Installation Manual Yamaha Stratoliner/Roadliner Version 2 Copyright 2020, Pete Giarrusso, Inc.
Table of Contents INTRODUCTION .................................................................................... 4 WARRANTY ............................................................................................ 5 INSTALLATION INSTRUCTIONS ...................................................... 6 COMPONENTS: .................................................................................................... 6 1) 2) 3) 4) 5) 6) 7) 8) Control Switch Box................................................
Introduction This manual covers installation of the LegUp Landingear system by Chopper Design Services. This system should only be installed by a qualified technician, or those with above average mechanical skills. If you are not SURE that you can perform this installation, please contact us and we will help you find a qualified shop to assist you.
Warranty Chopper Design Services warrants the LegUp system for a period of one year from date of purchase. This warranty covers replacement parts and/or manufacturer defects. Incidental damages or costs are the responsibility of the purchaser. Defective parts are to be returned to Chopper Design at the address below. Purchaser must contact Chopper Design to receive a Return Material Authorization, prior to returning defective parts to Chopper Design.
Installation Instructions The LegUp® system has many components. Pleased be sure you have them all before starting your installation. COMPONENTS: 1) Control Switch Box 2) Linear Actuator 3) On-board Computer Module 4) Proximity Sensor 5) Leg Support Stand 6) Leg/Wheel System 7) Hardware Bag 8) Actuator Bracket If you believe you are missing any parts, please contact Chopper Design at 407-834-5007, and we will rectify the situation.
PREPARE FOR INSTALLATION Place the motorcycle on an acceptable bike lift. You will need to keep the bike on its wheels for most of the installation, and jack the rear wheel off the lift for some portion of the installation. Make SURE the motorcycle is secure on the lift! Remove the seat, saddlebags and side covers, they are not needed until the very end of the installation.
INSTALL LEG SUPPORT STAND LegUp has developed a new, stronger attachment system which holds the Leg system to the bike! You will need to remove the two Exhaust Bolts from the exhaust bracket on the right side in order to install the support stand. These Bolts are replaced with two from the kit. Remove the Black button-head bolt from the left side of the bike, directly below the left foot peg. This bolt will also be replaced.
Locktite, and get lined up from the bottom of the ‘L’ brackets into the threaded holes of the support plate (picture left). Gets these bolts just barely started to give us flexibility for the next step. You will find two ‘U’ shaped brackets in the box. Take these brackets and slide them on the top of the plate you just installed. These get oriented with the open side facing out and the threaded hole toward the plate. Slide these brackets from the middle out toward the frame.
ACTUATOR BRACKET The actuator bracket mounts to the vehicle on the bolts that hold the left foot peg to the bike. Remove these two bolts and the plate. These bolts are not re-used. Find two long hex-head bolts with chrome washers, put some blue Locktite on these bolts, guide them through the spacers, then the stock bracket, then the holes on the actuator bracket. Attached to this bracket is the upper actuator mount (brushed aluminum) with the upper actuator axle. This mount is tightened at the factory.
LEG/WHEEL ASSEMBLY If not completed already, first remove the bolts from the stainless steel rod in preparation for mounting the legs. With help from an assistant, slide the Leg/Wheel Assembly around the rear tire (careful of the finish!), and align the Leg Mounting Points (green) with the slots in the Support Stand. If available a very small amount of ‘Never Seize’ on the shaft is in order here.
MOUNT ACTUATOR Remove the axles from both the upper and lower actuator mounts (aluminum blocks - one on the legs and one on the upper actuator mount by passenger peg), and set them aside. Both actuator mount axles are chrome bolts with Nylock nuts. Align the actuator, motor side (big end) down with the hole in the upper actuator mount. Reinstall the axle bolt from the outside of the bike in, and install the Nylock nut on the inside. Tighten the nut as shown to the right.
CONTROL SWITCH BOX NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE system. The LITE System does NOT have a Proximity Sensor! Ignore all references to the Proximity Sensor, Its’ mount & wiring. Disassemble the 8-pin connector attaché to the switch housing and the 3 pin connector attached to the speed sensor (yellow on a black bracket).
WIRING HARNESS NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE Harness! The next step is to route the wiring harness. The harness and the plugs are routed mostly under the seat area cover. We already ran the wires from the handlebar switch and the speed sensor. The actuator wire should be run under the seat area behind the fender support (self-adhesive straps are included to secure wire away from swing-arm and belt).
Connect the orange plug to this, then remove the left bolt from the seat plate, and re-install the bolt with the black wire and its’ hoop connector, back into the hole for a ground. The picture below shows us tightening this bolt back in place. Plug the computer enclosure plug in its mating connector as well.
INITIAL SYSTEM TEST NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE system. Skip this section if you have a LITE System. Turn your key switch on. At this point, have a look at the yellow proximity sensor (it should be dangling near the front forks somewhere). The LED Should Not Be Lit. Take a metal object (screwdriver, wrench, etc) and hold it on the flat face of the sensor (it has a circle embossed in it).
MOUNT PROXIMITY SWITCH NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE system. Skip this section if you have a LITE System. This step is crucial!! Understand it before starting. The proximity sensor tells the system how fast the bike is traveling. The proximity sensor mounts to the lower front brake mounting bolt. The sensor will ultimately be mounted 5MM from the rotor bolts.
Once you feel you have the right place, tighten the brake bolt down securely, and test again! If this is not happening, you may need to get the sensor a bit closer to the bolts (5MM is a very small distance!). If you have to move the sensor closer, you may have to bend or adjust the angle of the bracket.
WIRE ROUTING NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE system. Guide the wires from the Proximity bracket up the brake line, and attach it to the line with wire ties.
FINISHING UP Now it is time to recheck everything! Check that all bolts that were loosened are tight. Reinstall the side cover and the bags; making sure that everything is clear. Reinstall the seat making sure all your wires are routed neatly, tied off nicely and don’t interfere with the seat installation. Now you can dial in the actuator, and adjust the wheels.
TEST RIDE NOTE: If you have a LITE System, Please refer to the addendum at the end of this manual, for differences between a Regular and LITE system. Deployment and Retraction of the wheels is COMPLETELY MANUAL if you have a LITE System. Get the bike to a clear paved mostly level area where you can test ride it. Start the bike, turn on the LegUp system and lower the legs. The first test should be done in a straight line. Put the bike in gear and slowly accelerate.
The next thing to try is to make a turn right after a dead stop with the wheels down. As soon as you start the bike moving, try a left or right turn immediately by leaning into that turn. You may find that you have to nudge the bike a little bit more than usual to get the bike to lean, and you won’t be able to lean as far as you can with the wheels up. Once into the turn, accelerating will raise the wheels.
LEGUP LITE - ADDENDUM If you have a Lite System, there are a few differences in the wiring compared to our Regular system. The plugs and their locations don’t change at all! Instead of plugging in the computer to the twelve pin plug, the Relay-Pack gets plugged into this plug. The Relay-Pack will be attached with Velcro as the computer would have been in the same location.
ILLUSTRATIONS Wiring 1 There are three different types of actuators with three different wiring configurations.
Wiring 3 25
PARTS LIST (4) 3/8-16 X 1” Cad Bolts w/ Lock Washers (2) 5/16 – 18 X 3/4” Cad Bolts w/Lock & Flat Washers (5) M10 x 45mm Black Hex Bolts (Uprights & Upper Actuator Bracket) (1) 7/16” x 1/4” x 1 1/16” Chrome Spacer (Handlebar) (1) M5 X (CUT) 2 5/16” Black Allen Bolt (HB Bracket) (2) 11/16” OD x 7/16”ID x 5/16” Spacers (Upper Actuator Bracket) (2) ¼-20 X 2” Chrome Allen Bolt w Nylock (actuator mounts) NOTE: Aluminum Actuator Brackets are Drilled Out for ¼-20 Bolt! 26
