. Next, use a flat washer and nylock nut from the outside bolt ends to attach the top box assembly. Torque the nuts to 19 ft-lbs. Attach chrome covers with OEM screws where possible.


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p. Connect all necessary wires from top box to motorcycle.

3.11 Wheel and Tire Installation

a. Install wheels and torque to 75 ft. lbs.

b. Set tire pressure to 20-25 psi.

3.12 Antenna Replacement

Champion recommends using a digital electronic hidden antenna for Vulcan models with a radio and no tour box. For example, a replacement antenna from Dakota Digital model ANT-2000 is available. See www.dakotadigital.com for more details.

3.13 Install Trailer Hitch Receiver (Optional)

a. Install hitch receiver to trike body frame with supplied hardware.

Qty Description

8 5/16"-18 x 1 hex bolts

8 5/16” SAE flat washers.

b. Electrical wiring for the trailer is located on the underside of the trike body at the rear. Electrical connectors not

supplied. Mounting tab for connector socket is located on hitch receiver.

c. Color code for wiring as follows: (Confirm by testing)

Function Color

Running lights BROWN

Brake lights RED

Turn signal, right GREEN

Turn signal, left YELLOW

Accessory BLUE

Ground BLACK

http://www.dakotadigital.com/


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4 Shock Adjustment

4.1 Adjusting Shock Preload

a. The preload adjuster is factory-set at the softest level for a plush ride. Increasing preload may be advisable if needed for additional weight.

b. To adjust the preload, turn the black collar located on the bottom of the spring just as you would with a fastener with right handed thread. See recommended tool below for adjusting the preoad.

Note: Both shock absorbers must be adjusted equally resulting in the equal spring preload. Not having equal adjustments will affect handling that could lead to potential harm.

More Preload = Stiffer Ride Less Preload = Softer Ride

c. Recommended spring preload from softest setting as follows:

+1/4” up to 200 lbs.

+1/2” up to 400 lbs.

+5/8” with trailer

d. Champion recommends using a shortened #2 Phillips head screwdriver to adjust spring preload. Tool tip diameter needs to be ¼”.

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