Installation Guide
Page 6 of 12
Harley-Davidson: Sportster
d. Connect the supplied braided brake line to the rear master
cylinder with the supplied banjo bolt with integrated pressure
switch using the OE crush washers. Torque to 17-19 lb. ft.
Then attach the brake line to the pressure residual valve
using a 10mm single banjo bolt and two crush washers as
seen in Figure 7. Torque 17 to 19 lb. ft. Use zip ties to attach
the brake line to the swing arm.
e. Crimp the supplied male spade electrical connectors to the
wires on the supplied brake pressure switch. Push the male
connectors into the OE female connectors and secure with
zip ties.
3.6 Assemble Rear End
a. Slide Right Rear End Assembly (RREA) from Box 5 into Left
Rear End with Differential Assembly (LREA) from Box 4.
- Ensure RREA has grease for bearing to slide into.
- Ensure RREA axle splines, LREA and differential are clean of debris.
*Mating of Components: Differential carrier bearing into RREA is a slip fit. If
assembly binds, separate the two and ensure RREA and LREA are aligned
properly. Lightly tap the two components into position with rubber mallet.
b. Apply 2-3 drops of oil to threads of
¾” front cross tube bolts
and assemble to specified torque of 150 lb. ft. Figure 8
c. Remove two remaining cross tubes for later installation.
Figure 8
3.7 Install Rear Axle Clamps
a. Install rear axle clamps from Box 2 using the supplied
hardware. The driver side clamp slot must register into dowel
pin on rear end. (Note: The rear brake lines run through
each clamp with nylon protective tube.) Figure 8
Qty per
side
Description
2
3/8-16x2-1/2 socket head bolt
2
3/8-16x3-1/2 socket head bolt
8
3/8 SAE SS flat washers
4
3/8-16 nylock nut
Figure 7
Figure 8
3.8 Install Rear End Assembly
CAUTION
: Do not use air driven
impact tools to assemble the
Champion aluminum rear end
assembly.
a. Install the supplied 5/16-18x2-1/4 hex
head adjuster bolts and jam nuts onto
swing arm. Adjuster bolt should be in
the furthest forward position to allow
room to place belt around rear pulley in
a later step. Figure 9
Figure 9
b. Loosen axle housing clamps just
enough to be able to align clamps with
rear of swing arm.
c. Passing the left side of the rear end
assembly through drive belt, position
assembly accordingly and slide axle
clamps into the end of the swing arm.
Figure 10
