LegUp LandinGear Generation II Installation Manual

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Installation Manual

Generation II Harley

Touring Models

1988-Present

REV B

D/B/A Chopper Design Services

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Summary of Contents for LegUp LandinGear Generation II

Page 3: Table Of Contents
Table of Contents INTRODUCTION ..................4 WARRANTY .................... 5 INSTALLATION INSTRUCTIONS ............6 PREPARE FOR INSTALLATION ..............7 CONTROL SWITCH BOX ................... 8 WIRING HARNESS .................... 10 LEG & MOUNT ASSEMBLIES ................. 13 RUNNING AIR LINES ..................16 SADDLEBAG PREP (HARD BAGS) ..............18 SADDLEBAG PREP (SOFT BAGS) ..............
Page 4: Introduction
Introduction This manual covers installation of the Generation II LegUp LandinGear system by Chopper Design Services. This system should only be installed by a qualified technician, or those with above average mechanical skills. If you are not SURE that you can perform this installation, please contact us and we will help you find a qualified shop to assist you.
Page 5: Warranty
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 of the system implies agreement to the above statements. If you can’t agree with the above, Chopper Design and its dealers would be happy to refund your full purchase price, before you install the LegUp System.
Page 6: Installation Instructions
Installation Instructions The LegUp® system has many components. Pleased be sure you have them all before starting your installation. COMPONENTS: Wire Harness W Switch Box Leg and Mount Assembly (L/R) On-board Computer Module Proximity Sensor Saddlebag Mounted Compressor System Hardware Bag If you believe you are missing any parts, please contact Chopper Design at 407-834-5007, and we will rectify the situation.
Page 7: Prepare For Installation
PREPARE FOR INSTALLATION IF YOU ARE UPGRADING FROM A GENERATION I SYSTEM, PLEASE READ THE ADDENDUM TOWARD THE END OF THIS MANUAL ON THIS SUBJECT FIRST! Please do not let the size of this manual intimidate you. We cover many different bikes and circumstances here, and we feel that more pictures and more detail can only help someone trying to install our systems.
Page 8: Control Switch Box
CONTROL SWITCH BOX NOTE: ON pre 1996 models as well as 2014 and up models, you will need a bracket to mount the switch housing, which we should have supplied. In this case, remove the bolts that secure the clutch perch clamp on the left side, install the supplied bolts through the bracket that has the box mounted to it, through the supplied spacers, and into the clutch perch (Blue Loctite here).
Page 9 Pin Out for Handlebar Control Box Plugs...
Page 10: Wiring Harness
WIRING HARNESS NOTE: If you are upgrading your existing Generation 1 system, please read the addendum on this upgrade at the end of this manual, before continuing with the wiring harness. The next step is to route the wiring harness. The harness and the plugs are routed mostly under the seat.
Page 11 On some 2010 and later bikes (FLHX, FLTR), the fender plug is not like the one shown here, so we plug into the accessory connector instead. The picture below shows this connector, under the seat below the ECM. Remove the rubber plug and plug the four pin (with just two wires;...
Page 12 Start by getting the wire with the 2 big plugs on it, run inside the left shock toward the back of the bike. Next, measure 10 inches back from the 12 pin (biggest) plug and mark the wire. We are trying to make sure we have all the wire we need but not too much extra.
Page 13: Leg & Mount Assemblies
LEG & MOUNT ASSEMBLIES This manual covers our Rev B Mounting system, which replaces IMPORTANT! the stock passenger single bolt design with our own, two bolt mounts. If you have the earlier mounting system that clamps to existing floorboards, please see the link below for the correct manual for your application: http://landingear.com/pdf/g2installhdfl.pdf First we want to remove the passenger floorboards (if installed).
Page 14 Each leg has two pieces; we have a mount that attaches directly to the bike and a leg that mounts to this piece. This new mounting system is MUCH stronger that Harley’s floorboard mounts. Find the mount as shown at left, and (2) 3/8X1”...
Page 15 At left, you can see the leg system mounted. The arrow points to the installed spring and ball- bearing. Make sure this is in place and offer up the floorboard carefully to this mount. Just like when we removed the floorboard, we want to slide the pins in to hold it in place.
Page 16: Running Air Lines
RUNNING AIR LINES We need to route the air lines from the cylinders to the area near the left saddlebag. You should find 2 long air lines of identical lengths. On the right side of the bike, press one end into the fitting on the back of the air cylinder.
Page 17 We want to run the lines behind or through the area under the left side cover. Here Ben ties the two together on their way toward the back. We want to guide these up to where the wire running along the fender support is. We like to tie two loose wire ties to that wire, and run the air lines through them.
Page 18: Saddlebag Prep (Hard Bags)
SADDLEBAG PREP (HARD BAGS) NOTE: If you have soft bags (Road King Classics and Customs), skip to the next section; ‘Saddlebag Prep (Soft Bags)’. On one of the last pages of this manual, you will find a drilling template for Hard Bags. Carefully cut the template out (making sure it is to scale), and tape it to the inside of the left saddlebag as shown.
Page 19 The last thing we need to do is create a small notch for the wires to get through when the bag is closed. We use a rotary burr, but you could use a file or a small saw, to cut the notch you see here.
Page 20: Saddlebag Prep (Soft Bags)
SADDLEBAG PREP (SOFT BAGS) NOTE: If you have hard bags (all but Road King Customs & Classics), skip to the next section; ‘Install Compressor (Hard Bags)’. On bikes with Harley® soft bags (Road King Customs & Classics), we used to mount the air tank outside the saddlebags, due to how narrow the soft bags are.
Page 21: Install The Compressor (Hard Bags)
INSTALL THE COMPRESSOR (HARD BAGS) NOTE: If you have soft bags (Road King Customs & Classics), skip to the next section; ‘Install Compressor (Soft Bags)’. Find the compressor, as shown here. We need to remove the top, as it won’t be needed until the very end! We do this by removing the three nylon nuts on the top of the plate.
Page 22: Install The Compressor (Soft Bags)
INSTALL THE COMPRESSOR (SOFT BAGS) NOTE: If you have hard bags (all but Road King Customs & Classics), skip to the next section; ‘Initial System Test’. Now we need to install the compressor into the bag. The fit is tight and the bag is flexible, so take your time here.
Page 23 We need to find the inline connectors (white in this picture, could be a different color) and attach them to the end of the lines you ran toward the back of the saddlebag. Next, put the bag on the support rail, tilted out toward you as shown here.
Page 24 (again for safety to make sure the legs stay pumped completely!). This test occurs once a minute for all the time the bike is powered up, whether you turn the LegUp system on or not! The RED LED (ON The Sensor) Should Not Be Lit.
Page 25: Mount Proximity Switch
MOUNT PROXIMITY SWITCH This step is crucial!! Understand it before starting. The proximity sensor tells the system how fast the bike is traveling. The proximity sensor mounts to the swing-arm at the rear pulley. Depending on the year of the bike, it will mount 5MM from the pulley bolts or we will be attaching metal squares to the face of the pulley.
Page 26: Bike With No Pulley Bolts (Cush-Drive)
BIKE WITH NO PULLEY BOLTS (CUSH-DRIVE) With the bike on the lift, the rear wheel off the lift and the bike in Neutral, remove the bottom bolt from the right shock at the rear of the bike. Insert the top of the bracket shown at left, behind the shock and in front of the hole in the swing-arm, so the bolt will pass though it when reinserted.
Page 27 If this is not happening, you may need to get the sensor a bit closer to the brake rotor (5MM is a very small distance!). If this is not happening, you may need to get the sensor a bit closer to the brake rotor (5MM is a very small distance!).
Page 28: Wire Routing
WIRE ROUTING Tie the Proximity sensor wire down the left side of the swing arm for pulley bolt bikes, or the right for Cush drive bikes. Use the supplied self-adhesive tabs, to secure the wire snugly to the swing arm. Just make sure you route this safely and tie it off securely! Finally pull all the extra wire under the seat area.
Page 29 (the When complete, you want to Velcro the computer onto the top and make sure the plug 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: Finishing Up
FINISHING UP Now it is time to reinstall everything you took off, and do final checking of everything! Reinstall the seat making sure all your wires are routed neatly, tied off nicely and don’t interfere with the seat installation. Once all of this is accomplished, we should get the bike on the ground, and with a helper, cycle the wheels up and down a few times, having your helper make sure the air lines are not being scuffed or are over tight, and that the wires are out of the way of anything that could damage them.
Page 31: Final Adjustments & Maintenance Mode
Chopper Design. Turn the ignition to Accessory and start the LegUp System (hold right button for 3 seconds). The system should be set at the factory for proper pressure, but some wheel adjustment may be needed.
Page 32: Wheel Adjustment
WHEEL ADJUSTMENT The LegUp GEN II system is typically set up at the factory for the height of your bike. The system is VERY height dependent! If after testing the initial installation, the bike does NOT feel stable, the wheel system MAY need to be adjusted to the height of your bike. AGAIN, we normally ask at order time if your bike is at stock height and we set the system up for whatever height you have furnished us.
Page 33 SYSTEM UP BEFORE SHIPPING. IF YOU ARE NOT SURE, PLEASE CONTACT US BEFORE ADJUSTING THE SETTINGS OUTLINED BELOW! IF YOU HAVE A REMOVEABLE LOWERING KIT INSTALLED, YOU MAY WISH TO CONSIDER REMOVING IT AS THE NEED SHOULD BE REDUCED SIGNIFICANTLY BY THE LEGUP SYSTEM.
Page 34 We now have designed wheel holders that allow SIGNIFICANT adjustment to make the LegUp system match the height of your bike perfectly. The adjustments can take time to get perfect, so be patient and understand this section before adjusting anything. We try to...
Page 35 On each supporting leg, you will find two bolts down near the end by the wheels. The two bolts control the angle of the ‘Wheel Holders’. By moving the wheel forward or back, we can tailor the length of the support arms to a particular bike.
Page 36 The picture below left, shows the wheel holders set up for touring bikes with full length shocks (Electra Glides etc.) The one at right is set up for lowered bikes (Street Glide and others). Notice how the curve of the left one is toward the front of the leg, and the curve on the right one is toward the back? This small change can make a big difference in how stable the bike may be.
Page 37: Test Ride
(again for safety to make sure the legs stay pumped completely!). This test occurs once a minute for all the time the bike is powered up, whether you turn the LegUp system on or not! The first test should be done in a straight line. Put the bike in gear and slowly accelerate. You may notice that the bike tends to want to steer a small amount left or right.
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...
Page 39: Generation I Upgrade Instructions
GENERATION I UPGRADE INSTRUCTIONS NOTE: Read this before starting your installation if this is an upgrade! If you are upgrading from a Generation 1 system, most all the instructions in this manual pertain to you, but some do not! The most important thing is to NOT take your wiring harness off the bike! We should have supplied you with an upgrade harness that will allow you to keep most everything as it was, and adapt the wiring to the new system.
Page 40: Illustrations
ILLUSTRATIONS...
Page 41: Saddlebag Drill Template (Hard Bags)
SADDLEBAG DRILL TEMPLATE (HARD BAGS) Print and Cut out Make Sure Dimension is Correct! Some printers don’t print to scale!!
Page 42: Saddlebag Drill Template (Soft Bags)
SADDLEBAG DRILL TEMPLATE (SOFT BAGS) Print and Cut out Make Sure Dimension is Correct! Some printers don’t print to scale!!
Page 43: Hardware List
HARDWARE LIST (Internal Use Only) (4) 3/8-16 X 1” Allen Bolts (Mount to Bike) (4) 5/16-18 X 3/4” Button Head bolts with nylon nuts (Top Mount holes on Legs) (4) 5/16-18 X 3/4” Hex Head bolts with nylon nuts (Bottom Mount holes on Legs) (2) 5/32”...