WICKED THUMB LIMITED Destroyer Sidecar Instruction Manual

WICKED THUMB LIMITED Destroyer Sidecar

Welcome

Welcome to the Wicked Thumb Army and congratulations on the purchase of your sidecar!

Over the course of this guide we will go over everything you need to know to get your sidecar unboxed, assembled and ready to roll.

If at any point during the assembly (including right now!), you are unsure of your ability to assemble the sidecar in a safe fashion, we strongly suggest taking it to your local bike shop, where they will be able to safely complete the process, while also checking for anything that may have loosened up during transit and tuning things to your riding ability and preference.

Before continuing any further, if there is any severe damage to the outside of the packaging, please take pictures before removing the sidecar and send them to info@wickedelectricbikes.com. Time is of the essence if there is shipping-related damage to your new sidecar.

All set? Let’s dive in!

| NEVER

• EXCEED 12 MPH
• EXCEED 120 POUNDS IN SIDECAR
• STOP SMILING

ALWAYS

• KEEP HANDS AND FEET IN SIDECAR
• WEAR A HELMET AND EYEWEAR
• MAINTAIN TIRE PRESSURE AT 20 PSI
• INSPECT MOUNTING HARDWARE PRIOR TO RIDING
• STAY WICKED

IMPORTANT

IT IS NOT UNCOMMON FOR THE OUTER BOX TO ARRIVE DAMAGED. WE PACK THE SIDECAR VERY SECURELY, BUT IT IS INEVITABLE THERE IS OCCASIONAL DAMAGE IN  SHIPPING.

IF THERE IS DAMAGE TO YOUR BOX:

TAKE PICTURES OF ALL 6 SIDES PRIOR TO OPENING. FAILURE TO DO SO MAY VOID ANY DAMAGE CLAIMS.

AFTER TAKING PICTURES OF THE OUTER CARTON, OPEN THE BOX AND

TAKE PHOTOS SHOWING THE INNER PACKING BEFORE REMOVING ANY COMPONENTS FROM THE BOX.

CAREFULLY INSPECT YOUR BIKE FOR DAMAGE. NOTE ANY DAMAGE.

IF YOU NOTICE ANY DAMAGE TO ITEMS SUCH AS THE MOUNTING FRAME, SIDECAR BODY, ETC. DO NOT USE YOUR SIDECAR UNTIL YOU HAVE BEEN CLEARED BY WICKED THUMB CUSTOMER SUPPORT.

OPERATING A DAMAGED SIDECAR AND THEREFORE CAUSING FURTHER DAMAGE WILL VOID YOUR WARRANTY ON THE ADDITIONAL DAMAGED PARTS.

IF EVERYTHING LOOKS GOOD ON INSPECTION, CONTINUE WITH THE REST OF THIS MANUAL AND ASSEMBLE AS INSTRUCTED.

TOOLS NEEDED FOR ASSEMBLY

• Scissors, flush cutters, or snippers
• 13mm wrench or socket
• 10mm wrench or socket
• 19mm wrench and socket
• Crescent wrench
• 5mm Allen wrench
• Tire pump
• Flathead screwdriver

Included in the box:

• Sidecar frame
• Sidecar body
• Seat
• Rubber carpet mat
• Seatbelt
• Sidecar fender
• Sidecar wheel
• Axle w/hardware
• Sidecar mounting plate
• U-bolts (two large, two small)
• 8 X nyloc nuts
• 4 X Spacers
• Shims
• Mounting bolts
• Quick-release pins
• Adjustment turnbuckle
• 2 X Heim adjuster bolts

Sidecar Mounting Plate Installation

Attach the mounting plate on the right side of bike frame by placing U-bolts around the rear tubes of the frame and through the base plate. The smaller U-bolts go to the rear of the plate, and the wider two go to the front.
For placement, the top rear U-bolt mounts about 1″ in front of the rear cargo rack bolt and the front top U-bolt will be right at the frame bend.

Make sure the shifter cable and main motor cable are free, and are not binding or pinched between the mounting plates, u-bolts, or bike frame.

the shifter cable will run inside the bottom back U-bolt. The motor cable sits below.

Put the large plastic spacer blocks on u-bolts, then add the metal bar washers and thread nyloc nuts onto the u-bolt just until finger tight. Note: do not fully tighten the nyloc nuts down at this time. Adjuster turnbuckle should hang free as shown.

Starting with the bottom rear U-bolt, Tighten all nyloc nuts down to 6 FOOT POUNDS. Work clockwise around the U-bolts.
DO NOT overtighten the nuts, as it could damage the frame of the bike. Check your gap at the top of the plate to make sure it fits as below.

Place rubber caps over the remaining threads on U-bolts

Sidecar frame and body assembly

Note front of sidecar frame with diamond tread plate step.
Mount fender to sidecar frame using 3 allen bolts inserted in frame.
One bolt will be in the front of the frame and two in the rear.
The Wicked Thumb logo should be on the rear of the fender. Tighten all 3 bolts down snug to 6 foot pounds)

Get a helper. Look for a direction arrow on tire. If there is a direction arrow make sure this is the outside of the wheel and must point clockwise. If not the wheel can go in either way. Insert the wheel into frame. Thread a nyloc nut onto the end of the axle. Slip axle through outside of frame hole and place spacer between frame and wheel bearing. Push axle through spacer and into wheel bearing.

Use flathead screwdriver to create a gap to put inner wheel spacer between inner wheel bearing and frame. Slide spacer in place and push axle through spacer and through frame. Add nyloc nut onto threads of axle.

Using 1 9mm or crescent wrench, hold inner axle nyloc in place while using 1 9mm socket or driver to tighten outer axle nut. Tighten to 6 foot pounds. Look for even threads on each nut. Wheel should spin freely.

Insert Heim Adjuster Bolts Into Frame Ends.

Jam nut should be adjusted to eye of bolt. Fully thread in both Heim bolts.

Once fully threaded, back the front heim bolt out 6 full turns. Lock jam nut against frame. Eyes of bolts should face sideways as shown.

Attach Heim Bolts To Mounting Plate

Using locking pins, insert heim bolt eye between mounting tabs on mounting plate. Feed pin through and lock in place.
Double check that front heim bolt is adjusted out as shown.

Verify turnbuckle is at a length of 8.5 – 8.75 inches. If not adjust loose end until in that range.
Lower Turnbuckle Down into mounting position and insert 8mm bolt through mounting tab and turnbuckle end. Affix nyloc nut and tighten to 6 foot pounds

Verify All Pins are Locked in Place and All nuts and bolts are tight. You should have a slight lean in to your bike.

Attach Sidecar Body to Frame

Please view all pics below for accessory positioning of d-rings and seatbelt

Place 6 mounting bolts and washers through holes in the sidecar body, lining them up with the holes in the frame. Note 2 low profile button head bolts are for the rear position.
Place nuts on the bolts on the underside of the frame. Have your helper hold the 13mm wrench on the nuts as you tighten the bolts. Do no fully tighten down until all bolts are in.
6 pound foot max.

f not using the seat you can lay your rubber mat in the sidecar and you are done!
If using the seat, you will take the 4 seat bolts/washers and feed the bolts through the body and into the threads in the seat bottom. Use 5mm allen wrench to loosely tighten. With all 4 in place, Tighten to 6 foot pounds. DO NOT OVERTIGHTEN.

Place the rubber carpet mat in the sidecar Inflate the sidecar tire to 20psi max Inspect all fasteners to ensure they are secure prior to riding. After the first few rides, inspect all fasteners again to ensure nothing has come loose.

Warning: the sidecar has a maximum load of 120 lbs and a maximum operating speed of 10mph. Exceeding these limits could damage the sidecar and/or cause a loss of control which could result in injury to yourself or others.

Note: when operating the sidecar without a passenger, it is advisable to place a load of at least 30-50lbs in the sidecar in order to improve handling.

Since each bike may have a different stance, some adjustment may be necessary. Please view the video entitled ‘sidecar toe adjustment’ for adjusting the position of your sidecar equipped bike.

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