Installation Manual Burgman 400 Version 1
Contents
1. E MI PA EN e Si GE A lt Be pat o First we will mount the switch housing so we know how much wire to put inside the handlebar Now we can run the wires from the switch housing into the handlebar cover and forward toward the forks Pull any extra slack out toward the bottom but not too tight cover Remove the stock bolt in the bottom of the switch housing Take the switchbox run the supplied bolt 1 4 X 3 25 through the hole in the back of the plate then through the supplied spacer and into the hole you just removed the stock bolt from Loctite Tighten the bolt as you align the switchbox Once completed the box and wires should look like the photo above and to the left 13 Now we need to join the wires running up from the left fork area and down from the handlebars so we can route them toward the under seat area The picture at left shows where the Proximity bracket will be mounted and how the wires should be run around the brake We suggest you mount this temporarily so you can judge how much wire to tie off and where to tie it off as you take this wire toward those attached to the switch box When we test later we will remove this bracket one more time ou It was difficult at best to get you a picture of the wires meeting at the fork area so you will have to brave this one alone Just make sure you leave enough wire to allow the forks to turn and n2. Installation Manual Burgman 400 Version 1 Copyright 2011 Pete Giarrusso Inc D B A Chopper Design Services All Rights Reserved Table of Contents INCRODUCIIO glielo 4 WARRANTY bian 5 INSTALLATION INSTRUCTIONS cccccssossscsesccsscesssescscssscscscesssescoes 6 COMPONENTS ee 6 Control SWIUCH Boris 6 2 Linear RTE 6 3 On board E 6 4 E NN E EE 6 5 Leg Suppor EE 6 6 E02 Wheel EEN 6 WE 6 o PRCRIGION DICK EE 6 PREPARE FOR INSTALLATION erre ec ceeesceteseeeseenee 7 INSTALL LEG SUPPORT STAND 5 ACTUATORBRACKE T lai 10 LEG WHEEL ASSEMBLY EE 11 CONTROL SWITCH BOX iii 13 WIRING HARNESS GE 15 INITIAL SYSTEM TEST KE 17 MOUNT PROXIMITY SWITCH 0c ieri 18 Rid Hall feo Cae Hi LEE 21 ACTUATOR ADJUSTMENT Maintenance Mode ccccccsssossccssccesccsscccecccecccesccesees 21 R Bet AER lla 25 LEGUP LEEE ADDENDUME cienza sari 25 ECSTIRAATIOSa ll 26 WV TAT GE 26 Eed 26 VOO GE 27 MN KAN CD RE 28 Introduction This manual covers installation of the LegUp LandinGear system by Chopper Design Services This system should only be installed by a qualified technician or those with above average mechanical skills If you are not SURE that you can perform this installation please contact us and we will help you find a qualified shop to assist you If you have been looking for a system that will keep your feet on the pegs this 1s NOT the system for you On the other hand
3. the bike and the two long bolts that bolt the center stand to the bike in order to install the plate these bolts are re used If inserted into the stand the long Stainless steel shaft with the small bolts in the end Should have one of the bolts removed and be slid out of the pipe in the stand Just set this aside for now We need to find the long 3 8 X 1 metal Bracket that has the 2 pipes welded to the top of it This bracket gets installed in the spot where the center stand was just removed from Just slide the pipes up into the spots under the bike ee up tege pipes with the holes in the frame and insert the bolts from the center stand into the frame through the pipes on the bracket and start them threaded into the nuts built onto the bike Don t tighten these bolts at this point we will do that later It is also a good idea to put a dab of Blue Loctite on these bolts before inserting them We next want to find the small block that is 3 8 thick with two threaded holes on it This block will be inserted in the wire formed bracket on the bike as seen here The wire is just in front of the bracket you just installed The plate s holes are not symmetrical The plate is inserted with the hole that is closest to the edge toward the right side of the bike This plate MUST be slipped in from the left side of the bike and pressed until it stops Next we need to find the main attachment plate It is t
4. slow down almost stopped the Yellow LED should illuminate at the proper speed Once it does sometimes hard to see hit the left button and put your feet down near the ground The top LED should flash and you should soon feel the wheels deploying underneath you Make sure you are ready to balance the bike Uneven ground or lack of familiarity could make the bike want to lean one way or the other With your feet ready to balance the bike this should be no big deal The slower you are going when deploying the wheels the smoother the transition will be from wheels up to wheels down Practice these maneuvers until you are comfortable with the wheel adjustments and the system operation SEMI AUTOMATIC DEPLOYMENT Another way to deploy the legs is to hit the left button while you are running at any speed over 10OMPH with the wheels up The bottom or yellow LED should start to flash When you slow down to around 8MPH the wheels will start to deploy see the red green flash on top LED Again prepare to put your feet down NOTE The bottom LED Should not be LIT if the legs are up over 10MPH In the event it is the wheels will deploy instantly if you try to set them as above this is dangerous You MUST re visit the sections on testing the proximity sensor You should always be aware that this light should NOT be on if you are traveling at speed and Arming the system for deployment should only be attempted if the lower LED is Not Lit Please see t
5. step is crucial Understand it before starting The proximity sensor tells the system how fast the bike is traveling The proximity sensor mounts to the lower front fork The sensor will ultimately be mounted SMM from the rotor bolts On the front of the left fork there are two bolts that hold the brake caliper to the bike The bottom of these bolts 1s used to mount our bracket This bracket with sensor should be in the area of the left fork already Remove the bolt put it through the mounting bracket and reinstall the bolt with a bit of Loctite Do Not tighten completely yet The bracket keeps from rotating by leaning on the fork leg It would be very helpful if you can Jack the front wheel of the ground or lift for this operation The idea here 1s to have the yellow proximity bracket line up with the rotor bolts and be placed no more than SMM away from them as they rotate The picture shows the bracket perfectly aligned and also shows how we tied the wire to the fork leg before routing it up the brake line toward the switch box wires With a bit of Loctite reinstall the bolt leaving it just barely tight for now We want to make sure the wires will run properly and can be tied off to the brake line to disappear Now have a look at the bracket and the yellow sensor red LED should be visible from the bottom The yellow sensor should be within 5MM of the rotor bolts as they spin Now we need to have the bike on the ground or the f
6. Bracket ACTUATOR BRACKET BN The next step is to mount the leg system J K The actuator bracket mounts to the vehicle on the Left side under what would be the rear footrest area i There is a single bolt on the frame see arrow Remove this bolt line the actuator bracket up as show and thread the replacement hex head bolt through the plate and back into the threads in the frame Loctite is in order here and be careful not to over tighten as this is a small bolt This bracket gets it strength from the extra mount that transfer the load 10 LEG WHEEL ASSEMBLY If not completed already first remove the bolts from the stainless steel rod in preparation for mounting the legs With help from an assistant slide the Leg Wheel Assembly around the rear tire careful of the finish and align the Leg Mounting Points Vertical Flat steel with Bushings with the slots in the Support Stand If available a very small amount of Never Seize on the shaft is in order here Then start the stainless steel shaft in from one side through the tube on the support stand and through the first leg mounting point and its bushing The fit is tight so take your time Carefully work the shaft through the tube and the second leg mounting point The shaft is inserted properly when it is inserted just past approximately 1 8 the end of the tube This distance should be about the same on both sides but it is not critic
7. al as long as both sides are inside the tube If you need to you can tap lightly on the shaft brass drift 1s preferred here Once the shaft is in place use a small amount of blue thread locker and install the 2 chrome bolts and washers on the end of the shaft to finish it off Make sure the legs move up and down without any binding 11 MOUNT ACTUATOR Remove the axles from both the upper and lower actuator mounts aluminum blocks one on the legs and one on the upper actuator mount and set them aside Align the actuator motor side big end down as shown with the hole in the upper actuator mount Reinstall the axle bolt on the upper actuator mount first Use just a touch of thread locker on the threads or n de e i With someone supporting the wheel gt r di mer A lt gt ss assembly raise the legs until the bottom hole in the actuator is aligned with the lower actuator mount Install the axle bolt you just removed into _ this mount through the actuator and the other side of the mount Some wiggling may be required NOTE If the actuator is too short to reach the other mount you may have to lengthen it using the system Temporarily plug the wiring harness into the bike and follow the direction for Maintenance Mode in the Initial System Test section below Using what would be the left button on the switch box just add a small amount of length to the actuator so you ca
8. attached Run the wire for the proximity bracket and plug it in test it and mount it as described in the MOUNT PROXIMITY SWITCH section of this manual Once the new pieces are attached and plugged in refer to ACTUATOR ADJUSTMENT Maintenance Mode earlier in this manual to set the lower and upper stops for the computer That s all it takes 25 ILLUSTRATIONS Proximity Sensor oe Game Plug Black Harness side Fa Ru Brown Sensor aide Orange Hamesr pide Wiring 1 Actuator Plug Type II Actuator Plug Type II Grey Harness Grey Harness Single wire grey No Warranty Void Label Brass Bushings in Holes There are three different types of actuators with three different wiring configurations Refer to the notes at the bottom of the pictures above so you can match your actuator with its wiring scheme Wiring 2 26 12 Place Enclosure Plug White White White Violet Green Bloe or White Crange or White Bine White Red Violet II n 000000 e 000000 Wiring 3 21 PARTS LIST 4 3 8 16 X 1 Cad Bolts w Lock Washers Piate to hangers 2 5 16 18 X 1 1 2 Cad Bolts w Lock Washers Cross Strap 1 Handlebar Spacer cut to 7 16 Switch Box 1 10 32 X 1 5 16 Chrome Allen Switch Box 1 M5 X 60 mm Allen Switch Box 1 Mo X 1 0 X 18 mm Hex Bolt Upper Actuator Bracket
9. e caliper bolt to allow it to dangle The RED LED ON The Sensor Should Not Be Lit Take a metal object screwdriver wrench etc and hold it on the flat face of the sensor it has a circle embossed in it The LED should light up and go out when you move the metal away If not check all your connections Next press the rightmost pushbutton and hold it for at least 3 seconds One or both LEDs on the switch panel should light up we really don t care which at this point If this occurs you are doing well If both LEDs are flashing maintenance mode you can skip the next step which is to press both buttons until both LEDs flash Next press both buttons for just an instant If everything 1s working the bottom or yellow LED on the switch box should flash and the top LED should be out The next step and be careful here 1s to touch the left button for a split second The legs should move down just a bit Touch the right button and they should move up With the bike on the lift you have to be very careful here If all of the above has occurred raise the legs Press and hold the right button until it stops and turn the ignition switch off The test is now complete Let s move on to mounting the Proximity Sensor 17 MOUNT PROXIMITY SWITCH NOTE If you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE system Skip this section if you have a LITE System This
10. g in the plug landing in front of the seat Make sure to leave enough slack in the wire to allow the actuator to lower the legs completely without tugging on the wire here You also need to wire tie this wire away What should be left is an Orange wire and a Black wire These need to be connector to switched 12Volt power orange wire only powered when key is on and ground black wire to chassis ground We got our 12V from the wires that ran to the running lights on the left side toward the back of the bike We even increased the fuse in the fuse box by 5 Amps for this circuit But you can use any 12 volt switched source you want Our system draw under 5 amps so most circuits can handle this type of load Once completed it should look something like the picture at left We supply these plugs 15 The left picture below is a close up of the wire we used to power the system just behind the yellow plug When everything is completed most all the plugs should be tied down neatly and thd should wind up under the computer as shown here to the right 16 INITIAL SYSTEM TEST NOTE f you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE system Skip this section if you have a LITE System Turn your key switch on At this point have a look at the yellow proximity sensor it should be dangling near the front forks somewhere If it is still mounted remove th
11. he User Manual for more information on Proximity Sensor Failure 23 The next thing to try is to make a turn right after a dead stop with the wheels down As soon as you start the bike moving try a left or right turn immediately by leaning into that turn You may find that you have to nudge the bike a little bit more than usual to get the bike to lean and you won t be able to lean as far as you can with the wheels up Once into the turn accelerating will raise the wheels You will hardly notice the wheels coming up unless you see the top LED blinking The next thing to try is slow speed maneuvering with the wheels lowered In a straight line on level ground you should be able to keep your feet on the floorboards and move the bike forward at very slow speeds simulate stop and go traffic I like keeping my feet near the ground during these maneuvers You can also try small Trike turns keeping the bike upright at slow speed and making turns as you would in a parking lot Be aware that if you get over the speed that the legs come up they will Another thing I like to do is donuts Start out slow lean the bike left or right and make circles at very slow speeds throttle on rear brake on clutch slipping you know like the cops do This helps you get familiar with the wheels being on the springs and allowing a lean angle Practice practice practice Enjoy your LegUp System 24 LEGUP LITE ADDENDUM If you have a Lite Sy
12. he piece that has the big round pipe welded on the end the one you removed the stainless shaft from earlier Offer the plate up to the bike to be attached to the bracket that was bolted in place of the center stand _ y s o This is bolted with the pipe offset toward the ceiling and the four holes get 3 8 Bolts The outer holes get 3 8 XI bolts with washers and the inside holes get 3 8 X3 4 bolts with lock washers Start all the bolts but leave them very loose for now The next step is to find 2 44 20 bolts with lock washers and 2 chrome spacers We will line these bolts up with the front of the plate you just installed and the plate we threaded in to the wire form on the frame Using a bit of Blue Loctite on the bolts run them through the hole in the big plate through a Chrome spacer and start threading into the plate in the wire form as shown here Ki Again leave these loose for now as we will be tightening everything in a specific sequence Now we can tighten the two center 3 8 bolts but NOT the outer two yet then the two front bolts that run through the spacers Next remove the two outside bolts so you can tighten the bolts that run through the center stand mounts on the frame Now reinstall the outside bolts and tighten them You shgo0uld now have a plate attached to the bike that is very strong and won t move when you tug on it Give it a try We can move on to the Actuator
13. if a system that will relieve you of the weight of the bike and help you avoid balance problems as you approach a stop LegUp is what you need Improper installation will void your warranty so please be very careful Thanks for choosing LegUp Warranty Chopper Design Services warrants the LegUp system for a period of one year from date of purchase This warranty covers replacement parts and or manufacturer defects Incidental damages or costs are the responsibility of the purchaser Defective parts are to be returned to Chopper Design at the address below Purchaser must contact Chopper Design to receive a Return Material Authorization prior to returning defective parts to Chopper Design Abuse improper installation or use collisions or accidents are not covered under this warranty Replacement parts for this type of damage are available through Chopper Design Users of the LegUp system agree that Chopper Design is NOT responsible for personal injuries or damage to property arising from the use of the system While we believe this system to be safe and reliable the user is advised that use of LegUp is done so at the users own risk Use of the system implies agreement to the above statements If you can t agree with the above Chopper Design and its dealers would be happy to refund your full purchase price before you use the LegUp System Chopper Design Services 1365 Bennett Dr 101 Longwood FL 32750 407 834 5007 LegUp La
14. ll lock of the handlebars both left amp right Take whatever extra slack from the two wires that is available and pull it back to the seat area Use wire ties to make sure that all wires will stay where you put them and that they will not come on contact with that moves Loop any excess as shown above Keep the excess wire clean and make sure the seat goes up and down without hitting any wires With help support the bike and turn on the LegUp system see owner s manual It should start in maintenance mode but if it doesn t please i enter maintenance mode again in the manual Now carefully mmm and raise the legs and make sure the wires are not binding and that they clear everything Raise the legs most of the way and turn off the bike Now we are ready to button everything up 20 FINISHING UP Now it is time to recheck everything Check that all bolts that were loosened are tight Reinstall the covers On the left side you will find a small tab that interferes with the actuator You will need to trim this tab It 1s perpendicular to the ground and inside the area we have circled in yellow here There is no down side to this small trim and everything still mounts perfectly Make sure all your wires are routed neatly tied off nicely and don t interfere with the seat installation Now you can dial in the actuator and adjust the wheels ACTUATOR ADJUSTMENT Maintenance Mode NOTE If you have a LITE System Please
15. n align the mounts then turn the bike back off At this point you need to make sure that the mounts are in alignment and the actuator is not in any sort of bind On this bike care must be taken that the actuator does not rub on the chrome bolt at the end of the shaft It is tight but it should clear The mounts should be tightened at the factory If need be readjust the actuator mounts in whatever position is the best with the actuator in its mounts If needed mark the mounts with a Sharpie remove the actuator tighten the mounts and reinstall the actuator Make sure the axles slide in easily and there is no bind at all MAKE SURE there is no bind or the actuator will fail prematurely 12 CONTROL SWITCH BOX NOTE If you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE Harness Ignore any reference to the Proximity Sensor and its mounting Disassemble the 8 pin connector attached to the switch housing and the 3 pin connector attached to the speed sensor yellow on a black bracket Run the wire from the speed sensor bracket which mounts on the left fork by the brake up the left fork area to join with the switch wires The switch wires will run inside the handlebar cover down to the fork area You will need to install the switch box on the handlebar then run the wires down the handlebar and meet the speed sensor wires near the front fork See the pictures below
16. ndinGear com Installation Instructions The LegUp system has many components Pleased be sure you have them all before starting your installation COMPONENTS 1 Control Switch Box 2 Linear Actuator 3 On board Computer Module 4 Proximity Sensor 5 Leg Support Stand 6 Leg Wheel System 7 Hardware Bag 8 Actuator Bracket If you believe you are missing any parts please contact Chopper Design at 407 834 5007 and we will rectify the situation Wire Harness a A KS Computer Hondl bar en X nclosure Control box Electronic Wiring Components Le Actuator Figure 1 PREPARE FOR INSTALLATION Place the motorcycle on an acceptable bike lift You will need to keep the bike on its wheels for most of the installation and jack the rear wheel off the lift for some portion of the installation Make SURE the motorcycle is secure on the lift In EE for the installation pra remove the side covers on the left side of the bike and the bottom skid plate These come off with a combination of push pins screws amp press fit parts The bike should look something like this If you don t have a manual and are not sure of how to remove these please seek help from qualified technicians for this bike We are now ready to begin INSTALL LEG SUPPORT STAND LegUp has developed a new stronger attachment system which holds the LegUp system to the bike You will need to remove the center stand from below
17. one of the wires will bind When you are done you should get the two wires out by the frame rails and run them to just in front of the seat area Take your time and find a wire route that works and does not bind or scrape the wires Once this is accomplished double check that you have the required slack for the Speed Proximity sensor on the fork and from the switch box wires make sure the bars can turn full left and right and take the excess into the under seat area This would be a good time to re assemble the plugs from the switchbox and the proximity sensor Be careful to assemble these according to the pictures switch box left speed sensor right below Control Box Plug Proximity Sensor Blue Sensor side Plug Brown Sensor side Orange Hamesr pide 14 WIRING HARNESS NOTE If you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE Harness from any moving parts on the swing arm Now take the harness and find the 12 place plug This Plugs into the Computer Assuming all the connectors are in front of the seat find each plugs mate they only plug in one way and plug them together The next step is to route the wiring harness The harness and the plugs are routed mostly under the cover in front of the seat We already ran the wires from the handlebar switch and the speed sensor The actuator wire should be run as show at left culminatin
18. r the legs You also need to make sure the system clears pipes clamps etc If you can t make the clearance to allow the legs to come up all 21 the way you can set the up stop just below whatever is interfering if not you will likely set up a permanent rattle Hit both buttons when complete and you will be done with these adjustment Now press the left button and the legs should lower Hit it again and the legs should retract If you are satisfied with these limits you have successfully installed the LegUp System Time for a test ride 22 TEST RIDE NOTE If you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE system Deployment and Retraction of the wheels is COMPLETELY MANUAL if you have a LITE System Get the bike to a clear paved mostly level area where you can test ride it Start the bike turn on the LegUp system and lower the legs The first test should be done in a straight line Put the bike in gear and slowly accelerate You may notice that the bike tends to want to steer a small amount left or right This is normal unless it is severe Once underway the top LED should flash at around 6 MPH meaning the legs are retracting You can lean on one wheel or the other as you leave to reduce any darting the system may be giving you Assuming the legs are retracted you should try to deploy the wheels As you come to a stop the Green LED should be on As you
19. refer to the addendum at the end of this manual for differences between a Regular and LITE system Skip this section if you have a LITE System Once you have the bike on the ground turn the ignition to the accessory position and start the LegUp System hold right button for 3 seconds The system should enter maintenance mode automatically Both LEDs Flash but if it does not enter maintenance mode manually Both buttons for 3 seconds With a helper nearby straddle the bike and hold it level Hit both buttons for an instant to get the system in the DOWN setting mode yellow LED flashing Straddle the bike so your weight is NOT on the seat hit and hold the left button until the wheels contact the ground and stop Make sure that the suspension raises a bit as you do this If not the legs are not going down far enough the bottom actuator mount may need to be moved left or right a bit to get the wheels all the way down Contact LegUp for assistance if you need help with this Once these wheels are down as described above try to put both feet on the floorboards The bike should be reasonably stable and you should be able to lean a bit in both directions without the bike falling over The DOWN stop is now set Hit both buttons for a moment to get into the UP stop mode top LED blinking Carefully use the right button to raise the legs Have your helper let you know as you approach anything that may come in contact with the wheels o
20. ront wheel raised so we can make the rotor bolts pass the sensor to test it and its placement 18 Turn the ignition switch to the on position The LED may or may not be on What we are looking for here is for the LED to light as a rotor bolt passes close to the sensor and to go out as the bolt passes by Have someone watch the LED as you roll the wheel or the bike back and forth making the bolts pass close to the sensor Once you feel you have the right place tighten the bolt in the bracket down securely and test again If this is not happening you may need to get the sensor a bit closer to the bolts SMM 1s a very small distance If you have to move the sensor closer you may have to bend or adjust the angle of the bracket No matter what you need to do you MUST make sure that as the wheel turns the light works as described above The automatic retraction of the legs as well as their deployment RELIES on this sensor being placed perfectly Once satisfied with the mount skip down to the wire routing instructions below 19 WIRE ROUTING NOTE If you have a LITE System Please refer to the addendum at the end of this manual for differences between a Regular and LITE system The Proximity sensor is NOT part of the LITE system Guide the wires from the Proximity bracket up the brake line and attach it to the line with wire ties Once routed make sure both this wire and the wires from the handlebars are secure and allow fu
21. stem there are a few differences in the wiring compared to our Regular system The plugs and their locations don t change at all Instead of plugging in the computer to the twelve pin plug the Relay Pack gets plugged into this plug The Relay Pack will be attached with Velcro as the computer would have been in the same location On the LITE system there is no proximity sensor so ignore the testing and mounting of this sensor and realize that the three pin plug will be left without a mating connector We keep this plug in the wiring harness in case you upgrade to a regular system in the future Using Your Lite System Unlike our Regular System you don t turn the LITE system on or adjust the legs as described in the Maintenance Mode section of the manual When you turn your bike on the LITE system 1s ready to go Press and hold the left button to lower the wheels press and hold the right button to raise them No lights will flash it is up to you to control the system manually Please use EXTREME Caution when using the LITE System Keeping the wheels lowered at speeds over 9MPH can be dangerous Since the system is manual please don t allow its operation to distract you from controlling the vehicle Upgrading Your LITE System If you have a LITE System and have chosen to upgrade it to the regular system there are just a few things you need to do Unplug the Relay Pack and plug the computer in where the Relay Pack was
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