Preparation And Mounting Procedures; Brakes; Attaching The Sidecar - Champion Sidecars DAYTONA 2+2 Owner's Manual

14
(Fig 9)
BRAKES (IF EQUIPPED) Locate the rear brake
master cylinder usually located near the
rear brake pedal. The brake connection is
accomplished by removing the existing banjo
bolt connecting the rear brake line to the
rear master cylinder and replacing it with a
longer double banjo bolt supplied by
Champion. The double banjo bolt will go
through both the new brake quick coupler
banjo end and the existing brake cable banjo
end shown (Figure 9). ( be sure to use new
crush washers between all banjo fittings and
connecting surfaces). The brake cable to the
sidecar is aircraft quality steel braided
hose with a quick disconnect coupler. This
coupler is sealed in both directions to prevent any brake fluid from
leaking out. Because your Harley Davidson uses DOT 5 brake fluid from the
factory and because DOT 5 brake fluid is not compatible with the brakes
used on your sidecar it will be necessary to drain and refill the rear
brake system with DOT 4 brake fluid and re-bleed the motorcycle rear brake
system. The sidecar is shipped without any brake fluid so it will be
necessary to replace the fluid with DOT 4 brake fluid and bleed the brake
system before riding the sidecar combination. Also at any time the rear
brake pedal feels spongy or softer than normal, the sidecar brake line
should be bled and checked.
rd th
(NOTE) It is recommended to bleed the brakes every 3 . or 4 time the
sidecar is removed.

PREPARATION AND MOUNTING PROCEDURES

ATTACHING THE SIDECAR

Mounting the sidecar should be done on a level even floor surface. The
sidecar frame should be supported at the front and rear cross member on 4x4
blocks or stands adjusted to a length of six and a half inches for the rear
and seven and a half inches in the front for the Daytona and Escort (Figure
L). If the sidecar you are installing is our Legend sidecar the front
measurement should be nine inches and the rear measurement is seven and
three quarter inches Figure L-1. If you have T.I.L.T. installed on the
sidecar, retract the wheel to ensure the wheel does not support the weight
of the sidecar. Slide the front and rear mounting hardware into the sidecar
frame. To ease adjustments, excess powder coat may have to be trimmed off
the leading edge of the tubes before being inserted into the frame tubes.
For the Escort and Daytona installation the front uses the 45 degree boss
and 45 degree clamp while the rear uses the 70 degree boss and 70 degree
clamp. For the Legend sidecar front hardware installation the offset clamp