TLE/TLE-Ultra Sidecar Attachment Kit
J032632006-04-07
GENERAL
WARNINGTLE and TLE-Ultra sidecars can only be installed on Touring Model family motorcycles. Use of sidecars on motorcycles other than those specified adversely affect handling and reduce braking efficiency, which could result in death or serious injury. (00103b)
NOTE
Harley-Davidson is currently developing a kit to be used to install sidecars on police vehicles equipped with anti-lock braking systems (ABS). Until that kit is developed, we do not recommend the use of sidecars on police vehicles equipped with ABS. Attempting to install a sidecar on police vehicles equipped with ABS requires special components still under development.
Kit Number
87166-99B
Models
This kit is designed and provides the mechanical components required to attach the TLE/TLE-Ultra Sidecar to 1999 and later Touring Model Motorcycles. This kit also contains the components and procedures required to install the Steering Damper Kit (Part Number 87142-83A). See Service Parts Page Illustration for kit contents.
Additional Parts Required
NOTE
Configuring Turn Signal/Security System Modules (TSM,TSSM) - See following notes:
2000 to 2002 models equipped with the following Part Number modules should be configured to sidecar use: 68920-01, 68920-01A 68922-00, 68922-00A 68924-00, and 68924-00A.
On 2003 and later model motorcycles or motorcycles with later TSM,TSSM configurations, have your Harley-Davidson dealer install a Bank Angle Sensor Switch kit, Part No. 88115-03 and configure the TSM/TSSM for sidecar use. Instruction Sheet -J02377 contains the kit installation instructions and the procedure to reprogram the TSM/TSSM to sidecar operation. The TSM/TSSM will not function properly if not switched to sidecar operation.
The TLE-Ultra Sidecar utilizes the same attaching kit as the TLE sidecar however, additional wiring harnesses (included with TLE-Ultra sidecar) need to be installed to connect the sidecar light harness and radio. Refer to the instructions in the Sidecar Service Manual for harness installation procedures. A Touring Model Service Manual and Sidecar Service Manual are available from your Harley-Davidson dealer. Use the Service Manuals in conjunction with this Instruction Sheet to properly install this kit.
NOTE
2004 and earlier Touring models use DOT 5 brake fluid. 2005 and later FLT models use DOT 4 brake fluid. It is important that these fluids are not mixed.
WARNINGHarley-Davidson recommends the use of its specified tires. Harley-Davidson vehicles are not designed for operation with non-specified tires, including snow, moped and other special-use tires. Use of non-specified tires can adversely affect stability, handling or braking and lead to loss of vehicle control, which could result in death or serious injury. (00024d)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
PRE-INSTALLATION
NOTE
Before installing the Sidecar Attachment Kit, three modifications must be made according to the instructions provided in this Instruction Sheet. Follow the Pre-Installation Instructions below for each procedure.
Stock Clutch Cable Removal
NOTE
The stock clutch cable must be removed and replaced with the longer clutch cable from kit. The new clutch cable will be routed down the left side of the bike versus the right.
- Refer to applicable Touring model Service Manual and remove right side footboard and entire exhaust system.
- Refer to applicable Touring model Service Manual procedures and remove stock clutch cable.
New Clutch Cable Installation
NOTE
The stock clutch cable must be removed and replaced with the longer clutch cable from kit. The new clutch cable will be routed down the left side of the bike versus the right.
| 1. | See Figure 20. Obtain Clutch Cable (57) from kit. Refer to applicable Touring model Service Manual and follow instructions to connect clutch cable to clutch hand lever. | |||||||||
| 2. | For FLHT/C/CU, follow instructions in applicable Service Manual to route clutch cable through fairing. NOTE Prior to performing the next step on FLHR/CI models, capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. | 
Figure 1. Route Cable Down Along Left Frame Tube (Left Side Shown) | ||||||||
| 3. | See Figure 1. Continue to route clutch cable down along left frame downtube. | |||||||||
| 4. | See Figures 2 and 3. Continue to route cable down behind regulator, over engine stabilizer link and diagonally under crankcase to clutch release cover on right side of transmission. | 
Figure 2. Revised Lower Clutch Cable Routing 
Figure 3. Clutch Cable Routing Under Crankcase (Shown from left side under jiffy stand) | ||||||||
| 5. | Follow procedures in applicable Touring model Service Manual and install clutch cable fitting into clutch release cover. NOTE The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. NOTE Clutch cable and brake line may make contact as shown in Figure 4. Contact between the cable and brake line could result in premature clutch wear (due to cable hanging up). To avoid contact between the brake and clutch cables, perform steps 5 and 6. | 
Figure 4. Contact Between Clutch Cable and Brake Line (Right side shown) | ||||||||
| 6. | See Figure 5. Open the cable clips shown and gently move brake line out of clips and down along inside of lower frame tube. | 
Figure 5. Relocating and Securing Brake line | ||||||||
| 7. | Check that clutch cable does not touch brake line. See Figure 20. Obtain three cable straps from kit and install under wiring harness, then around right frame tube just behind the rear master cylinder and brake line to secure brake line in new location. | 
Figure 6. Relocate Oil Pressure Sender |
Relocating Oil Pressure Sending Unit
NOTE
On motorcycles equipped with oil pressure gauges, the oil pressure sender must be reoriented (downward) using a 90° elbow and close nipple.
NOTE
If motorcycle is not equipped with oil pressure gauge, proceed to "Master Cylinder Assembly/Rear Brake Pedal Modification".
- Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and gently pull to disconnect connector from oil pressure sender.
- Remove the oil pressure sender using a 1-1/16 inch open end Crow Foot (Snap-On FC34A).
- See Figure 20 and Figure 6. Obtain the 90 degree brass elbow and brass close nipple from kit. Coat threads on nipple with PIPE SEALANT WITH TEFLON and install to 90° brass elbow. Install elbow into oil pressure sender threads and tighten completely. Aim elbow so open threaded end faces downward and angled slightly toward oil filter base.
- Coat threads of oil pressure sender with PIPE SEALANT WITH TEFLON and thread into 90° brass elbow. Using a 1-1/16 inch open end Crow Foot, tighten to 96-120 in-lbs (11-14 Nm).
- Install connector on oil pressure sender unit.
Master Cylinder/Rear Brake Pedal Assembly Modifications
NOTE
The existing rear master cylinder must be modified using components supplied in this kit. This upgrade is necessary for the additional brake (from sidecar). Also, on 2002 and later models, the brake pedal must be replaced with brake pedal supplied in this kit to avoid contact between the sidecar frame and brake pedal. These points are covered in detail in the instruction sheet.
NOTE
2004 and earlier Touring models use DOT 5 brake fluid. 2005 and later Touring models use DOT 4 brake fluid. It is important that these fluids are not mixed.
NOTE
2002 and later models require that brake pedal be replaced with shorter brake pedal supplied in kit.
| 1. | Refer to the applicable Touring model Service Manual and remove master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and cotter pin. Discard brake pedal and cotter pin. | |||||||||||||
| 2. | Thoroughly clean exterior of master cylinder assembly with denatured alcohol. | 
Figure 7. Mount Reservoir to Bracket | ||||||||||||
| 3. | Gently lift rubber boot from groove in plastic reservoir and slide boot off reservoir. | |||||||||||||
| 4. | Grip boot end of reservoir with finger tips and with thumbs push on threaded end of cartridge body to remove cartridge body from reservoir. Use hand pressure only. Exercise care to keep cartridge body free of dirt and grease. Discard reservoir. | |||||||||||||
| 5. | Carefully remove two O-rings from outside of cartridge body. Exercise caution to avoid scratching O-ring grooves. | 
Figure 8. Install Reservoir/Bracket to frame Crossmember 
Figure 9. Position Stabilizer Adjuster | ||||||||||||
| 6. | See Figure 20. Obtain the new Reservoir Adapter with O-rings (46) from kit. On 2004 and earlier model motorcycles: Lubricate O-rings with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID and carefully install in grooves on cartridge body. On 2005 and later model motorcycles: Lubricate O-rings with D.O.T. 4 HYDRAULIC BRAKE FLUID and carefully install in grooves on cartridge body. | |||||||||||||
| 7. | On 2004 and earlier model motorcycles: Wipe bore of new reservoir adapter with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID. On 2005 and later model motorcycles: Wipe bore of new reservoir adapter with D.O.T. 4 HYDRAULIC BRAKE FLUID. | 
Figure 10. Install Backing Plate to Stabilizer (left side) | ||||||||||||
| 8. | Insert cartridge body into reservoir adapter indexing tab on adapter in slot on threaded end of cartridge. Use hand pressure only. Cartridge body is fully installed when adapter contacts large retaining ring. | |||||||||||||
| 9. | Slide dust boot as necessary to seat lip in groove of reservoir adapter. | |||||||||||||
| 10. | See Figure 20. Obtain new brake pedal (21) from kit. Install rubber pedal pad (removed from old brake pedal in Step 1 of this procedure). Follow instructions in Service Manual and using a new cotter pin, install brake pedal from kit to master cylinder assembly. | 
Figure 11. Rear Mount | ||||||||||||
| 11. | Set brake pedal/master cylinder assembly aside, it will be installed later. |
Install Remote Master Cylinder Reservoir
- See Figures 20 and Figure 7. Obtain bracket (43), remote reservoir (41), two flatwashers (50), two lockwashers (52) and two screws (38) from kit. Orient reservoir as shown and attach to reservoir bracket. Tighten securely. Do not install hose at this time.
- See See Figures 20 and Figure 8. Obtain two bolts (40) and two lockwashers (51) from kit. Orient reservoir/bracket on engine side of frame downtubes and install to frame crossmember as shown.
INSTALLATION
Install Upper Mount
- See Figure 20. Obtain the rear half of upper clamp (7) from kit. Position the clamp at the rear of the frame downtubes. The mount is self-aligning and is located correctly when the grooves in the mount mate fully and cleanly with the frame tubes. Slide the clamp up or down on the frame tubes until it is correctly aligned.
- See Figure 20. Obtain the front half of the upper clamp (6), bolt (12) and lockwasher (13) from kit. Place the front upper clamp in position and align with rear half. Secure the clamp halves to the frame tubes by tightening bolt to 50-60 ft-lbs (68-81 Nm).
Install Front Lower Mount
| 1 | Swingarm mount |
| 2 | Alignment hole |
Figure 12. Swingarm Mount (2002 and earlier models)
NOTE
When performing the following step, note that stabilizers are marked with and "R" and "L" to indicate right and left respectively. The right stabilizer is equipped with right-hand threads; the left stabilizer is equipped with left-hand threads.
| 1. | See Figure 20. Obtain the stabilizer adjuster (22), left stabilizer (4) and right stabilizer (3). Thread the stabilizer adjuster into the right and left stabilizers. The stabilizers are marked with an "R" and "L" to indicate right and left respectively. The right stabilizer has right hand threads - the left stabilizer, left hand threads. | 
Figure 13. Swingarm Mount (2003 and later models) 
Figure 14. Install Rear Mount and Hardware | ||||||||||||||
| 2. | See Figure 9. Place the stabilizer assembly between the frame downtubes from the backside and position the assembly so 1/16 inch clearance exists between assembly bottom and regulator. When clearance is correct, tighten the stabilizer adjuster just enough to hold the assembly in place. | |||||||||||||||
| 3. | See Figure 20. Obtain the lower front mount (2) and four bolts (15) from kit. Position the lower front mount on the right frame downtube opposite the right stabilizer and insert four bolts thru mount and stabilizer. Finger tighten bolts. | |||||||||||||||
| 4. | See Figures 20 and Figure 10. Obtain the backing plate, four bolts (48), flatwasher (53) and clutch cable clamp (42) from kit. Install backing plate using four bolts however use fourth bolt in upper right hand side with clamp and secure clutch cable in place as shown. Tighten bolts finger tight. NOTE Check that clearance between lower front mount assembly and regulator is 1/16 inch and that clearance exists between backing plate and front alignment stabilizer. NOTE Do not raise lower front mount anymore than needed to obtain 1/16 inch clearance at regulator. Raising front mount higher will cause difficulty servicing oil filter. | |||||||||||||||
| 5. | Move entire front mount assembly up if there is interference with front alignment stabilizer or less than 1/16 inch clearance at voltage regulator. NOTE Do not over-tighten stabilizer adjuster. Frame down tubes could be forced apart. | 
Figure 15. Modifying Brake Line Connection 
Figure 16. Clutch Cable Attachment | ||||||||||||||
| 6. | With a wrench, turn the stabilizer adjuster so the stabilizers press, not pull, firmly against the frame down tubes. | |||||||||||||||
| 7. | Tighten the eight backing plate to mount bolts to 35-40 ft-lbs (47.5-54.2 Nm). |
Installing Rear Mount
NOTE
See Figure 11. The rear mount requires only two bolts for installation. The clevis opening for installing the connector rod end (bearing) from sidecar frame has been made wider to allow access to the swingarm pivot shaft nut without removing the mount. Therefore, a spacer (See Figure 20, item #54) is used with the connector rod end (bearing) when connecting the sidecar frame pivot mount to the rear mount.
| 1 | To master cylinder |
| 2 | To reservoir |
Figure 17. Reservoir-To-Master Cylinder Hose
| 1. | If not already removed, remove right side cover and both saddlebags. | |
| 2. | See Figure 20. Loosen and remove the screw with P-clamp (20) attaching rear brake line to right passenger footrest bracket. Retain screw and P-clamp to attach brake line to rear mount. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. |  Figure 18. Routing Brake Reservoir Hose  Figure 19. Brake Reservoir Hose at Master Cylinder |
| 3. | Remove the chrome plug from the right rear swing arm bracket. | |
| 4. | Remove the two bolts (w/lockwashers) to free the right rear swingarm bracket from frame and remove bracket. Save swingarm bracket for future installation and save bolts and lockwashers for installation of rear mount. See Figure 20. 12 and 13. Position the rear mount (1) over the two mounting holes and be certain roll pin enters the alignment hole shown in Figure 13 for the 2002 or earlier rubber mount. On 2003 and later mounts, the roll pin must enter the rubber mount's groove shown in Figure 13. | |
| 5. | Check the left pivot shaft rubber mount to be sure it is in place. | |
| 6. | Refer to Figure 14. Install upper and lower rear mount bolts w/lockwashers (removed in last step) to secure rear mount to frame. Tighten bolts to 34-42 ft-lbs (46-57 Nm). | |
| 7. | Using stock bolt and washer saved during removal of passenger footboard, install passenger footboard to threaded hole in upper portion of mount as shown. Tighten bolt to 15-18 ft-lbs (20.3-24.4 Nm). | |
| 8. | Obtain screw with P-clamp (20) removed in Step 2 of this procedure. Secure brake line to mount at threaded position shown. Tighten screw securely. |
Attaching Steering Damper Bracket
NOTE
For the 3 tapped holes in the lower triple clamp, the steering damper bracket will have plastic plugs installed. Prior to performing Step 1, remove the plastic plugs.
- See Figure 20. Obtain the steering damper bracket (27), three screws (34) and three washers (35) from kit. Using the Illustration as a guide, install the steering damper bracket to lower triple clamp. Tighten the screws to 96-120 in-lbs (10.8-13.6 Nm).
- Refer to the Sidecar Service Manual for instructions for attaching and adjusting the steering damper.
Installing Tee Fitting to Frame Bracket
- See Figure 15. Carefully remove stoplamp switch from existing fitting at frame bracket. Clean threads.
- See Figure 20. Obtain new brake line ee-fitting (8) from kit. Coat male threads of fitting with Loctite Pipe Sealant with Teflon (Harley-Davidson part number 99818-97). Thread tee into frame bracket fitting and tighten so that right angle opening is vertical (facing upward).
- Coat threads of stoplight switch with Loctite Pipe Sealant with Teflon. Thread switch into end of tee.
- See Figure 20. Obtain plug (9) from kit and save. If sidecar is not being attached, install plug in the right angle opening. A union and plug is provided with the sidecar to plug the sidecar brake line.
Clutch Cable Placement and Adjustment
- See Figure 16. Remove stock T-stud clip that secures stator wires on left end of front engine bracket behind voltage regulator.
- See Figure 20. Obtain large clip (37) from kit. Capture stator wires and clutch cable in larger clip and install clip on T-stud.
- Refer to applicable Touring model Service Manual and perform the Clutch Adjustment procedure.
Installing Pedal/Master Cylinder Assembly
WARNINGOn 2002 and later motorcycles, the existing brake pedal must be replaced with the pedal supplied in this kit. Failure to replace the original brake pedal could result in contact between the sidecar frame and brake pedal, limiting pedal travel. This decrease of full brake pedal travel can result in loss of control and death or serious injury. (00485b)
- Refer to Touring model Service Manual and follow instructions to install the modified master cylinder and brake pedal assemblies. The fitting on the reservoir adapter must point inboard.
- See Figures 20 and 17. Obtain hose (44) and two hose clamps (36) from kit. See Figure 18. Route hose from master cylinder reservoir over stabilizer then back down under lower right front mount. See Figure 19 for routing at master cylinder.
- Install hose clamps as shown in Figures 18 and 19.
- Refer to Touring model Service Manual. On 2004 and earlier motorcycles: Fill reservoir with D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID, and bleed rear brake system. On 2005 and later motorcycles: Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID, and bleed rear brakes.
- Install reservoir gasket, cover and screws. Be certain to use correct cover for the application. (D.O.T. 5 cover for 2004 and earlier motorcycles and D.O.T. 4 cover for 2005 and later motorcycles.)
NOTE
Do not use excessive force installing hose on reservoir adapter. The fitting on adapter may break off if excessive force is applied.
Install Exhaust System and All Other Items Removed To Allow Connection Kit Installation
Refer to Touring model Service Manual and install exhaust system. Also install side cover, saddlebags and other parts/assemblies removed during kit installation.
NOTE
See Figure 20. Highlighted hardware, Items 10, 11, 14, 16, 17, 24, 25, 26, 28, 29, 30, 31, 32, 33 and 54 are used for attaching the sidecar to the motorcycle. See Sidecar Service Manual for installation procedures regarding the highlighted items.
Installing Right Passenger Footboard
Fasten the footboard to the rear mount assembly (Figure 20, item 1) using the footboard attaching hardware. Adjust footboard to suit the passenger and install and tighten bolt to 15-18 ft-lbs (20.3-24.4 Nm).
Steering Damper Mounting Kit, Part Number 87142-83A
The contents of this kit are listed as item numbers 26 through 35 on Figure 20. To install the steering damper bracket, follow the procedure "Attaching Steering Damper Bracket" above. Installation of the remaining parts and adjustment is covered in the Sidecar Service Manual.
NOTE
The steering damper (25) and rod end (26) have M10 x1.5 metric threads.
TLE Ultra Sidecar
The TLE-ULTRA SIDECAR utilizes the same attaching kit as the TLE sidecar. There are, however, additional wiring harnesses that need to be installed to connect the sidecar light harness and the radio. See instructions in the Sidecar Service Manual.
Wiring Harness Connections
NOTE
The sidecar harness is included with the sidecar and is not part of the connection kit.
See Sidecar Service Manual for wiring harness connection procedures.
SERVICE PARTS
Figure 20. Service Parts: TLE Sidecar Installation Kits
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Rear mount kit, includes item 54 | 87114-02 | 36 | Clamp, hose (2) | 10038A | |
2 | Lower front mount, right side | 87122-83A | 37 | Clip, large | 10108 | |
3 | Stabilizer, right side | 87148-92 | 38 | Screw, 10-32 x 3/4 inch, Torx (2) | 2576 | |
4 | Stabilizer, left side | 87137-92 | 39 | Kit, oil sender relocation (90 elbow & Close nipple) | 26337-99A | |
5 | Plate, backing (left) | 87123-83 | 40 | Screw, 1/4-20 x 1/2 inch (4) | 4365 | |
6 | Clamp, upper front kit | 87131-99 | 41 | Reservoir, brake fluid | 41804-84A | |
7 | Clamp, upper rear | 87132-92 | 42 | Clamp, clutch cable | 42327-70 | |
8 | Tee, brake line | 87113-83 | 43 | Bracket, brake reservoir | 42354-99A | |
9 | Plug, 3/8-24 | 42311-58 | 44 | Hose, brake reservoir to master cyl. | 42365-02 | |
10* | Bolt, 1/2-13 x 2-1/4 inch | 3902 | 45 | Cover, reservoir gasket | 42455-80 | |
11* | Cotter pin | 559 | 46 | Kit, brake reservoir adapter | 42457-95 | |
12 | Bolt, 1/2-13 x 1-3/4 inch | 4052 | 47 | Screw, 10-32 x 5/8 inch, hex socket (2) | 42534-90 | |
13 | Washer, lock, 1/2 inch I.D. | 7068 | 48 | Bolt, 3/8-16 x 1-1/2 inch (4) | 4356 | |
14* | Washer, 17/32 x 1-1/2 x 9/64 inch | 6723 | 49 | Cover, reservoir, DOT 5 (04 & earlier) | 45057-82 | |
15 | Bolt, 3/8-16 x 1-3/4 inch (4) | 4357 | 49A | Cover, reservoir, DOT 4 (05 FLT models) | 45603-05 | |
16* | Bolt, 3/4-10 x 2-1/4 inch | 4151 | 50 | Washer, flat #10 (2) | 6716 | |
17* | Bolt, 3/4-10 x 2-3/4 inch | 4045 | 51 | Washer, lock 1/4 inch I.D. (2) | 7036 | |
18 | Bolt, 7/16-14 x 1-1/4 inch (stock part) | 3782 | 52 | Washer, lock #10 (2) | 7069 | |
19 | Washer, lock, 7/16 I.D. (stock part) | 53 | Washer, flat, 3/8 inch I.D. | 6701 | ||
20 | P-clamp w/screw | Use stock | 54* | Spacer, rod end bearing | 87181-02 | |
21 | Assy, brake pedal (use stock pad) | 42407-87C | Items in kit but not shown | |||
22 | Stabilizer adjuster | 87156-83 | Cable, clutch control | 38649-98 | ||
23 | Brake pedal pad (stock) | Clamp | 10036 | |||
24* | Locknut, 1/2-13 | 7843 | Strap, cable (3) | 10006 | ||
25* | Steering damper | 87141-83 | O-ring (2), brake pedal pivot | 11364 | ||
Steering damper mounting kit Items 26 through 35 (not sold separately) | NOTE: Hardware items with (*) 10, 11, 14, 16, 17, 24, 25, 26, 28, 29, 30, 31, 32, 33, and 54 are used for attaching the sidecar to the motorcycle. | |||||
26* | Rod end | 87144-83 | ||||
27 | Bracket | 87143-83 | ||||
28* | Spacer (2) | 59938-72 | ||||
29* | Bolt, 3/8-16 x 3/4 inch (2) | 4720W | ||||
30* | Locknut, 3/8-24 (2) | 7601 | ||||
31* | Washer, flat, 3/8 inch I.D. (3) | 6701 | ||||
32* | Washer, flat, 13/32 x 1-1/32 x 1/8 inch (3) | 6519 | ||||
33* | Bolt, 3/8-16 x 2-3/4 inch | 4420 | ||||
34 | Screw (3) | 3892 | ||||
35 | Washer, 1/4 inch I.D. (3) | 6703 | ||||