Install the hardtail to the stock frame starting with the top tube first and the bottom tubes second. OPTIONAL STEP - If you took the engine out, now is the time to re-install it If this isn’t the case you will need to double check the squareness of all the cuts. If the cuts are not square, grind them square using a grinder. The slugs from the hardtail should be able to slide easily into the stock frame tubes with very little force. Grab the hardtail and check clearance of all stock tubes individually to verify fitment and that there are no restrictions. Remove at least ¾” of the paint off the exterior side of where the tube was cut to prevent weld contamination. Make sure the burrs are also removed from the drilled hole for the rosette weld. Remove all burrs from the interior and exterior of the tubes using your tool of choice. Visually make sure the drill bit is square while entering the second side of the tubing. Using a center punch and a 5/16” drill bit, drill a hole at the ½” locations which will be used for the rosette weld. Using a marker, mark a center point ½” from the edge of all cuts. If the cuts are not square, grind them square using a grinder. Use a square to check the squareness of all the cuts. Leave all of the other engine mounting bolts. Remove the 4 bolts holding the rear of the motor/ transmission to the frame and remove the back section. If the engine is in, cover it with a blanket and place the piece of metal directly under the top tube where the cut is being made.Ĭut the top tube first using either a cut off wheel, sawzall, hacksaw, or some other cutting tool of your choice.Ĭut the two bottom tubes next using the same tool. You will have to re-install it after making these three cuts. OPTIONAL STEP - If you’d like to take your engine out because you don’t think you’ll be able to make these cuts without damaging something, this is the time. Use painters tape and wrap it around the top tube and two bottom tubes to help mark the cut location and use it as a guide for keeping the cuts square. Note: the kickstand mount isn’t always in the same position so do not use this for taking measurements. Use a square and transfer this cut line to the other bottom tube.ĭouble check this dimension from the bottom brace and make sure that it is approximately 2”. You will need to verify fitment with the engine installed and trim to the correct length if necessary. The desired cut length from this intersection is 5 1/8”. Keep the tape measure in line with the bottom tube, hold the straight edge to the edge of the engine casting. Measure and mark the two lower tubes using a straight edge, tape measure and fine tip Sharpie. The proper measurement is approximately 1.25”. Measure and mark the top tube 14⅛” from the neck tube back.ĭouble check the cut position from the back of the top engine mount. Remove all items to get down to a bare frame. Blanket (Used to keep dust and grinding grit off your engine while cutting).Piece of thin wood or metal ~¼” x 3” x 3” (Used to protect your engine while cutting).Die Grinder - Pneumatic, Dremel, or hand deburring tool. Angle grinder with ~60 grit disk for removing paint and deburring outside of the diameter edges.Cutting Tool - Pneumatic or electric cut off wheel, sawzall, hacksaw, etc.Basic tools for disassembly and assembly.Motorcycle lift or heavy duty and stable stand.See below for install instructions: Tools Required Necessary hardware, slugs, bungs and fittings included.Accommodates stock components such as wheels, axles and brakes.’82-’03 Sportster Hardtail Kit Features Include: With a goal to stay as close to OEM specs as possible, we made the frame with 1.5” stretch to allow room for fender clearance, seat fitment and an oil tank.Įverything needed for installation is included such as hardware, slugs, bungs and fittings. We developed this kit for the home builder and designed it to accommodate stock components such as wheels, axles and brakes. Coupled with 1” diameter tubing, this kit enables you to bring classic big twin chopper style to your Evo Sportster. The looped back end is a node to the motorshop frames from the ’60s and ’70s. Our ’82-’03 Sportster Hardtail Kit is 100% made in Charlotte, NC and completely tig welded from top to bottom.
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