1982-2003 Throttle Addiction Sportster Hardtail Installation Guide

1982-2003 Throttle Addiction Sportster Hardtail

HOW TO INSTALL YOUR THROTTLE ADDICTION SPORTSTER HARDTAIL

1982-2003 Instructions

Made in the USA

The Deluxe Evolution Sportster Hardtail Kit 1982-2003

Tools Needed

Square/Straightedge, Tape Measure, Marker/Scribe, Cardstock, Cutting Tool, Grinder, Center Punch, Drill, 3/8″ Bit, Barrel/Drum Sander, Disassembly Tools, Service Manual, 230V Welder
Important Stuff

• Before you begin this installation, read all of the instructions completely and carefully. This installation requires welding and the use of power tools.
• All welding must be performed by a certified welding professional. All welding must be done using equipment powered by a 230V power source or larger to allow for sufficient weld penetration.
• Prior to final assembly chase all threaded holes (Axle adjuster, sissy bar mount, oil tank mount, etc.) and any chrome hardware or axle adjusters.
• Always use the proper protective equipment during installation.
• Throttle Addiction assumes no liability for damage to property or personal injury caused during installation or because of misuse.

Hardware included with the Deluxe Hardtail Kit

• Banerv Tie-down Strap & Hardware 4pieces
• Fender Spacer Long & Short 2 pieces  1
• Colonv Axle Adiusters and Nuts 4pieces
• Rear Caliper Mount 1982-1999 3 pieces
• Rear Caliper Mount 2000-2003 5 pieces

Video install instructions

• Cutting OEM tame and welding the hardtail +
• Full disassembly, assembly, and lineal result
• Measure 16″ from the front ot the neck down the backbone. Mark tor cut.
• Measure hardtail from bottom motor mount to the end ot the frame  not the end ot the slug.
• Using the measurement from Figure A, measure and mark the frame from the bottom motor mount on the stock frame. Mark for cut.
• Use cardstock with square edges and wrap the tube to ensure a square cut line.
• Cut  your tubes a little longer than your marks.
• Then sand down to the marks to ensure a flat mating surface.
• Drill 3/8″ holes tor plug welds 1/2″ in from end ot tube. Bevel ends ot tubing and barrel sand inner area.
• Insert the hardtail into the OEM frame section. Ratchet straps may be needed to pull the two halves together.
• Cut on the shipping strap.
• We ship the hardtail with small tack welds on the slug to keep a small gap between frame and hardtail.
• This is to ensure your welds penetrate the slug and both sides of the tube.

1. Install the motor into the frame.

2. Tighten rear motor mounts first. ENSURE LOWER MOTOR MOUNT DOWELLS ARE FULLY SEATED.

3. Install remaining motor mounts and hardware IOOSIV

4. With a straight edge on the backbone, adjust the backbone gap until straight edge lays flat on the backbone.

5. Go back and tighten all motor mounts

6. Weld top and bottom as much as you can with the motor in, including slug welds.

7. Remove motor and finish welding.

8. Sand to desired smoothness.

Additional Assembly Resources

How to mount OEM brake calipers on the hardtail kit

Video instructions tor brake caliper mount install Runtime -11 minutes

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

It may be necessary to gind bottom of bracket to reduce contact with frame

1. Remove rubber bumper and grind off tab
2. Measure 2″ back from end of lower web
3. Grind lower web to 1/2″ thick from mark back
   It may be necessary to grind bottom of bracket to reduce contact with frame

Proper installation of the battery tie down shown above

• Cut hoop from stock axle adjuster as shown in Figure A.
• Hoop will be reused as an axle spacer during final assembly. Installation shown in Figure B.
• Oil line locations

HARDWARE LIST FOR THE SPORTSTER HARDTAIL KIT

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