Custom Motorcycle  Parts & Accessories

Chopper Supply LLC

662-449-0956
Hernando, Mississippi. 38632

www.CHOPPER-KIT-USA.COM

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Installation Instructions
Bolt-on Rake Kits by Chopper Supply

The Safety and Quality of this kit depends on correct installation. Read and follow all instructions carefully.
 Inspect each part before you start the installation.
We are not responsible for damage caused by installing the wrong part.
 If you're unsure about any part of the install, give us a call at 662 449-0956

Click Here for printable PDF Instructions
  

2009 XLC, Harley-Davidson 1200 Sportster

Before install of + 14 rake kit, w/4" longer tubes

After install. Increase in length 8.5"

09before018c.jpg (993701 bytes)    

install062b.jpg (827346 bytes)

(Click image below to enlarge, use back button to return)

1. Secure Motorcycle on lift or suitable jack.

2. Disconnect battery cable to disable electrical system, then remove seat, gas tank, front wheel, front fender, and brake caliper.
 
  Secure Motorcycle on lift or suitable jack.

3. Unplug electrical connectors (under tank area) that run through the opening in top triple tree, then pull wiring harnesses out through the opening.
Now you can unbolt the handlebar/riser assembly, and secure it on a pad further back on the frame out of the way. Remove the headlight, and fork tube assemblies from trees. 
 Unplug electrical connectors

4. Remove triple trees, neck bearings and races.  Clean the inside of the steering head, be sure no burs have been left in the bearing race seat. 
(note; factory bearings and races must be removed & will not be reinstalled.)
Also shown below, tool used to remove races from steering head. Ask us about renting one.
Remove triple trees, neck bearings and races  tool used to remove races from steering head. Ask us about renting one  tool used to remove races from steering head  tool used to remove races from steering head  

1st step of reinstall.

5. Set the top tree assembly on the steering head. Notice, the steering head adaptor (collar) doesn't just drop into the steering head, it's a precision press fit, by design. 
Set the top tree assembly on the steering head

6. Insert the stem bolt through the bottom of the offset adapter and screw it into stem of the top tree. 
As you tighten the stem bolt to 148 lbs., the collars on the top tree assembly and offset adapter will press fit into the steering head.
Be sure to position the adapter in the steering head so that it is facing straight ahead when tightening. 
If after tightening, its not straight, loosen the stem bolt and with a non metallic hammer, strike the
side of the adapter to align it, then re-torque stem bolt to 148 lbs.
 Insert the stem bolt through the bottom of the offset adapter and screw it into stem of the top tree  Be sure to position the adapter in the steering head so that it is facing straight ahead when tightening  re-torque stem bolt to 148 lbs  

Note: 1st photo below shows the collar on top tree, fully seated in 7 1/4" Harley steering head. 
2nd pic shows collar fully seated on Harley steering heads that measure 7" in length.
 collar on top tree, fully seated in 7 1/4" Harley steering head  shows collar fully seated on Harley steering heads that measure 7" in length

7. Install fork stops on bottom of offset adapter, and remove circlip from the shaft.
   Install fork stops on bottom of offset adapter remove circlip from the shaft

8.Remove bearing cover from bottom tree
Remove bearing cover from bottom tree

9. Slide lower tree bearing onto shaft of offset adapter & install circlip in groove on shaft.
   Slide lower tree bearing onto shaft of offset adapter install circlip in groove on shaft  

NOTE: Consult your shop manual to complete step # 10 below. 
 

10. Remove fork tubes from lower legs and replace with longer fork tubes (6). Use stock pre-load when assembling forks. Spring spacers (5) included may or may not need shortened. Refill
with the factory recommended amount of fork oil. Refer to service manual for your year motorcycle for the exact amount of oil. 
(Extra oil is NOT needed for extended tubes). 

(Use caution installing fork tubes through the trees, according to your repair manual. 
A second
person to help align the trees during this step is recommended. We are not responsible for
scratched tubes)

11. With the tube assemblies ready to install, align the locking cams (12) in bottom tree so the tubes can slide thru. Locking cam should have 1/4 gap between the 2 halves to allow the tube to slide thru. Insert the fork tubes thru both trees and install the fork tube caps (1) and washers (2).
tube assemblies ready to install   align the locking cams  nstall the fork tube caps (1) and washers (2).

12. Don't forget to set the clearance between the bottom of the adapter block and the bearing in the lower tree, before you torque the cam screws. There should be a min. 1/8" of space between the two components. With the locking cam screws loose, simply tap up or down on the lower tree (with a non-metallic hammer) to establish the clearance, then tighten cam screws with specified torque, and reinstall bearing cover on lower tree,.
Don't forget to set the clearance between the bottom of the adapter block and the bearing in the lower tree  

13. Feed electrical harnesses through opening in top tree then install the handlebar/riser assembly. Install headlight. Plug in electrical connectors.
Feed electrical harnesses through opening in top tree

14. Install the brake caliper, front fender, new brake line and fittings

15. When converting from a narrow glide to a wide glide, remove the brake rotor from your wheel and install the supplied spacer between the rotor and hub. 
converting from a narrow glide to a wide glide   install the supplied spacer between the rotor and hub

16. Install the front wheel. Add brake fluid and bleed the brake system.
Install the front wheel. 

17. Install gas tank, seat, & reconnect battery cables.
 Install gas tank, seat, & reconnect battery cables
18. Check all bolts for correct torque before riding and again after 100 miles. Motorcycles are prone to vibrate, therefore thread lock is always recommended.

"Ride Safe"
Notice: Correct function of the brake system is necessary for vehicle safety. Therefore this installation should only be done by a Certified motorcycle mechanic. 
Do not modify the delivered parts. Damaged parts should not be used or repaired in any way. Use thread lock on all bolted connections. 
If
you have
any questions about this installation please contact Chopper Supply LLC - 662-449-0956

 

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