SETTING-UP INSTRUCTIONS These instructions and illustrations describe how to set up an LS model (Right Hand) sidecar.

Proceed in same manner in setting-up LLS model (Left Hand) sidecar. To assemble sidecar frame refer to Illus. 2 and 3. When installing sidecar frame to motorcycle refer to Illus. 4, 5 and 6. Mudguard, mudguard lamp, floor mat will be found in sidecar body. All other necessary fittings will be found in package below sidecar cushion. Installing Axle Assembly Remove nut and lock washer from tapered end of axle (G). Wipe tapered end of axle and taper in boss clean then insert tapered end of axle into boss on right end of frame rear tube (R). Reinstall lock washer and nut and tighten nut very tight. Mounting Wheel Remove lock nut, axle nut, keyed lock washer, adjusting nut and small bearing from axle (G). Apply wheel bearing grease to both bearings and inside of hub shell. Mount wheel and re-install small bearing and adjusting nut. Turn adjusting nut inward, against bearing, until wheel has only slight shake or play. Install keyed lock washer axle nut and lock nut and tighten lock nut securely. Pack open end of hub with wheel bearing grease and re-install hub cap. Assembling Frame Block up left side of frame rear tube (R) high enough so it is even with wheel axle. Place frame front tube assembly (K) in position, and support on blocks of suitable height. Install frame brace clamp bolt (T) in bracket on frame front tube assembly (K). Insert lower end of frame brace (O) through clamp (U) (clamp forward). Do not tighten clamp bolt until sidecar has been installed on motorcycle and has been correctly aligned. Installing Body Support Spring Mount body rear support spring (S) right end shackle onto bracket on frame rear tube (R), using bolt (Z), lock washer and nut furnished. Mount left end of spring onto lug on left side of frame rear tube (R) using bolt (Z1) washers and nut furnished; one large plain washer on each side of spring loop. Tighten all nuts securely. Mount body front spring assembly (L) with U-bolt furnished, on frame front tube (K). Do not tighten U-bolt nuts until body mounting has been completed.

Installing Mudguard Braces Insert horizontal brace (V) into mudguard brace clamp (F) above axle boss, with offset upward. Install clamp bolts, lock washers and nuts. Do not tighten nuts securely as yet. Secure lower end of brace (W) to rear side of clamp (D) on frame rear tube. Install upper clamp (E) on brace. Secure clamp to rear side of extended bracket on top of mudguard brace clamp (F). Install mudguard mounting brackets (X) to mudguard braces (V and W) with U-bolts (Y) furnished. Do not tighten U-bolts securely as yet. Installing Mudguard Lamp and Mudguard Holes for mudguard lamp and for mounting mudguard are already drilled. Install mudguard lamp; connect wire to lamp terminal and lead wire through lamp wire clamp. If not equipped with lamp disregard this and last paragraph under this caption. Secure mudguard to brackets with bolts, lock washers and nuts furnished. Tighten nuts securely. Shift brace (V) and/or U-bolts (Y) to correctly position mudguard. Front and rear ends of guard must be centered over wheel. Tighten U-bolt nuts and mudguard brace bracket nuts securely. Lead mudguard lamp wire down along mudguard brace (W), along frame rear tube (R) to motorcycle. When sidecar frame finally is attached to motorcycle, lead wire up along frame rear stay and connect wire to insulated front terminal under saddle. Secure wire to mudguard brace, frame tube and frame stay with clamps furnished. Installing Sidecar Frame on Motorcycle As shown in Illustration 3 attach front connection (H) to front connecting yoke (J) and rear frame connection ball socket joint (P) to rear frame tube connecting arm (Q). Tighten ball socket mounting stud nut securely; do not securely tighten hinge bolt (I). Raise motorcycle on rear stand. Attach front connection (H) on motorcycle frame front tube (below) footboard support bracket) by means of U-bolt. Do not securely tighten U-bolt nuts as yet. Apply a small amount of grease to rear frame connection ball socket joint (P). Attach rear connection to frame lower stay, as far to rear as possible. Be sure rubber cushion is n place between ball stud and motorcycle frame tube. Securely tighten crews. Loosen front connection yoke (J) and frame rear tube connecting arm (Q) clamp cap screws. Yoke and arm may have to be turned slightly on their respective frame tubes to attain alignment with connections (H and P). Attach sidecar to motorcycle. Connect front connection first and tighten hinge bolt nut (I) only. Connect rear connection. Turn frame rear tube connecting arm (Q) as may be necessary to align with rear ball stud. Install lock washer and nut on ball stud and tighten nut securely. Do not tighten arm (Q) cap screw as yet.

Apply a small amount of grease to come on frame brace upper connection (N). Connect frame brace connection (N) by inserting cone end into right side hole in rear mudguard support (underneath saddle). Insert frame brace connecting bolt (M) from top and engage bolt head into socket in connection. Install plain washer, spring and nut. Tighten nut just enough to expose cotter pin hole. (Do not bottom spring). Install cotter pin. Aligning Motorcycle and Sidecar Chassis Push motorcycle off rear stand and temporarily adjust motorcycle so it leans about 2 degrees away from sidecar. Do not tighten brace clamp screw (T) as yet. Tighten front connection (H) U-bolt nuts. Adjust frame rear tube connecting arm (Q) so straight section of frame rear tube (R) is parallel with floor (floor must be level). Tighten connecting arm (Q) cap screw securely. For correct handling, sidecar wheel must be "toed-in" slightly in relation to motorcycle wheels. Check "toe-in" as follows: Using two 2 x 4's as straight edges, set one against right side of front and rear motorcycle tires (handlebars turned straight ahead) and the other against left side of side car tire. 2 x 4's should be blocked up at least four inches so they contact each tire at two points. Measure distance between 2 x 4's and at side car wheel and also at front wheel. When sidecar is "toed-in" correctly, 2 x 4's will be 5/8" closer together at front wheel than at sidecar wheel. Adjust by shifting end of frame tube right or left in front connecting yoke. When correct "toe-in" is attained, tighten connecting yoke clamp screw securely. Turn frame brace in lower clamp to such a position that starter crank will not strike it when operated a full stroke, an so there is sufficient clearance between frame brace and sidecar body. Adjust frame brace so motorcycle leans about 2 degrees away from sidecar. It is of prime importance that this adjustment be carefully made, as it affects steering. With adjustment correct, motorcycle will have no appreciable tendency to pull to either right or left when driven on a level highway. Tighten brace clamp cap screw securely. Be sure all screws and nuts are securely tightened. LS CHASSIS AND BODY EXP. ENG. 51 OR xxxxx Printed in U.S.A. HARLEY-DAVIDSON MOTOR CO Milwaukee, Wis., U.S.A.