Champion Sidecars DAYTONA 2+2 User manual

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CHAMPION SIDECARS
DAYTONA 2+2, LEGEND AND ESCORT
OWNERS MANUAL
(HARLEY DAVIDSON SIDECAR GENERAL INSTRUCTION)
Champion Sidecars Inc.
11841 Monarch Street
Garden Grove, CA 92841
[phone] (sales)
[phone] (customer service)
[phone] (parts)
[phone] (fax)
http://www.champion sidecars.com (web site)
[email protected] (e-mail)

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TABLE OF CONTENTS
SPECIFICATIONS------------------------------- 3
Information on tire size, wheel bearings, brake pads
tire air pressure, T.I.L.T. actuator and information
regarding the removal and re-installation of your
sidecar.
GENERAL------------------------------------- 4
Drawing of frame and suspension parts inc frame
and suspension parts list
ELECTRICAL----------------------------------- 5
Wiring harness pin location and color call out for
wiring harness installation to motorcycle.
Wiring of fuse link, ground, clock and accessories. 6
brake lights, running lights, right turn signal,
and back up light.
wiring of canopy switch (Daytona Sidecar)
T.I.L.T. electrical installation.
Wiring instructions Legend Sidecar
INSTALLATION OF REAR SUB FRAME--------------- 7
CONTINUED INSTALLATION OF SUB FRAME--------- 8
INSTALLATION OF UPPER FRONT MOUNT------------ 9
INSTALLATION OF LOWER FRONT MOUNT------------ 9
BRAKES--------------------------------------- 10
PREPARATION AND MOUNTING OF SIDECAR TO
MOTORCYCLE----------------------------------- 10
This section covers all aspects of installing the
sidecar to the motorcycle including helpful hints for
pre installation.
Mounting of sidecar continued. This section includes 11
instructions on wheel lead, toe in, and torque specs.
Mounting of sidecar continued to include diagram 12
showing the correct frame height and location of
measurement points for the Daytona, Legend and Escort
sidecar installation.
Mounting of sidecar continued. Diagrams showing 13
hardware used in the installation of the Daytona,
Legend and Escort sidecar. This section also covers
some information regarding the chrome struts.
STEERING DAMPER ------------------------------- 14
Photo showing installation of steering damper
DRIVING A SIDECAR------------------------------ 15
Helpful hints and safety precautions for the first
time sidecar rider and sidecar passenger.
Also information regarding what to expect when you take
your sidecar for its first ride.

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Escort (E) Daytona (D) Legend (L)
SPECIFICATIONS
TIRE (E)(D) ----- 145SR13 DUNLOP
Tire (L) ----- 130 x 90 x 16"
WHEEL (E)(D) ----- #22-3511 4 x 100 modified to 4 x 4
Wheel wire (L) ----- Wire 16"x3"84 up FXST
Wheel alloy (L) ----- Alloy 10 spoke HD #43345-87
WHEEL BEARINGS (E)(D) ----- #L44643 bearings L44610 race
WHEEL BEARING SEAL(E)(D) ----- #AD7128EO
BRAKE PADS(E)(D) ----- #220018 Brembo
SHOCK Progressive ----- Escort#6602-007 Daytona#6602-011
T.I.L.T. ACTUATOR (All) ----- 20A at 1500 lbs.
CARE AND MAINTENANCE
PAINT Champion uses only PPG paint products for maximum quality and finish.
Your sidecar is painted using only base coat/clear coat urethane finishes.
This finish is hand polished at the factory and requires very little
maintenance except normal wash and wax. It is advisable not to wax your
sidecar for roughly three to four weeks after receiving it in order for the
paint to cure thoroughly.
WHEEL BEARING MAINTENANCE The wheel bearings used on your sidecar are
automotive grade tapered wheel bearings. It is advisable to check the wheel
bearing adjustment periodically, and to clean and re-pack the bearings
roughly every 3000 miles. These bearings and seals are available at most
automotive part stores.
TIRE AND TIRE AIR PRESSURE The tire used on your Daytona or Escort sidecar
is manufactured by the Dunlop Tire Co. and is available at most tire
centers. This tire is manufactured to automotive stress and wear factors
that are much higher then those you will ever experience with your sidecar.
There is a good chance that through normal use of your sidecar you will
never wear out the tire tread, but you must inspect the tire periodically
for air pressure, dry rot and sidewall damage. The manufacturer recommended
air pressure for this tire is 28 lbs. psi, but because of the light duty
application this tire is being used for, you may want to experiment with
the tire pressure to enhance the suspension comfort.
Tire pressure for the legend should be maintained at 40 PSI.
SHOCK SUSPENSION The shock suspension used on the Daytona, Legend and the
Escort sidecar are manufactured by Progressive Suspension. Progressive
Suspension has a reputation for manufacturing high quality aftermarket
motorcycle shocks and springs. Although the sidecar is shipped to you from
the factory with the shock spring set at it’s softest setting, there are a
total of five performance adjustments you can set your shock spring at.
SIDECAR REMOVAL AND REINSTALLATION To remove the sidecar from the
motorcycle first remove the two ½" bolts connecting the struts to their
upper eye mounting positions. Be sure to have someone support the
motorcycle as you remove the last of the ½" bolts . Now with the side stand
in it’s down position lean the motorcycle to the left so it rests on the
side stand. Now with the sidecar frame supported with a jack or dolly
remove the two lower 5/8" bolts connecting the lower mounting positions.

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Disconnect the wiring harness plug, brake quick coupler, and steering
damper if you are using one. Now slide the sidecar away from the
motorcycle. (IMPORTANT NOTE)( UNLESS IT IS YOUR INTENT TO RE-ALIGN THE
SIDECAR DO NOT LOOSEN ANY OF THE JAM NUTS OR PINCH BOLTS DURING REMOVAL OF

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ELECTRICAL
SIDECAR POWER CONNECTOR (sidecar side)
Motorcycle Wiring Diagram Code (Escort, Daytona)
Pin # Description Color Gauge
1 Clock Green 22
2 Accessory Red 18
3 Ground Black 18
4 Brake Light Red 22
5 Running Light White 22
6 Right Turn Signal Yellow 22
7 Backup Utility Blue 22
8 Canopy Switch on Bike Orange 22
9 TILT (all models) Yellow 14
10 TILT (all models) Pink 14
TILT Switch Wiring Colors (all models)
Positive Battery (+) Red 14
Negative Battery (-) Black 14
Harness Yellow 14 Yellow 14
Harness Pink 14 Purple 14
WIRING LEGEND SIDECAR - red (stop), green (running), black (- battery)
Wiring Description (Most applications require the removal of the seat.)
* Fuse link When connecting wires directly to the positive terminal
of the battery always use a fused connection to prevent fire or
damage to motorcycle and sidecar if a short occurs.
* Ground The ground wire should be connected directly to the battery
ground or negative terminal or to another suitable frame ground. The
ground connection on the sidecar is not connected to the sidecar
frame, however the sidecar frame is connected to the motorcycle
frame. * Clock The clock signal is used for supplying constant power to
the backup circuit of a stereo. This should be connected directly to the
positive terminal of the battery or any other wire that is always live . IF
you are not installing a stereo in the sidecar this wire can be left
disconnected.
* Accessories This should be attached to the switched accessory terminal of
your bike. If you are already using this circuit, it would be advisable to

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use the accessory terminal to control a relay that feeds this. This will
prevent overloading the accessory circuit on your bike.
* Brake Lights, Running Lights, Right Turn Signal, Backup light
These wires need to attach to the corresponding signal from the motorcycle.
There are several ways to do this. The first method is to remove the seat
and locate the corresponding wires with the use of a test light. The second
method although more expensive is to install a Station 9 from Kriss
Industries, where most of the wires to the sidecar can be isolated and
fused. If you do not have a reverse gear on your motorcycle the sidecar
backup light makes a very useful utility light when wired to a positive
battery connection and to a switch.
We suggest that you remove the right turn signal bulbs from your motorcycle
and cover the appropriate terminals with a small piece of electrical tape;
then replace the bulbs. This will prevent any confusion by following
motorists that could result from having two signals flashing, especially at
night when the extra signal appears to be in the center of the vehicle. If
you remove the sidecar, remember to put the bulbs back to their original
condition.
* Canopy Switch on Bike (Daytona Sidecar) This goes to a momentary switch
installed anywhere on the bike to open the canopy latch. It is recommended
that the power to this switch comes from switched power on the bike , thus
only allowing the canopy to be opened when the bike is switched on.
* TILT There are a total of 6 wires involved in the TILT system. The red
and black wires of the second harness need to go to the positive and
negative terminal of the battery respectively.. This is because of the high
current draw. The switch is momentary only and therefore cannot cause
unnecessary drain on the battery. You must run the power for this through a
20 amp fuse. The yellow and purple wires from the switch are connected
directly to the yellow and pink wires from the harness using the butt
connectors provided.
Mount the switch in a convenient location on the left side of your fairing.
The switch should be mounted so that moving it to the left or away from the
sidecar causes the sidecar to lift and the motorcycle to lean to the left.
Moving the switch to the right or toward the sidecar should cause the
sidecar to lower and cause motorcycle to lean to the right.
WIRING LEGEND SIDECAR
The wiring of the legend sidecar can be accomplished by first removing the
seat of your motorcycle and with the use of a test light locate the brake
light wire connection , the tail light wire connection and the battery
positive terminal. Now using the hardware supplied connect the red wire
from the sidecar harness to the motorcycle brake light connection, the
black wire to the negative battery post and the green wire to the
motorcycle tail light connection. If you have ordered other accessories

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such as driving light, interior light etc. it will be necessary to locate
you motorcycle accessory lead or positive battery terminal for this
connection. (NOTE) Remember to use a fused connection if you are connecting
to the battery. And if you are connecting to your motorcycle accessory lead
it may be necessary to use a larger amperage fuse.

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1996 - 1997 Harley Davidson FLH Hardware Instructions
Figure 1
1. Remove the seat.
2. Remove the right side passenger and driver foot rest.
(Allen hex head bolt)
3. Remove the front lower crash bar bolt.
4. Remove the saddlebag crash bar upper mount.
5. Take the rear mount Fig 1 and starting with the
passenger foot rest put the bolts in place from the center
out. Leave the bolts loose until the lower rear and upper
rear mounts are connected together Fig 3 # 2 and all the
bolts are in place.
6. Now install the lower rear mount to the frame rails as
shown in Fig #2 . Now tighten all bolts to the upper rear
mount and the lower rear mount.
If you are installing the sidecar to a FLHTCU with
front lower leg guards it will be necessary to remove
the right side. (This part will not be reinstalled)
1. Number 1 of (figure 2) shows the location of crash bar
mount located under the seat (position the mount under
the factory crash guard). Figure 2
2. Number 2 of (Figure 1) shows the
location of the mount to the foot rest bolt.
3. # 1 and # 2 of (figure 2) shows the
location of the lower rear sub frame to the
motorcycle frame. Take notice of the
clamp location and the bolts supplied by
Champion.
4. Number 2 of (figure 3) shows the bolt
supplied by Champion that is used to
connect the upper rear and lower rear sub-
frame together.

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Figure 3
Figure 4
(1996-1997)
Lower Front Mount (figure 4)
Remove the two socket head cap screws
holding the right floorboard. Remove the
bolt holding the bottom of the crash guard.
Install the mount between the crash guard
and the frame and replace the crash guard
bolt Align the mount slots with those for
the floorboard and replace the floorboard.
Now tighten all bolts .

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98 - 2000 FLH REAR MOUNT
(FIG 2)
(FIG 3)
(FIG 4)
1. Number 3 of (figure 2) shows location of crash bar mount
located under the seat (position under factory crash guard).
2. Number 2 of (Figure 2) shows location of mount to foot
rest bolt.
3. Number 1 of (figure 2) shows the location of the 7/16"
bolt supplied by Champion installed to open threaded in bike
frame.
4. Number 1 of (figure 3) shows ½" bolt supplied by Champion used to connect part A & B of the rear sub-
frame.
5 # 1 and # 2 of (Figure 4) shows the two clamps and bolts connecting
the lower rear mount to the bike frame.
02/03 REAR MOUNT

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Upper Front Mount (1984 through 2003)
(FIG 5)
Eye Clamp Assembly
Install the strap clamp (figure 5) as high as possible on the
right side vertical frame tube. Do not tighten the eye bolt at
this time . Note: Be sure to install the two 1/4 bolts from the
rear with the nuts facing forward to allow sufficient
clearance between the volt heads and the engine.
(FIG 6)
Remember the engine moves
when it is running and if the
clamp bolts are too close it
could damage the head finish.
(FIG
7)
Lower Front Mount (figure 7 & 8)
Remove the two socket head cap screws holding the right floorboard.
Remove the bolt holding the bottom of the crash guard. Install the mount
between the crash guard and the frame and replace the crash guard bolt
Align the mount slots with those for the floorboard and replace the
floorboard. Now tighten all bolts .
(FIG 8)

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(Fig 9)
BRAKES (IF EQUIPPED) Locate the rear brake
master cylinder usually located near the
rear brake pedal. The brake connection is
accomplished by removing the existing banjo
bolt connecting the rear brake line to the
rear master cylinder and replacing it with a
longer double banjo bolt supplied by
Champion. The double banjo bolt will go
through both the new brake quick coupler
banjo end and the existing brake cable banjo
end shown (Figure 9). ( be sure to use new
crush washers between all banjo fittings and
connecting surfaces). The brake cable to the
sidecar is aircraft quality steel braided
hose with a quick disconnect coupler. This
coupler is sealed in both directions to prevent any brake fluid from
leaking out. Because your Harley Davidson uses DOT 5 brake fluid from the
factory and because DOT 5 brake fluid is not compatible with the brakes
used on your sidecar it will be necessary to drain and refill the rear
brake system with DOT 4 brake fluid and re-bleed the motorcycle rear brake
system. The sidecar is shipped without any brake fluid so it will be
necessary to replace the fluid with DOT 4 brake fluid and bleed the brake
system before riding the sidecar combination. Also at any time the rear
brake pedal feels spongy or softer than normal, the sidecar brake line
should be bled and checked.
(NOTE) It is recommended to bleed the brakes every 3rd. or 4th time the
sidecar is removed.
PREPARATION AND MOUNTING PROCEDURES
ATTACHING THE SIDECAR
Mounting the sidecar should be done on a level even floor surface. The
sidecar frame should be supported at the front and rear cross member on 4x4
blocks or stands adjusted to a length of six and a half inches for the rear
and seven and a half inches in the front for the Daytona and Escort (Figure
L). If the sidecar you are installing is our Legend sidecar the front
measurement should be nine inches and the rear measurement is seven and
three quarter inches Figure L-1. If you have T.I.L.T. installed on the
sidecar, retract the wheel to ensure the wheel does not support the weight
of the sidecar. Slide the front and rear mounting hardware into the sidecar
frame. To ease adjustments, excess powder coat may have to be trimmed off
the leading edge of the tubes before being inserted into the frame tubes.
For the Escort and Daytona installation the front uses the 45 degree boss
and 45 degree clamp while the rear uses the 70 degree boss and 70 degree
clamp. For the Legend sidecar front hardware installation the offset clamp

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will slide into the sidecar frame first and then install the 45 degree
clamp and 45 degree boss to the offset clamp. The rear mounting hardware
will use a 70 degree clamp and a 70 degree boss.
THE SIDECAR) To reinstall the sidecar reverse the process.

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The motorcycle ride height should be adjusted to simulate your current
riding height. This can usually be accomplished by removing all the air
from your rear shocks to a close approximation of bike height with a rider
on it.
Wheel the motorcycle alongside the sidecar in preparation for an average 60
inch MC wheel to SC wheel measurement. Use two jack stands to balance the
motorcycle. One should be placed under each rear bag guard and adjusted to
just balance the motorcycle not support it as full weight should be on the
suspension. A false setting of the frame or MC suspension will require you
to readjust the alignment settings just when you think everything is
completed.
The wheel lead should be set at approximately 9 ½" as per the diagram
(Figure M location C). The toe in measurement (Figure M ) should be
approximately 1" less at location B then location A . This measurement can
easily be accomplished using a long straight edge supported off the ground
about 4" and resting against the sidecar tire. The straight edge should be
5' to 6' long. If you do not have a long straight edge, a 6' flourescent
bulb will work fine.
Engage the lower rear mount insert then snug up the 5/8" through bolt. Do
the same for the front lower mount. All the half inch fasteners should be
final torque to 80 ft lbs. at this time. After you have torqued the half
inch pinch bolts to 85 ft. lbs., you should now install the rear strut and
front strut from the sidecar frame eye to the upper rear mount eye. It may
be necessary to rotate the eyes on the frame and the upper mounts slightly
for strut installation (only turn the top front frame eye clockwise for
this adjustment). After the pinch bolts have been torqued and struts
installed, you should remove the supports holding the sidecar at its
correct height. This will assure that the sidecar remains level after
installation. The motorcycle should be set up so that it leans away from
the sidecar. (ie, the upper part of the rear wheel) should be about 1/4"
further away from the SC than the bottom of the MC wheel. The lean out or
lean in of the motorcycle is accomplished by adjusting the struts only. If
you have the optional TILT (trimming device) it is a good idea to first
lower the sidecar to its full down position and then raise it one inch to
do the final strut adjustment. This will allow three inches of up
adjustment and one inch of down adjustment. NOTE If the sidecar does not
drift left or right at a cruising speed of approximately 50 mph and with
the passenger weight that would normally be in the sidecar , you have
adjusted the lean of the motorcycle correctly. If the motorcycle drift’s to
the right and the toe in has been checked and found to be correct adjust
the struts and lean the motorcycle to left in small increments and vice-
versa if it pulls to the left.
RE-Check Ensure that all fasteners have been torqued to the correct
values. Do not forget the jam nuts in the struts or frame mounts! Bleed
the brake system and check SC brake operation with the SC wheel lifted off

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the ground. ---Enjoy!---

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Figure L, is showing the correct frame height and location of measurement
points for the Daytona and the Escort sidecar installation.
(Fig L)
Figure L-1, is showing the correct frame height and location for
measurement points for the Legend sidecar installation.
(Fig L-1)
Figure M is showing the correct measurement points for toe in and wheel
lead for the Daytona Legend and Escort sidecar.
Harley Davidson toe in and wheel lead specifications.
Toe in measurement at Figure (B) should be approximately 1" less then at
Figure (A).
Wheel lead Figure (C) should be approximately 9 ½"
Also the measurement at Figure A should be approximately 54".
(Fig M)

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Chrome Struts
Push the outer sleeve
downward with a slight twisting
to free it from the retaining
O Ring. This will allow access to
the jam nut. (keep O ring lubricated)