Throttle Addiction 1982-2003 Sportster Hardtail Installation Guide

Throttle Addiction 1982-2003 Sportster Hardtail

DIMENSION

Measure 16″ from front of neck to backbone and mark for cut

1982-1991 Models

• Measure hardtail from motor mount to the end of the frame (not the end of the slug).

• Transfer that measurement to the stock frame and make your cutin that location.

1992-2003 Models

• Measure 2 3 / 8″ back from the back edge of the rear cross bracket and make cut marks

• Cut behind your mark and sand to ensure a flat mating surface

• Use cardstock with square edges and wrap tube to ensure a square cut line

• Drill 21/64″ holes for plug welds 1/2″ in from end of tube
• Bevel end of tubing and barrel sand inner area. (Do these steps for backbone and lower frame tubes)

• Keep small gap to be sure weld penetrates the frame slug and both sides of tube.

• Leave a small gap between beveled ends to let the weld penetrate the slug as well as the tubing

• Use a clamp to bring frame sections together. Build a temporary jig as shown, or install engine to be sure placement is correct before welding

HARDWARE LIST FDA THE SPOATSTEA HAADTAIL KIT

HOW TO MOUNT OEM BRAKE CALIPERS ON THE HARDTAIL KIT

1982-1999
SKU: 8180

1982-1986

1. REMOVE RUBBER BUMPER
2. USE A FILE TO OPEN UP THE CHANNEL UNTIL THE BRAKE STAY BLOCK SLIDES IN
3. GRIND LOWER WEB TO 5/8″ DEPTH 11 MAY BE NECESSARY TO GRIND BOTTOM OF BRACKET TO REDUCE CONTACT WITH FRAME

1987-1999

1. REMOVE RUBBER BUMPER AND GRIND OFF TAB
2. MEASURE 2· BACK FROM END OF LOWER WEB
3. GRIND LOWER WEB TO 112· THICK FROM MARK BACK ‘IT MAY BE NECESSARY TO GRIND BOTTOM OF BRACKET TO REDUCE CONTACT WITH FRAME

2000-2003
SKU:8151
NO CALIPER MODIFICATION REOUIRED

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