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2003 Harley sidecar mounting
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coalminer16
Posted 11/7/2010 4:49 AM (#54486)
Subject: 2003 Harley sidecar mounting


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Father bought a 2003 Harley Unltra sidecar and needs to mount it to the 03 Unltra Classic Harley. It has all the mounts as it came off a dealer mechanics bike that the guy just didn't want it anymore so he took it all off. Question is I am 750 miles from home and don't know how to mount anything but a Hitchhiker sidecar and they don't want to pay the $600 the dealer wants to charge to mount it. Is there any instruction manual or a online writeup or something to help them out.
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bikeridermark
Posted 11/7/2010 8:40 AM (#54491 - in reply to #54486)
Subject: RE: 2003 Harley sidecar mounting


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Posts: 27
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Harley has a factory manual available. Dealer should have one for sale. My dealer sold me one for about $50. Was very helpful with the install. If this rig has already been on a bike, part of the set up is already done. You'll still need a few parts for your master cylinder, if it's the same as my '01.
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gnm109
Posted 11/7/2010 6:11 PM (#54495 - in reply to #54491)
Subject: RE: 2003 Harley sidecar mounting



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Location: Sacramento County, California
The manual is a 99485-03 for your bike.
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bikeridermark
Posted 11/7/2010 7:07 PM (#54496 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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Where are you at? If you are close I could offer up a manual and some help.
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coalminer16
Posted 11/7/2010 11:21 PM (#54497 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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The bike and sidecar are near St. Cloud Minnesota. Your help would be appreciated. Thanks for the manual number.
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coalminer16
Posted 11/12/2010 6:16 AM (#54553 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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Well, we found one of the last service manuals around. They may be a few more out there at dealers but they stopped making them. Thanks for the help though. It will get mounted before next summer so we know we aren't missing parts while there is still a few parts left out there.
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timo482
Posted 11/12/2010 10:14 PM (#54566 - in reply to #54553)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
im in belle plaine - been through st cloud a dozen times this summer.

be sure and get it aligned really properly - then try it . most folks seem to do fine with the stock assy

i put on a raked tree to lessen the steering effort - two fingers is all thats needed at 70 with the cruise on - it is a godsend as i get sore wrists.

2007 bike, 2004 tle with tleu wiring

to
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coalminer16
Posted 11/13/2010 2:21 AM (#54570 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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I don't think they will do much actual traveling with it on as it will off on this bike. I have heard that the raked triple tree isn't fun without the sidecar. Is that true? The next bike I am co-buying it with my father and putting a hanigan sidecar on there for me. I would consider the raked triple tree if you can ride it decent without the sidecar on as well. 2013 is the next bike.

This sidecar will likely run from their home (25 miles south of St. Cloud) to St. Cloud to pick up some groceries or maybe a weekend camping with the dog but nothing major like my father normally does. He put 25,000 miles this summer on and regularly 5,000 in a week isn't uncommon with him. Not common with the rest of the family.
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timo482
Posted 11/13/2010 8:20 AM (#54573 - in reply to #54570)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
the back yard term is that you are "smoking something"

it takes about a hour with two strong folks to remove the sidecar, then about a half hour to bleed the brakes - then a trip to the digital tech to reset the rollover switch

but it takes a long day to get it on and aligned, then bleed the brakes, then the digital tech for the rollover switch

plus the seat, bags, sidecover are off each move

it totally sucks to remove and really totally sucks to install - once right it works really nice

the other issue is wt.. the wt IN the sidecar MUST be higher than the wt on the rear of the bike so no riding a passenger on the back with a empty sidecar. the rear tire really is not heavy enough there are suits galore over that issue but with a sidecar the gcvwr is 1600 lb - the rear tire is the one that is the issue - if the rider and passenger together are over 400 you cant ride anybody on the rear seat at all and you need to carry heavy luggage in the rear of the sidecar or on its rack, not on the bike.

its a bummer but nobody wants you to get hurt or try something that will not work.

and yes once the tree is raked its a sidecar bike. on mine i run a car rear tire and a raked tree - it wont be off the sidecar till it sells or i expire.

harleys easy on, easy off stuff is a comparison to way back with the large swivel nuts - its markeing myth at best

to
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gnm109
Posted 11/13/2010 10:32 AM (#54576 - in reply to #54573)
Subject: Re: 2003 Harley sidecar mounting



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Location: Sacramento County, California
timo482 - 11/13/2010 5:20 AM

the back yard term is that you are "smoking something"

it takes about a hour with two strong folks to remove the sidecar, then about a half hour to bleed the brakes - then a trip to the digital tech to reset the rollover switch

but it takes a long day to get it on and aligned, then bleed the brakes, then the digital tech for the rollover switch

plus the seat, bags, sidecover are off each move

it totally sucks to remove and really totally sucks to install - once right it works really nice

the other issue is wt.. the wt IN the sidecar MUST be higher than the wt on the rear of the bike so no riding a passenger on the back with a empty sidecar. the rear tire really is not heavy enough there are suits galore over that issue but with a sidecar the gcvwr is 1600 lb - the rear tire is the one that is the issue - if the rider and passenger together are over 400 you cant ride anybody on the rear seat at all and you need to carry heavy luggage in the rear of the sidecar or on its rack, not on the bike.

its a bummer but nobody wants you to get hurt or try something that will not work.

and yes once the tree is raked its a sidecar bike. on mine i run a car rear tire and a raked tree - it wont be off the sidecar till it sells or i expire.

harleys easy on, easy off stuff is a comparison to way back with the large swivel nuts - its markeing myth at best

to


All good points you make. There's nothing simple about removing the sidecar. As to the triple tree changeover, that is a good idea but should only be done on a motorcycle that is to be dedicated to sidecar use. They are unsafe when ridden solo with reduced rake.

Since you mentioned the Digital Technician rollover change, what does the dealer in your area charge for toggling the rollover switch to solo or to sidecar?

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coalminer16
Posted 11/13/2010 8:58 PM (#54582 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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Good points on the mounting and I am VERY glad the above was/is mentioned since the only sidecar I have is the Hitchhiker which seems to be a little less involved process. Question on that the Digital Technician Rollover Change is for the rollover switch?
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bikeridermark
Posted 11/13/2010 10:22 PM (#54585 - in reply to #54582)
Subject: Re: 2003 Harley sidecar mounting


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I've had mine off and on about 3 times, no big deal. A few hours and I'm good to go!
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timo482
Posted 11/14/2010 7:53 AM (#54588 - in reply to #54582)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
yup - its to change the tsm settings so it wont cut the engine on a turn....
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timo482
Posted 11/14/2010 7:55 AM (#54589 - in reply to #54585)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
i had a sidecar in my 20's - it was no big deal

im in my 50's and it SUCKS

but i intend to leave it on due to a issue where my ankle that i broke when i was 14 goes to sleep every so often.....

to
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bikeridermark
Posted 11/14/2010 8:25 PM (#54600 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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Posts: 27
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What's this TSM setting you speak of? I never changed anything on my '01, even though they mentioned something in the book about security settings for the alarm. Mine's carbed, maybe that'sthe reason.
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timo482
Posted 11/14/2010 8:40 PM (#54602 - in reply to #54600)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
the turn signal module has a giz in it that will shut off the ignition if the bike leans too far - with a sidecar if you corner hard or fly the chair the roll over sensor kills the ignition - not a good thing so there is a giz that comes with the sidecar and is mounted in the bike [hidden well] that is set with the digital tech that only kills the ignition if its upside down - cornering or flying the chair will not shut off the ignition

to
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gnm109
Posted 11/14/2010 8:46 PM (#54603 - in reply to #54602)
Subject: Re: 2003 Harley sidecar mounting



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Location: Sacramento County, California
timo482 - 11/14/2010 5:40 PM

the turn signal module has a giz in it that will shut off the ignition if the bike leans too far - with a sidecar if you corner hard or fly the chair the roll over sensor kills the ignition - not a good thing so there is a giz that comes with the sidecar and is mounted in the bike [hidden well] that is set with the digital tech that only kills the ignition if its upside down - cornering or flying the chair will not shut off the ignition

to


Yep, that's the way it works. The TSSM (or TSM if no security) has within it an electro-mechanical pendulum that is designed to shut off the engine on a solo bike if it falls over. That is if the bike is leaning at greater than 45 degrees either way. With the rollover change (2003 on, IIRC) the TSSM has an add-on switch that supplants the original and will shut off upside down only as TIMO says.

I think there was one year that didn't need the add-on switch, maybe 2001 or 2002. The TSSM could be programmed using the turn signals in programing mode. That would have been much easier than having to visit the dealer to pay to have it changed. As far as I know, HD was the only one that used a rollover switch.

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coalminer16
Posted 11/14/2010 9:05 PM (#54605 - in reply to #54486)
Subject: Re: 2003 Harley sidecar mounting


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Posts: 46
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Thank you. Good points to know these things. On the newer models now that they stopped making the sidecars for the Harley can you still get that TSSM switched or programed?
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gnm109
Posted 11/14/2010 9:41 PM (#54606 - in reply to #54605)
Subject: Re: 2003 Harley sidecar mounting



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Location: Sacramento County, California
coalminer16 - 11/14/2010 6:05 PM

Thank you. Good points to know these things. On the newer models now that they stopped making the sidecars for the Harley can you still get that TSSM switched or programed?


They have quit taking orders for new sidecars as of 2011. I presume that they are in the process of completing their existing orders. The TSSM programming is done with the Digital Technician (proprietary HD laptop) Whether HD makes sidecars or not, they will continue to be able to do the programming.

For the record, you can ride without doing the change. It's only if you should take a severe corner that you might have a problem. If you have the equipment installed on a 2004 and later machine, you should have it set correctly for sidecar work to be on the safe side.
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timo482
Posted 11/14/2010 10:05 PM (#54607 - in reply to #54602)
Subject: Re: 2003 Harley sidecar mounting


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Location: Belle Plaine MN
this is where the "issues" of used sidecars rears it ugly head

folks think they have all the mounts - but only have the big parts - and even those are only good for certain years.

and folks breaking the set and selling them off seperate have a tendency to leave 2k of sidecar parts on the bike...

now that they are no longer made its going to be a bigger deal - folks buying a "complete" set are going to get mighty upset when they find 2k worth of parts missing

there are lots of tle & tle u sidecars out there - but the tiny parts for the mount kit will soon be worth more than the car

even now the mount set is more important than the car & harder to get.

to
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gnm109
Posted 11/14/2010 10:39 PM (#54608 - in reply to #54607)
Subject: Re: 2003 Harley sidecar mounting



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Posts: 1370
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Location: Sacramento County, California
timo482 - 11/14/2010 7:05 PM

this is where the "issues" of used sidecars rears it ugly head

folks think they have all the mounts - but only have the big parts - and even those are only good for certain years.

and folks breaking the set and selling them off seperate have a tendency to leave 2k of sidecar parts on the bike...

now that they are no longer made its going to be a bigger deal - folks buying a "complete" set are going to get mighty upset when they find 2k worth of parts missing

there are lots of tle & tle u sidecars out there - but the tiny parts for the mount kit will soon be worth more than the car

even now the mount set is more important than the car & harder to get.

to


Man, you can say that again. I was pretty much in that position on the first two HD sidecars I had. That's why I decided to get a new one in the crate for my present bike. It was all there, complete down to the last nut, bolt and washer. Installing it was rather involved, as well. Those connection kits will eventually get scarce when they quit making parts.

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