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velorex 562 mounting on a 1997 883 sportster
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sidehack411
Posted 12/22/2014 2:53 AM (#81812)
Subject: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
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I bought a used velorex 562 that I want to mount on an 883 sportster. I have no instructions that came with the sidecar. Any advice or ideas would be much appreciated...
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wvsporty
Posted 12/22/2014 9:49 AM (#81815 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Extreme Veteran

Posts: 410
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Location: Inwood WV
I have a Velorex on my 01 883 and I just downloaded all the instructions from www.velorexusa.com . BUT the minimum upgrade you should make is making a new lower rear mount point. Jay over at DMC sidecare has an awesome subframe setup for Sportys that would the best route though.

http://www.velorexusa.com/installation.shtml

Edited by wvsporty 12/22/2014 9:52 AM




Attachments
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Attachments dragon19.jpeg (297KB - 13 downloads)
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jaydmc
Posted 12/22/2014 11:46 AM (#81818 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


Expert

Posts: 1492
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You did not say what year your bike is. How to install the sidecar depends on if your bike is a rubber mounted engine bike or not. Sub frames are always the best way to go as the Velorex clamps are slightly better then just using scrap metal. Here is a link to an article about mounting a Velorex to a rubber mounted sportster http://www.dmcsidecars.com/the-result-of-improper-sidecar-mounting-... if covers every thing you should need to know.
If your bike is a solid engine mount bike 1986 or newer we make a sub frame that gives you all 4 mounting points. The upper rear is a frame clamps similar but much higher quality then the Velorex clamp. The other three mounts are on a single sub frame that attaches to the bike at 7 points.
You will also want to once installed should you stay with the Velorex lower mounts rather then change over to the style in the article weld the lower rear mount on the sidecar frame in place or at least cross bolt it.
The Velorex is a very light sidecar and as such you will always need ballast in the sidecar.
Should you want easier steering with the sidecar we offer triple tree's to lower the steering effort $550
I have also linked basic alignment instructions.
Jay G
DMC sidecars
866-638-1793
www.dmcsidecars.com




Attachments
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Attachments BASIC SIDECAR INSTRUCTIONS.doc (388KB - 12 downloads)
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wvsporty
Posted 12/22/2014 3:56 PM (#81820 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Extreme Veteran

Posts: 410
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Location: Inwood WV
its a 1997 in the thread title
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Hack'n
Posted 12/22/2014 6:40 PM (#81821 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
Having mounted hundreds of Velorex sidecars to both early and late Harley Sportsters in the past decades, I've found that the rear lower mount is the cause of most problems. The other three have proven quite adequate.
Most Velorex cars are mounted as per the instructions in the Owners Handbook on page 6, figure 5, which shows the (over engineered) rear sliding clamp mounted with the strut in an angular position. This allows the clamp to slip, or rotate easily, under stress causing a loss of alignment. Mounting the strut as shown in the attachment will keep it from slipping in most cases. A spot weld or two will eliminate slipping altogether.
A fabricated lower rear bracket as shown, will allow the sidecar to be mounted further back in relation to the bike.

A full subframe mounting system that employs both sides of the frame to reduce stress is naturally superior.

Lonnie Cook (Retired)
Northwest Sidecars, LLC



(DSCF2885.JPG)



('05 XL 1200Roadster - 562C 001.jpg)



('02 Harley XL883 Hugger- 562 Cruiser 011.jpg)



('02 Harley XL883 Hugger- 562 Cruiser 002.jpg)



('02 Harley XL883 Hugger- 562 Cruiser 011.jpg)



Attachments
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Attachments DSCF2885.JPG (116KB - 3 downloads)
Attachments '05 XL 1200Roadster - 562C 001.jpg (125KB - 5 downloads)
Attachments '02 Harley XL883 Hugger- 562 Cruiser 011.jpg (552KB - 1 downloads)
Attachments '02 Harley XL883 Hugger- 562 Cruiser 002.jpg (617KB - 3 downloads)
Attachments '02 Harley XL883 Hugger- 562 Cruiser 011.jpg (552KB - 4 downloads)
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sidehack411
Posted 12/23/2014 11:20 AM (#81834 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
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Thank you gentlemen for the quick replies. After Christmas I hope to get out in the garage and start trying to get the car on the bike. I will probably have many questions.
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sidehack411
Posted 12/23/2014 5:35 PM (#81838 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
0
Lonnie,

The bracket shown in the pictures just bolts on to the subframe which runs back to the exhaust? Any idea on the cost of such bracket? I could probably fabricate one myself, I have a welder, drill press, etc.

Also I would think all threaded fasteners should have blue Loctite on them??
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wvsporty
Posted 12/24/2014 12:58 PM (#81846 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Extreme Veteran

Posts: 410
100100100100
Location: Inwood WV
That bracket is a self made part and looks preety simple , my plan is to make one similar to that and maybe a little over engineered this winter. The threaded fasteners on my most all had nylon nuts or castle nuts with cotter pins.
I am converting my Velorex to a 12" utility trailer tire and wheel and lowering my bike back to its new to me state. Should be a total of 3 inches lower. A friend helped me mount the sidecar originally and we did it in about 5 hours including wiring in a 4 pin trailer harness plug for ease in removal of the sidecar .
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BlankDocs
Posted 1/15/2015 12:50 AM (#82160 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


New User

Posts: 2
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Location: Indianapolis, Indiana
I have a velorex frame, and I'm curious as to how important is it for the rear lower mount to be 90 degrees, or perpendicular, to the bike? To do so, I have to mount it at the mid-point of the sidecar frame, and it seems to create a fulcrum or pivot point. The only way to move the attachment point back further, is to mount the attachment to the bike up and towards the back of the bike. The whole rig seems much more stable this way, but I'm not sure if that changes the stress points in an unsafe manner.
Thanks in advance for the help.
Dave
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Hack'n
Posted 1/15/2015 1:59 PM (#82167 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
The reason for the 90 degree angle is for a neutral standoff point for the sidecar, to maintain the position of the sidecar to the bike and keeping the toe-in static.
The rearmost strut mount position can also be used for this function allowing a few more inches more rearward attachment.

Lonnie

Edited by Hack'n 1/15/2015 2:05 PM
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BlankDocs
Posted 1/15/2015 3:25 PM (#82171 - in reply to #82167)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


New User

Posts: 2
0
Location: Indianapolis, Indiana
Thanks, Hack'n.
So, as long as one of the rear attachment points (either the lower mount or the strut) is perpendicular to the bike, I should be OK.
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wvsporty
Posted 1/21/2015 2:00 PM (#82328 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Extreme Veteran

Posts: 410
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Location: Inwood WV
Dave your problem is exactly what I have. The lower rear is almoxt centered on the sidecar frame. the picture i putup of the metal plate is an extension to move the mount back farther. The 90* is not exactly needed but the bolt in the mount to strut attachement should be vertical to help prevent the clamp on the sidecar frame from rolling or slipping.
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jaydmc
Posted 1/21/2015 2:39 PM (#82330 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


Expert

Posts: 1492
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Here is what our sub frame looks like for the 1986 to 2003 Sportster, as you will see the lower mounts are equal distance from the ground and the lower rear is quite a bit further aft then the main frame of the bike.
Jay G
DMC sidecars
www.dmcsidecars.com
866-638-1793



(HD 1986-2003 Sportster Mts Assy.JPG)



Attachments
----------------
Attachments HD 1986-2003 Sportster Mts Assy.JPG (71KB - 10 downloads)
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sidehack411
Posted 2/8/2015 12:30 AM (#82661 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
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Finally got around to getting the car mounted to the bike. When setting the toe in would I be better off with a board on its side clamped to the tire on the car, just laying it against the tire doesn't seem very accurate. Every time I measure I get a different measurement.

I am also missing the windshield and have a broken rear light on the sidecar. Any suggestions for where to source these parts?

Finally someone who owned the sidecar before me mounted a car battery behind the seat, anyone have any experience with this??
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wvsporty
Posted 2/9/2015 8:24 AM (#82689 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Extreme Veteran

Posts: 410
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Location: Inwood WV
Jay can hook you up with new parts usually. I made my own windshield out of lexan. It's only 4" tall and Aiden loves it. For the toe in i used a string line on both wheels and it seemed to work for me
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Hack'n
Posted 2/9/2015 11:20 AM (#82695 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
OEM windshields are available for those who still want to use the convertible top.

$200. plus shipping.

Lonnie
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sidehack411
Posted 2/9/2015 2:13 PM (#82699 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


Member

Posts: 8
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Thanks gentlemen for the continued advice. New question with the lower rear sliding clamp mounted as far back on the frame of the bike as possible while maintaining the 90 degree angle to the car, the axle of the car is about 15 inches ahead of the rear axle. Is this too much?? If I slide the car back, the rear strut wouldn't be angled back any, and may even be angled forward. I have the rear strut attached just in front of the rear shock.
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jaydmc
Posted 2/9/2015 2:22 PM (#82700 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


Expert

Posts: 1492
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Your wheel lead should be 10-15% of the wheel base of the bike. Here is a link to basic sidecar installation instructions that explains this.
Jay G
DMC sidecars
www.dmcsidecars.com
866-638-1793



Attachments
----------------
Attachments BASIC SIDECAR INSTRUCTIONS.doc (388KB - 14 downloads)
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sidehack411
Posted 3/10/2015 8:18 PM (#83311 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
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Hack'n, I have the car mounted, it sits level, left to right and front to back. I have the lean out set, and the tow in. The sidecar axle is 15 inch ahead of the rear axle, so at about 25 percent. Seems to go ok with a passenger or empty. Except for the terrible head shake if you let go of the bars. Any ideas? Is it because the car axle is too far forward? Or is something else wrong? Or is that typical with a sidecar?
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Hack'n
Posted 3/11/2015 10:56 AM (#83316 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
Usually there isn't much head shake with this combo. It's typical to have a slight amount at low speeds with a hack rig unless the steering has been altered.
Try jacking up your front wheel and seeing if the front end just flops from side to side. If so, tighten the neck bearings so it just has a bit of resistance to flopping. This should slow it down.
Other things can also cause this: Out of balance front tire, wheel run out, worn swing arm bearings.
Even without head shake you should ALWAYS have at least one hand on the bars. One little rut or bump can possibly
cause a tank slapper before you could grab the bars.

Lonnie
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sidehack411
Posted 3/11/2015 1:37 PM (#83317 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


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Posts: 8
0
Thanks, Lonnie. I will try those fixes. Again thanks for the help, spring seems to be here and I do really want to get this rig out in the wind.
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Hack'n
Posted 3/13/2015 3:48 PM (#83358 - in reply to #83317)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
BTW,
Have you upgraded the suspension? The early Velorex models with the 15mm axles were designed to support 300# 350cc Jawas and MZs.

Check my Suspension ad in Misc. sidecar related parts.

Lonnie
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sidehack411
Posted 3/14/2015 2:25 PM (#83365 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster


Member

Posts: 8
0
Again, sorry for my lack of knowledge here, I'm not sure on the suspension. It says it is a 1991 model on the car. My wife (the usual passenger in the car, weighs about 120 lbs. plus on trips maybe we will have another 20-25 pounds of stuff loaded. Do you factor that weight into suspension setup? To measure the axles do I just measure the outside diameter of the axle?

Dan
Bismarck, ND
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Hack'n
Posted 3/14/2015 5:13 PM (#83366 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Expert

Posts: 4833
2000200050010010010025
Location: Boise, Idaho
Pre 2005 Velorexs all have 15mm axles.

Your 883 weighs twice what the sidecar suspension was designed for.
You need to upgrade the suspension just to support the motorcycle safely in turns. Add a passenger and you have bottoming and wallowing in the turns.

You can upgrade the suspension with OEM Velorex late model parts for about $700.

I have a bolt on suspension upgrade using a 1" axle that sell for $300. with US shipping.

Lonnie
nwsidecar@aol.com



(20mm Velorex suspension 001.jpg)



(Velorex HD Option 562 & 700S.jpg)



Attachments
----------------
Attachments 20mm Velorex suspension 001.jpg (112KB - 10 downloads)
Attachments Velorex HD Option 562 & 700S.jpg (350KB - 13 downloads)
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Sal
Posted 3/14/2015 8:32 PM (#83377 - in reply to #81812)
Subject: Re: velorex 562 mounting on a 1997 883 sportster



Regular

Posts: 84
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Location: Houston Tx
Received some Velorex parts in the mail today from Lonnie and they are top notch as he described them.
Now is time for the mock up and install...
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