LegUp LandinGear Generation II, Installation Manual

Page 1: ...Installation Manual Generation II Harley Touring Models 1988 Present REV B Copyright 2016 Pete Giarrusso Inc D B A Chopper Design Services All Rights Reserved ...

Page 2: ...2 ...

Page 3: ... 20 INSTALL THE COMPRESSOR HARD BAGS 21 INSTALL THE COMPRESSOR SOFT BAGS 22 MOUNT PROXIMITY SWITCH 25 BIKES WITH PULLEY BOLTS 25 BIKE WITH NO PULLEY BOLTS CUSH DRIVE 26 WIRE ROUTING 28 FINISHING UP 30 FINAL ADJUSTMENTS MAINTENANCE MODE 31 MAINTENANCE MODE 31 WHEEL ADJUSTMENT 32 TEST RIDE 37 GENERATION I UPGRADE INSTRUCTIONS 39 ILLUSTRATIONS 40 SADDLEBAG DRILL TEMPLATE HARD BAGS 41 SADDLEBAG DRILL ...

Page 4: ...this installation please contact us and we will help you find a qualified shop to assist you While the Generation II System holds your bike upright very well you are STILL responsible for balancing the bike The system WILL relieve you of some of the weight of the bike and help you avoid balance problems as you approach a stop maneuver at slow speeds and back the bike up Improper installation will ...

Page 5: ...cidents are not covered under this warranty Replacement parts for this type of damage are available through Chopper Design Users of the LegUp system agree that Chopper Design is NOT responsible for personal injuries or damage to property arising from the use of the system While we believe this system to be safe and reliable the user is advised that use of LegUp is done so at the users own risk Use...

Page 6: ...lation COMPONENTS 1 Wire Harness W Switch Box 2 Leg and Mount Assembly L R 3 On board Computer Module 4 Proximity Sensor 5 Saddlebag Mounted Compressor System 6 Hardware Bag If you believe you are missing any parts please contact Chopper Design at 407 834 5007 and we will rectify the situation Some of the parts are shown below ...

Page 7: ... to install our systems Better to have the details than want for them Place the motorcycle on an acceptable bike lift You will need to keep the bike on its wheels for most of the installation and jack the rear wheel off the lift for some portion of the installation Make SURE the motorcycle is secure on the lift Remove the seat and disconnect the negative cable on the battery This manual is availab...

Page 8: ...ire to the bar Run the wire through the top triple tree if you can to control it The idea here is to get the wires neatly to the front of the tank and routed under the tank It may be easier to remove the plug end and tape the silver plug ends together for this We have some pictures below to give you an idea of what this looks like On some bikes it is easier to loosen or remove some of the tank mou...

Page 9: ...9 Pin Out for Handlebar Control Box Plugs ...

Page 10: ...ttached and slide them through the seat area and out just below the left fender support Leave the remainder of the wire harness under the seat for now Once both plugs are through you can pull most of the slack out We will be pulling these plugs back toward the back end of the saddlebag behind the shock The plug from the Proximity Sensor 3 wire needs to routed under the seat as well If you have Pul...

Page 11: ...atching connector Don t worry the plugs only work one way you can t make a mistake here We need to find the fuse holder and the black wire with the hoop ends and get them to the battery These two wires run direct power to the compressor when it needs it This wire should already be under the seat area We want to connect the wire with the fuse holder to the positive terminal of the battery the batte...

Page 12: ...k a bit different just make sure you leave the wire needed and tie it off securely and out of the way of anything that moves or could hurt the wire No Matter how you need to secure the wire make sure you have 10 inches of wire sticking out from the end of the fender support to allow us enough wire to get what we need into the saddlebag You can now pull the extra wire back into the under seat area ...

Page 13: ... inboard part of the floorboard cover which exposes 2 pins and soon a ball bearing and a spring The arrow shows Ben pushing one of the pins toward the center Do this on both sides but keep pressure downward on the board to maintain the ball bearing and spring that is beneath it in the middle Once this is done carefully raise the board off the mount catching said spring setup and set the board hard...

Page 14: ...t to attach the leg system First gather 2 5 16 18 X 7 8 button head bolts with Nylock nuts and 2 5 16 X 7 8 Hex Head bolts with Nylock nuts Make sure you have the correct leg raise it up to the plate you just mounted and insert the button head bolts into the top holes This should support the heavy leg system Install the two Nylock nuts to these bolts Ben is shown tightening the top bolts at right ...

Page 15: ...h the board and the mount holes on the leg system until they have about showing on both sides of the floorboard casting You will know you have the correct amount if the floor board cover can fall back into place If not make small adjustments to the pins to center them and make sure the floorboard cover sits back down nicely Please Note The floorboards on our mount only flip a small amount This all...

Page 16: ... have a picture of the line running under the right floorboard mount tied lightly to the floorboard mount Notice Ben is extending the leg so he gets the needed slack from the line and run under the right side cover area to get to the other side of the bike and joining the left line Get the line there any way you can just be sure that it is secure and cannot be damaged by anything hot or moving Onc...

Page 17: ... to anything you like as long as they are safe and out of the way Then you can start working back tying off the lines Tighten the lines under the fender strut and just leave the end wild for now These are air lines so tie them off snugly Careful though too tight could restrict the air flow Once we have everything tied up we want to make a loop with the extra line This will keep the lines the same ...

Page 18: ... depending on the fittings we supply 2 different sizes from 2 different vendors If you are unsure drill a 3 8 hole if it is too small move up to Once the holes are in place find the bulkhead fittings The 90 degree part stays on the outside of the bag with the straight part inside Start with the lower hole and tighten the fitting No reason to make it too tight there is no chance for leaks here and ...

Page 19: ...ill keep the wire from being hurt as you open and close the bag over time At the top of the bag about 1 to the left of the bail nut the bolt that holds the bag on is where you want to place the relief A bit left or right makes little difference but this wire goes down into a relief cut in the top of the compressor cover so the more accurate you are here the better Make sure that the wire when plac...

Page 20: ...red hole in the saddlebag back The hole allows the air lines to get in and out of the saddlebag and also allow easy removal of the bag First we need to find near the end of the manual the drilling template for soft bags Carefully cut this template out and tape it to the inside of the left saddlebag as seen in the next picture The flat bottom of the template lines up with the bottom of the bag just...

Page 21: ... a vibration If once the compressor is on you need to cut pieces of the rubber and slide it on the metal where needed to keep the vibration down Once the compressor is in place the air lines should be attached to the fittings you mounted in the saddlebag The right hose closest to the outside of the bag should be attached to the bottom fitting and the left hose should be attached to the top fitting...

Page 22: ... the compressor into the bag As we do this we take the two air lines with male male fittings attached and start it through the hole you drilled into the bag When we install the wire harness you will need to tilt the compressor forward to reach the plug under the top Once the compressor is nestled into the bag it should look like the picture below Make sure the system is pushed all the way to the b...

Page 23: ...the safety valve of the tank to let the air out tilt the compressor forward to disconnect the plugs and remove the rear bail nut then disconnect the hoses at the white connectors and remove the bag Run the wire with the two plugs into the bag all the way toward the back just behind the end of the rubber gasket Find the computer and plug it into the big plug then plug the small plug into the plug f...

Page 24: ...turn the LegUp system on or not The RED LED ON The Sensor Should Not Be Lit Take a metal object screwdriver wrench etc and hold it on the flat face of the sensor it has a circle embossed in it The LED should light up and go out when you move the metal away If not check all your connections Next press the rightmost pushbutton on the handlebar switchbox and hold it for at least 3 seconds Both LEDs o...

Page 25: ...pulley bolt passes the sensor Play with this by rotating the wheel back and forth while holding the bracket in place Once you feel you have the right place hold the bracket steady and slowly rotate the wheel Every time a bolt passes the light should get bright when the bolt is nearby and off after it passes If this is not happening you may need to get the sensor a bit closer to the bolts 5MM is a ...

Page 26: ...rotor and below the shock bolt see below Reinsert the shock bolt and tighten the nut while holding the bracket forward against the swingarm as seen here Get the shock bolt snug We next have to set the sensor so it finds the spokes of the brake rotor not the bolts as in the past at a distance of 5MM about Be prepared to bend the bracket to get to the sensor in the correct position When you think yo...

Page 27: ... tad you may even need to loosen or remove it to bend it as you need to No matter what you need to do you MUST make sure that as the wheel turns the light works as described above Once you are certain tighten the shock bolt and test it again Rotate the wheel past all 5 spokes on the brake rotor and make sure the light blinks and goes out each time If all is perfect you are done The automatic retra...

Page 28: ...tie the excess as a bundle make sure they don t interfere with the seat and tuck them in as shown here We need to make sure the compressor plug is attached and tucked in as we install the top Find the L shaped metal top that you removed from the compressor earlier The top mounts with the two holes toward the back of the bag with the single hole toward the front It is a tight fit so slanting it int...

Page 29: ... compressor plug stays UNDER the top and wires look something like this The top picture shows a hard bag while the bottom shows a soft bag Our main concern here is to give you as much of the saddlebag as possible and make sure the wires and components are not going to be chaffed or damaged ...

Page 30: ...kstand down and turn the bars all the way left If the compressor makes noise more than once every two minutes you may have a leak at the lines that connect to the compressor or the tank fittings Some soapy water will tell you where you will need to remove the compressor top to test for these leaks Assuming the compressor doesn t lose enough air to kick on after 2 minutes you should be fine You can...

Page 31: ...gs Once flashing hit both buttons for an instant to get the system in the DOWN setting mode lower yellow LED flashing Touch the left button briefly the wheels should go down immediately This is VERY quick don t be startled Using very short pushes of the left button press and then feel the stability of the bike If it feels firm enough try leaning the bike a bit If the wheels return the bike to upri...

Page 32: ... by just leaning to the right move on to the next section Test Ride the wheel settings are fine The stability of the GEN II LegUp system relies on the pneumatic actuator when deployed being at an angle that is forward of perpendicular for best results Different bikes are at different heights and Chopper Design uses an ingenious method to adjust the length of the supporting legs to maximize the sta...

Page 33: ... to offset the low height of the bike The floorboard needs to be in the highest hole The bolts that orient the wheel holder need to be in the third and fifth hole from the back They also need to be threaded through the hole that is second from the back on the wheel holder 3 If you told us you have an Ultra Low this is how we would configure the system before shipping We just furnish this info to d...

Page 34: ...he bike held level we set the bike on a jack here but you can have someone try to hold it upright if need be We suggest taking this measurement from both sides and dividing them in half Armed with this info we can use the list below to find a good starting point to set the wheels up properly FLH 14 One from Back Strap Up FLHX 13 3 4 Two from Back Strap Down Low Bike 13 1 16 One from Back Strap Dow...

Page 35: ...s point Lower the legs Is the bike more or less stable If it is more stable and you can sit on the bike and rock it back and forth without it leaning over you are done If not remove the bolts again and move them in the opposite direction two holes and retest If everything is fine final tighten the lock nuts and you are done If you need to you can move the wheels from the lowest hole up one hole Yo...

Page 36: ...one side of the bike to the other This will reverse the direction of the wheel holders and keep the wheels aligned properly Again this is only needed if you are not getting the stability we describe above Below is a picture that shows the angle of the actuator when the wheels are set properly Notice the bottom of the cylinder silver inside the black legs is further forward than the top Yours shoul...

Page 37: ...ish to raise the wheels manually if the bike is steering due to uneven pavement Assuming the legs are retracted you should try to deploy the wheels As you come to a stop the Green LED should be on As you slow down almost stopped the Yellow LED should illuminate at the proper speed Once it does sometimes hard to see hit the left button and put your feet down near the ground The top LED should flash...

Page 38: ... The next thing to try is to make a turn from a dead stop with the wheels down As soon as you start the bike moving turns can only be made by using the handlebars The LegUp system is too strong to allow a great deal of lean with the wheels down If you need to make a turn shortly after departing from a stop raise the wheels manually left button and you will get complete control again The next thing...

Page 39: ...nto where the old computer plugged in This is a 12 pin plug on the opposite end of the upgrade harness from the two plugs that are close together Once this is plugged in we like to run the wire with the two plugs along the bottom of the bag back to the compressor The thin wire with the fuse holder on it gets run back toward the seat area to get connected to the battery You can tie this up to the e...

Page 40: ...40 ILLUSTRATIONS ...

Page 41: ...41 SADDLEBAG DRILL TEMPLATE HARD BAGS Print and Cut out Make Sure Dimension is Correct Some printers don t print to scale ...

Page 42: ...42 SADDLEBAG DRILL TEMPLATE SOFT BAGS Print and Cut out Make Sure Dimension is Correct Some printers don t print to scale ...

Page 43: ...ulkhead or Unions 2 5 32 90 Degree Bulkhead Fittings Hard Bags Only 2 5 32 Union Fittings Soft Bags Only 1 10 24 X 2 Stainless Allen with Spacer 7 8 X3 8 Mount for Handlebar Switch no Bracket 1 10 32 Nylon Acorn Cover excess thread on Mount Bolt 1 10 32 X 1 Stainless Allen Mount Handlebar Switch to Bracket 2 1 4 20 X 2 Chrome Allen Bolts w Split Washers HB Bracket 2014 UP 95 Down 2 X 7 16 X 7 8 Sp...