Second Trike Build Underway

[Darth]

As some of you remember, two years ago I did a Champion trike conversion on my wife's 2009 Sportster. The trike has performed flawlessly and is a blast to ride. If you care to read about it, here is the link to the build...
http://www.triketalk.com/forum/threa...uild-Sportster

Anyways, because of some lower back issues and the fact that trikes are fun to ride, I decided to convert my 2010 Sportster with the same kit. Thanks to Randy, I got a great price on the kit and an awesome set of HHI raked trees. Finally got a chance this weekend to start the conversion. Saturday evening I got the bike stripped down in preparation to start the installation... removed the exhaust, rear tire, rear brakes, swing arm, rear shocks, right side engine cover and passenger pegs.

Last view as a two wheeler



Upon removing the exhuast, I found a broken mount for the V&H Double Barrels which will have to be replaced or repaired


Inspected the rear motor mounts for wear while they were exposed... they were fine.


End of Saturday evening... bike is ready to start the trike install.

 

[Darth]

Sunday Afternoon Progress

Sunday afternoon things started out well...



Unpacked the boxes and assembled the axle/differential, pressed new hiem joints into the trike swing arm, installed the trike swing arm and new shocks.

Left side (with differential & pulley)


Ride side


Both halves on the bench


Getting ready to mount the axle to the bike, but hold on...

something doesn't look right (&^*%*%^$#@!*&^%)


This is where everything ground to an abrupt halt for the day...

the belt is wider than the pulley. Checked the belt p/n, it's the right belt. Next checked and measured the pulley and belt on my wife's bike... sure enough... Champion installed the wrong pulley on the axle before shipping. It's 1/4 inch narrower than it should be.


That ended the install for today. Tomorrow I'll have to get on the phone with Champion to see where to go from here. The bad news is that I already mated the two halves of the axle and seated the bearing, so it will not be easy to undo. Stay tuned for the next chapter!

 

[Dirtydan]

Would it be easier to just go with a 1" belt?

 

[tfdeputydawg]

Just a suggestion. Take the weight off the rear brake hose by tying the caliper up to something on the bike. ThumbUp
I would request Champion over night the correct pieces with the understanding you will return what you have at their cost and assembled as is, lest something be damaged trying to take it apart:AGGHH:

 

[Papa Zook]

Would it be easier to just go with a 1" belt?

That's an option. The 1" belt is plenty strong, it's what the late model dressers run. The front pulley doesn't matter, it's 2" wide.

 

[Champion Trikes]

new pulley

New pulley is coming your way 2day air day today

Thank you for bringing this to our attention

 

[Darth]

Just a suggestion. Take the weight off the rear brake hose by tying the caliper up to something on the bike. ThumbUp
I would request Champion over night the correct pieces with the understanding you will return what you have at their cost and assembled as is, lest something be damaged trying to take it apart:AGGHH:

I understand your concern, but that whole OEM caliper and hose will get removed and replaced with a new line/splitter/check valve assembly as the trike kit has dual calipers (one at each wheel). It's just hanging there because I didn't want to break into the system and possibly contaminate it with dirt and such until I'm ready to hook the brake lines up... which I can't do until the pulley/belt issue gets resolved and the axle gets mounted to the swing arm.

 

[Darth]

After a significant delay (for which I won't air dirty laundry here), the trike is finally complete. It was great weather in Michigan this weekend, so between Saturday and Sunday, I put around 350 miles on the conversion... so far so good! I also installed an HHI 5 degree rake kit (thanks Randy!), and it handles like it has power steering. The nice thing is that with the HD detachable docking hardware, the windshield and tour pak both pop right off, plus I have the sissy bar/backrest and passenger seat that can pop on if needed. This thing should be a blast come September in Maggie Valley!

 

[Capt.Bob]

Darth, That is one rad looking trike. How do you like the way it handles from a stability standpoint and comfort level in going around turns, etc?

 

[Darth]

Darth, That is one rad looking trike. How do you like the way it handles from a stability standpoint and comfort level in going around turns, etc?

Thanks for the compliment. The bike is very stable... between the wide stance of the Champion kit plus the 5 degree of rake, it really holds the road well. Straight line is rock steady, sweeping curves the same, and low speed maneuvering is easy. The limiting factor is the driver... I still find myself trying to lean into the corners from time to time!