TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT
J043412007-05-02
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)
Kit Number
87166-08
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
NOTE
Configuring Turn Signal/Security System Modules (TSM,TSSM) - See following notes:
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
If your motorcycle is equipped with lower fairings, the right lower fairing must be replaced with a non-vented version for sidecar applications. Refer to the Painted Parts Manual for additional information.
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, four modifications must be made according to the instructions provided in this Instruction Sheet. Follow the Pre-Installation Instructions below for each procedure.
NOTE
On Ultra models, both lower fairings must be removed prior to starting this installation.
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. | Obtain Clutch Cable 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. | 
Figure 2. Revised Lower Clutch Cable Routing | ||||||
| 4. | See Figure 2 and Figure 3. Continue to route cable down behind regulator, over engine stabilizer link and diagonally under crankcase, over the electrical caddy, and to clutch release cover on right side of transmission. | |||||||
| 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.
| 1 | Clutch cable |
| 2 | Brake line |
Figure 3. Contact Between Clutch Cable and Brake Line (Right side shown)
| 1 | Cable tie/saddle |
Figure 4. Relocating and Securing Brake line
NOTE
Clutch cable and brake line may make contact as shown in Figure 3. Contact between the cable and brake line could result in premature clutch wear (due to cable hanging up).
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".
| 1. | 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. | |||||||
| 2. | Remove the oil pressure sender using a 1-1/16 inch open end Crow Foot wrench (Snap-On FC34A). | 
Figure 5. Relocate Oil Pressure Sender | ||||||
| 3. | See Figure 19 and Table 1. Obtain the 90° brass elbow and brass close nipple (39) 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 (See Figure 5). | |||||||
| 4. | 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 11–14 N·m (96–120 in-lbs). | |||||||
| 5. | Install connector on oil pressure sender unit. |
Master Cylinder/Rear Brake Pedal Assembly Modifications
NOTE
This kit requires that the brake pedal be replaced with shorter brake pedal and new rear master cylinder supplied in kit.
- Refer to the applicable Touring model Service Manual and remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad. Discard brake pedal and cotter pin.
- See Figure 19. 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.
- Set brake pedal/master cylinder assembly aside, it will be installed later.
Remove Voltage Regulator Mounting Studs
NOTE
The existing voltage regulator mounting studs on the frame must be modified using components supplied in this kit to improve servicing components after the sidecar is installed.
| 1. | Refer to applicable Touring model Service Manual and follow instructions to remove the voltage regulator and electrical caddy plate. | 
Figure 6. Remove Voltage Regulator Studs | ||
| 2. | See Figure 6. Drive the original equipment voltage regulator studs out of the frame. |
NOTE
Fasteners will be installed during front lower mount installation.
INSTALLATION
Install Upper Mount
| 1. | See Figure 19. 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. | |
| 2. | See Figure 19. 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 68–81 N·m (50–60 ft-lbs). |
Install Front Lower Mount
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.
NOTE
When installing the front lower mount, it may be necessary to remove the oil filter to gain clearance for the lower mount during installation. The oil filter should be re-installed upon completion of the lower mount installation.
| 1. | See Figure 19. 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 7. Position Stabilizer Adjuster | ||||
| 2. | See Figure 7. Place the stabilizer assembly between the frame downtubes from the backside and tighten the stabilizer adjuster just enough to hold the assembly in place. | |||||
| 3. | See Figure 19. 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 through mount and stabilizer. Finger tighten bolts. | 
Figure 8. Clutch Cable Clamp Location | ||||
| 4. | See Figure 19. Obtain the backing plate (5), four bolts (47), flat washer (52) and clutch cable clamp (41) 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 (See Figure 8). Tighten bolts finger tight. | |||||
| 5. | Refer to applicable Touring model Service Manual and follow instructions to install voltage regulator and electrical caddy plate using two hex head capscrews (42), flat washers (35) and lock nuts (46). | |||||
| 6. | Tighten the screws to 7.9–11.3 N·m (70–100 in-lbs). 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. | |||||
| 7. | 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. | |||||
| 8. | With a wrench, turn the stabilizer adjuster so the stabilizers press, not pull, firmly against the frame down tubes. | |||||
| 9. | Tighten the eight backing plate to mount bolts to 35-40 ft-lbs (47.5-54.2 Nm). |
Install Remote Master Cylinder Reservoir
| 1 | Cable Ties |
| 2 | Oxygen sensor harness |
Figure 9. Cut Oxygen Sensor Harness Cable Ties
| 1. | See Figure 9. Cut the cable ties (1) holding front oxygen sensor connector to frame bracket. |  Figure 10. Brake Cylinder Reservoir |
| 2. | See Figure 10 and Figure 19. Obtain remote reservoir (40), two flat washers (49), two lock washers (51) and two socket head screws (38) from kit. Orient reservoir on wheel side of frame downtubes and install to frame crossmember as shown. Tighten the reservoir mounting screws securely. Do not install hose at this time. |
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 19 , Item #37) is used with the connector rod end (bearing) when connecting the sidecar frame pivot mount to the rear mount.
| 1 | Large clevis opening |
| 2 | Spacer |
Figure 11. Rear Mount
| 1. | If not already removed, remove right side cover and both saddlebags. | |||||||||
| 2. | See Figure 19. 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. | |||||||||
| 3. | Remove the chrome plug from the right rear swing arm bracket. | 
Figure 12. Swingarm Mount | ||||||||
| 4. | Remove the two bolts (w/lockwashers) to free the right rear swingarm bracket from frame and remove bracket. See Figure 19 and Figure 13. Position the rear mount (1) over the two mounting holes and be certain roll pin enters the rubber mount's groove as shown in Figure 13. | |||||||||
| 5. | See Figure 12. Check the right pivot shaft rubber mount to be sure it is in place. | 
Figure 13. Install Rear Mount and Hardware | ||||||||
| 6. | See Figure 13. Install upper and lower rear mount bolts (18) with lockwashers to secure rear mount to frame. Tighten bolts to 40.6–54.2 N·m (30–40 ft-lbs). | |||||||||
| 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 20.3–24.4 N·m (15–18 ft-lbs). | |||||||||
| 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.
| 1. | See Figure 19. 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 10.8–13.6 N·m (96–120 in-lbs). | |
| 2. | Refer to the Sidecar Service Manual for instructions for attaching and adjusting the steering damper. |
| 1 | Sidecar brake line |
Figure 14. Sidecar Brake Line Routing
| 1 | Gasket |
| 2 | Motorcycle rear brake line |
| 3 | Sidecar brake line |
Figure 15. Brake Line Stack Up
Installing Brake Line
| 1. | See Figure 14 Route the brake line from sidecar to the motorcycle forward of the wiring harness. The sidecar brake line will run along with the motorcycle brake line as it is routed to the rear caliper. Verify that sidecar brake line is clear of rear fender and rear wheel/tire. | |
| 2. | See Figure 15. The sidecar and motorcycle rear brake lines stack up on the rear caliper using a double stack banjo bolt (9). a. Install a gasket washer (8) on double stack banjo bolt (9). b. Insert double stack banjo bolt through sidecar brake line banjo fitting. c. Install second gasket washer (8). d. Insert banjo bolt through motorcycle brake line banjo fitting. e. Install third gasket washer (8) and thread bolt into caliper. f. See Figure 15. Position brake lines as shown and tighten the banjo bolt to 26–30 N·m (19–22 ft-lbs). |
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)
| 1 | Upper hose clamp |
Figure 16. Routing Brake Reservoir Hose
| 1 | Lower hose clamp |
Figure 17. Brake Reservoir Hose at Master Cylinder
| 1. | Refer to Touring model Service Manual and follow instructions to remove the original rear master cylinder and install the sidecar master cylinder (45) and brake pedal assembly. Verify that the fitting on the sidecar master cylinder is rotated to point inboard. If it is not, gently rotate it inboard. | |
| 2. | After the banjo bolt is installed to the master cylinder torque the bolt to 17–20 N·m (13–15 ft-lbs) NOTE Do not use excessive force installing hose on master cylinder. The fitting may break off if excessive force is applied. | |
| 3. | See Figure 19. Obtain hose (43) and two hose clamps (36) from kit. See the label on the reservoir hose to identify the correct orientation of the hose to the reservoir and the master cylinder. Route hose from master cylinder reservoir over stabilizer then back down under lower right front mount. See Figures 16 and 17 for routing at master cylinder. | |
| 4. | Install hose clamps as shown in Figures 16 and 17. | |
| 5. | Refer to Touring model Service Manual. Fill reservoir with D.O.T. 4 HYDRAULIC BRAKE FLUID, and bleed rear brakes. | |
| 6. | See Figure 19 and Table 1. Install reservoir gasket (44), cover(48) and screws (38). Tighten the reservoir cover to 0.7–0.9 N·m (6–8 in-lbs). |
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, lower left fairing and other parts/assemblies removed during kit installation.
| 1 | Cable ties |
| 2 | Oxygen sensor connector |
Figure 18. Secure Oxygen Sensor Connector
- See Figure 18. Install two cable ties to retain front oxygen sensor connector to the rear of frame bracket.
NOTE
See Figure 19. Highlighted hardware, Items 10, 11, 14, 16, 17, 24, 25, 26, 28, 29, 30, 31, 32, 33 and 37 are used for attaching the sidecar to the motorcycle. See Sidecar Service Manual for installation procedures regarding the highlighted items.
Steering Damper Mounting Kit, Part Number 87142-83A
The contents of this kit are listed as item numbers 26 through 35 in Figure 19. 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 x 1.5 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 19. TLE Sidecar Installation Kit
SERVICE PARTS
Table 1. Service Parts Table: Sidecar Mounting
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Rear mount kit, includes item 37 | 87126 -07 | 31* | Washer, flat, 3/8 inch I.D. (4) | 6701 | |
2 | Lower front mount, right side | 87122-07 | 32* | Washer, flat, 13/32 x 1-1/32 x 1/8 inch (3) | 6519 | |
3 | Stabilizer, right side | 87148-07 | 33* | Bolt, 3/8-16 x 2-3/4 inch | 4420 | |
4 | Stabilizer, left side | 87137-92 | 34 | Screw (3) | 3892 | |
5 | Plate, backing (left) | 87123-83 | 35 | Washer, 1/4 inch I.D. (5) | 6703 | |
6 | Clamp, upper front kit | 87131-99 | 36 | Clamp, hose (2) | 10038A | |
7 | Clamp, upper rear | 87132-92 | 37* | Spacer, rod end bearing | 87181-02 | |
8 | Gasket, brake line (3) | 41751-06A | 38 | Screw (4) | 2528 | |
9 | Banjo bolt, double stack, brake line | 4848 | 39 | Kit, oil sender relocation (90° elbow & Close nipple) | 26337-99A | |
10* | Bolt, with hole, 1/2-13 x 1-3/4 inch | 3902A | 40 | Reservoir, brake fluid | 41804-07 | |
11* | Cotter pin | 559 | 41 | Clamp, clutch cable | 42327-70 | |
12 | Bolt, 1/2-13 x 1-3/4 inch | 4052 | 42 | Screw, hex cap (2) | 3993 | |
13 | Washer, lock, 1/2 inch I.D. | 7068 | 43 | Hose, brake reservoir to master cylinder. | 42365-08 | |
14* | Washer, 17/32 x 1-1/2 x 9/64 inch | 6723 | 44 | Cover, reservoir gasket | 42455-07 | |
15 | Bolt, 3/8-16 x 1-3/4 inch (4) | 4357 | 45 | Master cylinder, sidecar | 42735-08 | |
16* | Bolt, 3/4-10 x 2-1/4 inch | 4151 | 46 | Nut,flange (2) | 7716 | |
17* | Bolt, 3/4-10 x 2-3/4 inch | 4045 | 47 | Bolt, 3/8-16 x 1-1/2 inch (4) | 4356 | |
18 | Bolt, 7/16-14 x 1-1/4 inch | 3057 | 48 | Cover, reservoir | 45057-07 | |
20 | P-clamp w/screw | Use stock | 49 | Washer, flat #10 (2) | 6716 | |
21 | Assembly, brake pedal (use stock pad) | 42631-08 | 51 | Washer, lock #10 (2) | 7069 | |
22 | Stabilizer adjuster | 87156-83 | ||||
23 | Brake pedal pad | Use stock pad | ||||
24* | Locknut, 1/2-13 | 7843 | ||||
25* | Steering damper | 87141-83 | Items in kit but not shown | |||
Steering damper mounting kit: Items 26 through 35 | Not Sold Separately | Cable, clutch control | 38649-08 | |||
26* | Rod end | 87144-83 | Clamp | 10036 | ||
27* | Bracket | 87143-83 | Strap, cable (3) | 10006 | ||
28 | Spacer (2) | 59938-72 | O-ring (2), brake pedal pivot | 11364 | ||
29 | Bolt, 3/8-16 x 1-3/4 inch (2) | 4720W | NOTE: Hardware items with (*) 10, 11, 14, 16, 17, 24, 25, 26, 28, 29, 30, 31, 32, 33, and 37 are used for attaching the sidecar to the motorcycle. | |||
30* | Locknut, 3/8-24 (2) | 7601 | ||||