Installation Instructions for AME 14 Degree Chopper Kit

The Safety and Quality of this kit depends on correct installation. Read and follow all instructions carefully.

Notice:
Correct function of the brake system is necessary for vehicle safety. Therefore this installation should be only made by authorization motorbike dealers. Do not modify the delivered parts. Damaged or bent parts should not be used or repaired in any way.

If there are any questions please contact your distributor:
AME-Choppers (Custom Bikes and Choppers)

Note: Avoid allowing brake fluid on painted surface, it will damage the paint.
Note: Use Loctite on all bolted connections.

1. Secure Motorcycle on lift or suitable jack.

2. Disconnect negative batter cable to disable electrical system.

3. Remove front wheel, front fender, and brake body.

4. Loosen lower triple tree clamp screws and remove fork slider assembly.

5. Remove handlebars and headlight.

6. Remove triple tree.

7. Top and bottom Bearings and bearings races must be removed. A bearing race removal tool will be needed on 2004 up XL models.

8. Clean the inside of the steering head, be sure no burs have been left in the bearing race seat.

9. Place a small amount of grease on the inside of the bearing race seat top and bottom of the steering head. Then slide the top tree assembly down into the steering head.

10. Loosen the alignment screws on each side of the adapter. Insert the adapter block into the bottom of the steering head. Make sure it is straight; it will use the original steering stops as a guide.

11. Insert the large bolt through the bottom of the adapter and screw it into the shaft of the top tree assembly using a 14 mm allen socket Make sure that both parts are completely seated. Remove the bolt, check to make sure the original steering stop is centered in the adapter. (If not use alignment screws to center it) Clean any lubricate off the bolt, apply Loctite to the bolt and reinstall. Torque to 148 ft Ibs. (This torque amount must be reached!)

12. Remove fork tubes from lower legs and replace with longer fork tubes. See figure 1 for exploded view.

13. Insert fork tubes from lower triple and pre tighten pinch bolts.. (Please use extreme caution installing fork tubes, lubricate tubes with Vaseline. A second person to help align the trees during this step is recommended. We are not responsible for scratched tubes)

14. Pull up fork tubes against upper triple tree and tighten fork tube cap screws.

15. Remove circlip from the shaft on the bottom of the adapter. Loosen lower triple tree pinch bolts. Slide the lower triple tree with bearing on the bearing pin. Position the bottom triple tree on the adapter shaft leaving 1mm of space between the bottom of the adapter block and the bearing. Secure the lower triple tree using the circlip. Install the handlebars and risers.

16. Tighten clamp screws with specified torque.

17. Install the Handlebars and risers.

18. Install the caliper

19. Install the fender using the spacer and bolts provided.

20. Install the new brake line.

21. Remove the brake rotor from your wheel and install the rotor spacer between the rotor and hub.

22. Install the front wheel using the axel and wheel spacer provided

23. Headlight can be mounted with included bracket or use a bottom mount light on lower tree Check all bolts for correct torque.

Torque Specs (ft lbs)
Pinch Bolt (30-35)
Front axel (25-30)
Front axel clamp bolt (11-15)
Riser Bolts (40-50)
Bottom adapter bolt (M12) (148)
Fork bridge lower clamp bolt (40-45)
Caliper mounting bolts (18-29)
Fork caps (60-70)
Banjo fittings (brake line) (15-18)


Special Tools Needed

14mm Allen Socket
Torque Wrench
Bearing Race Removal Tool

Parts Not Included

Fork Oil
Fork Seals