THESE ARE FOR AN 05 CHOPPER simple install this should help till you get correct instruction. 2005 DT Chopper Air Ride Kit
REQUIRED TOOLS
SAE Allen wrench set 3/8-16 bottoming tap
2 mm Allen wrench Electric or pneumatic drill
10 mm box end wrench Loctite 2440
1/2” box end wrench Loctite 2760
3/4” box end wrench Loctite 567 PST thread sealer
7/16” socket and wrench Razor blade or tube cutter
5/16” drill bit Safety glasses
CAUTIONS: Use these instructions to insure proper installation of this product. Failure to comply with
these instructions may result in serious bodily harm and void product warranty. Manufacturer assumes no
liability for loss or damage of any kind, expressed or implied resulting from improper use of this product.
Wear appropriate safety equipment when installing any Big Dog Motorcycles accessory.
Before attempting this or any other accessory installation do the following:
1.
Read and understand all instructions included with the accessory.
2.
Make sure all parts on packing list are included.
3.
Check required tool list and gather those tools.
4.
Do not attempt to “rush” the installation. Make sure you have the time required to complete the
installation.
5.
If you are not comfortable doing this installation, STOP and take to the nearest Authorized Dealer or
Service Center.
6.
Always exercise caution.
WARNING! If motorcycle has been running, wait until engine and exhaust have cooled to avoid personal
injury.
WARNING! Failure to disconnect battery while working on motorcycle may result in inadvertent
engagement of starter and cause personal injury. Disconnect the battery and any other source of electrical
power, ground cable first.
INSTRUCTIONS
1.
Place motorcycle on a lift, clamping the
front tire securely. Strap the front end to the
lift on both sides to ensure safety.
2.
Remove seat. To remove, locate the suction
release tabs under the rear of seat with your
fingertips. Relieve suction by prying release
tabs upwards with fingertips. Remove seat,
being careful not to scratch any painted
surface.
3.
Remove electrical covers by removing the
four bolts on the top, and two bolts under
bottom of tray.
NOTE: Place a clean rag on top of the
transmission to prevent damage to chrome or
painted surfaces.
4.
Loosen battery strap from rear of battery
tray and remove battery from the tray.
5.
Remove bolts holding battery tray to frame,
allowing movement of tray to provide extra
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room to install the compressor and bracket
onto the battery tray.
6.
Mount bracket to pump as shown below
using M3 screws and washers provided.
Typical
7. Cut wire ties holding the main harness to the
battery tray, being careful not to cut any
harness wires.
Typical
8.
Find the two compressor wires and attach to
compressor. The small black connector
snaps onto the solenoid and the white
connector snaps onto the compressor. The
third wire from the compressor will connect
to the negative battery post.
9.
Push air line firmly into solenoid fitting until
air line stops.
10. Remove circuit breaker from battery tray.
11. Install bracket, pump assembly and circuit
breaker spacer onto left side of battery tray
as shown below. Apply Loctite 2440 to
threads of 1” screws provided and mount
bracket to tray. Bracket mounts between tray
and circuit breaker spacer.
Typical
12. Reinstall circuit breaker, reset button down,
to battery tray with nylock nuts provided as
shown below.
Typical
13. Reinstall bolts connecting battery tray to
frame. Torque to 5 in•lbs.
14. Reinstall the battery and battery strap.
15. Connect positive battery cable first. Connect
negative battery cable, including the new
ground cable from the compressor.
16. Turn ignition key to ON position and test the
system as described in the air ride operating
instructions located at end of the installation
section. You should hear the compressor
run. If the compressor doesn’t run check
your wiring.
17. Route air line behind starter, dropping down
to the rear eyelet on the right shock.
18. Reinstall electrical covers. Reinstall bolts
connecting top and bottom of covers to
frame. Torque top bolts of electrical cover to
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5 in•lbs. Tighten bottom bolts of electrical
cover firmly.
19. Reinstall seat.
SHOCK REMOVAL
1.
Place a jack under rear frame support and
lift motorcycle until rear shocks bottom out.
2.
Remove the shock plate.
3.
Remove right shock, removing front bolt
and spacer first, and then remove rear bolt
and spacer.
4.
Remove left shock, removing front bolt and
spacer first, and then remove rear bolt and
spacer.
5.
Remove the bump stops from the frame
cross-member and rotate the swing-arm
through the full range of travel.
Typical
NOTE: If swing-arm contacts the frame side-
plate, install included bump stop spacers behind
the bump stops.
Typical
PRESSURE GAUGE INSTALLATION
1.
Install air line onto gauge using Loctite 567
PST thread sealant.
2.
Remove the set screw from the gauge
assembly, apply Loctite2440 and reinstall.
Tighten until gauge ceases to rotate inside
the bracket. Ensure bracket is oriented for
visibility when installed on motorcycle.
3.
Remove the right front bolt from the rear
rocker box, making sure the O-ring is left in
place.
4.
Install the gauge and bracket on to the
rocker box with the new bolt provided and
torque to 120 in•lbs.
Typical.
1.
FHCS, ¼-20 x 1-1/2”.
2.
Fiberglass washer.
3.
Countersunk spacer.
4.
Spacer.
5.
Flat washer (part of S&S rocker box).
6.
Rubber or silicone washer (part of S&S rocker
box).
5.
Route air line behind air cleaner cover,
under the transmission plate and over the
shocks to the middle of the motorcycle.
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SHOCK INSTALLATION
NOTE: A slight rattle may be heard in the body
of the air shock - this is normal. Apply Loctite
2760 to all shock bolt threads before assembly.
1.
Install the air shock on the right hand side,
only connecting the front shock, bolt and
spacer loosely to the frame.
NOTE: The fittings should be in the inside of
the frame.
2.
Connect air line from the gauge to the elbow
fitting on the shock using Loctite 567 PST
thread sealant.
3.
While holding the air shock in position,
mark the air line for cut length.
4.
Cut air line at mark with a sharp razor blade
or tube cutter.
NOTE: Air line must be cut straight to avoid
leakage.
5.
Connect air line to shock fitting by pushing
firmly until the air line stops.
6.
Install rear shock bolt and spacer through
the air shock and into the bung on the
swing-arm.
7.
Install the standard hydraulic shock (smaller
diameter) on the left-hand side of
motorcycle, installing its front bolt and
spacer onto the frame first, then the rear
shock bolt and spacer onto the swing-arm.
8.
Torque all shock bolts to 100 ft•lbs.
9.
Ensure spacers on shock bolts can spin and
move side to side freely. Side to side
movement should be a minimum of 0.030”.
10. Air the system up to 90 PSI. Lower and
remove the jack.
NOTE: If system pressure drops, a leak is
present. De-pressurize system, tighten all fittings
and re-pressurize. Allowable leak-down is 10
PSI in a 24-hour period, or 15 PSI over 200
miles.
KICKSTAND REMOVAL AND
INSTALLATION
1.
Remove the kickstand mounting bolts.
2.
Use the socket head bolts provided to bolt
the drill template to the frame in the existing
tapped holes.
3.
Drill through the side plate using a 5/16”
drill bit.
CAUTION: Be careful to only drill through the
side plate. Drilling too deep could cause damage
to the swing-arm plate.
WARNING! Always wear OSHA-approved eye
protection before beginning any work that might
cause injury to the eye.
4.
Tap the drilled holes with the 3/8-16 tap.
5.
Install the kickstand with new spacer onto
the side-plate using the newly tapped holes.
Apply Loctite 2440 to kickstand bolts before
assembly and torque to 35 ft•lbs.
AIR RIDE OPERATING
INSTRUCTIONS
The air ride system includes the compressor,
pressure relief valve, air shock, hydraulic shock
and airline, and has been incorporated into the
EHC and wiring harness.
System controls are integrated into the hand
control buttons. These buttons are now dual
function buttons, operating normally as labeled
and alternately as suspension controls when air
ride function is activated.
Air ride controls are activated as follows:
1.
Turn the key switch to the ON position.
2.
Press the START button to activate the air
ride control mode.
NOTE: Pressing the RUN button activates the
starting circuit and returns the START button
into starter control mode.
3.
Once activated, air ride is controlled with
the lights HI/LO switch.
a.
Pressing HI raises the motorcycle
(pressurizes the system).
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b.
Pressing LO lowers the motorcycle
(releases the system pressure). The
buttons must be pressed until the desired
ride height is achieved.
c.
Typical system pressure is 90-120 PSI
without rider. Maximum static pressure
is 150 PSI, limited by the compressor.
(Maximum system pressure is 250 PSI,
limited by the pressure relief valve.)
4.
After 10-seconds of no input while in the air
ride control mode, the START and HI/LO
controls will return to normal mode of
operation.
5.
Air ride mode can be entered with the
motorcycle running by pressing the START
button. Air ride control functions operate the
same as above.
NOTE: Highway riding in the completely
lowered position is not recommended.
KICKSTAND OPERATION AND
PARKING
When your motorcycle is resting on the
kickstand, the air ride system should be deflated
and normal parking procedures should be
followed. With the kickstand down and air ride
in the lowest position, always leave the
handlebars turned to the left.
CAUTION: Parking on level ground or on a
right-slanted grade with the handlebars turned to
the right could cause the motorcycle to fall to the
right side.
3.
Operation in the lowered position will limit
the cornering ability and the ground
clearance of the motorcycle.
4.
Do not park the motorcycle with the air ride
system pressurized.
5.
Do not inflate the air ride suspension with
any outside source.
The air ride shock and the conventional shock
are non-serviceable items.
WARNING! During operation in the lowered
position, sharp cornering and road surface
bumps may cause ground clearance issues.
Acute cornering to the right will cause ground
contact with the exhaust system.
It is important to remember the following
when operating the air ride suspension
system.
1.
The air ride suspension is designed to
function in a fully-extended position.
2.
Operation above idle speed in the lowered
position is not recommended.
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