Wednesday, June 2, 2010

HT1500 Honda Gold Wing Conversion Kit Installation Instructions

11:16 PM by onesecond ·
Put bike on center stand Removal of Bike parts: Remove the following parts following the factory manual: side covers, passenger foot rests, exhaust covers, seat, tour pack, saddlebags, battery and box, rear tire, brake line (at rubber hose near swing arm pivot), shocks (air compressor line is disconnected at shock, and stays with compressor), Swingarm and driveshaft (reverse box may stay connected, just pull out to side), mufflers, and helmet locks. Preparation: Cut-off the saddlebag support tubes where the vertical tube meets the angled tube in the front and back. All you want left is the tour pack support. Loosen tour pack support at bottom bolts, remove top bolts, and then lift up a little. This allows the body to go under the support. If you have the fuel tank: Secure the two black control boxes, facing each other, one on top of the other. Secure to frame using the green ground wire hole at center of frame. Use the 2 ΕΎ” spacer tube and long screw provided to hold them together. If no fuel tank: leave rear half of fender in place Install air-compressor relocation bracket (1 ―” x 4" w/ 3 holes) and remount compressor. After mounting, secure the compressor to the bracket with a wire tie

Install suspension:
See brake amendment for master cylinder prep Install machined studs in the swing arm pivot hole with some blue Locktite on them. This provides a 5/8” stud on the side of the frame for the suspension side plates. Screw in until flush with frame. Remove the 6mm bolts from the exhaust heat shield on the outside of the frame rail. Install the shock replacement bars on the top shock stud and re-install bolts, leave bars hanging loose for now. Put the suspension on a floor jack and roll up to the bike. (note: once forward all the way, jack up to meet the studs.) Spread the chassis plates over the studs and start the nuts. Be careful not to damage the threads on the machined studs. Jack up the rear to align the shock replacement bars, slip in the bolts.

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