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Harley-Davidson Sportster - INSTALLATION GUIDE


All Legend Air Suspension System™ parts are guaranteed to the                 Leg        S
                                                                          (3) Legend Air Suspension Systems™ shall not be liable for any con-
                                         uring               rkman
original purchaser to be free of manufacturing defects and workman-                         incid
                                                                              sequential or incidenta damages resulting from the failure of a
ship. Merchandise that fails to conform to these cond
                                              se conditions will be
                                                                 b                       Susp    on Systems™ part, the breach of any war-
                                                                              Legend Air Suspension Syste
                           end     Suspension Systems™ option if
repaired or replaced at Legend Air Suspens                                                     ure o deli , delay
                                                                              ranties, the failure to deliver, del in delivery in non-conforming
                        o s       e pu
                                    purchaser. Warranty coverage is
the parts are returned to us by the purch                                     condition, or for an other br
                                                                                 dition, r for an
                                                                                       ,        any           h o contract of duty between
                                                                                                       r breach of c
limited lifetime.                                                             Legend Air S
                                                                                gend Air Suspension Systems™ and a cust
                                                                                              nsio         ™
                                                                                                         ms™ an    c
                                                                           4) rts a designed for use on Harley-Davidson S
                                                                          (4) Parts are des                    Davidson
                                                                                                            ey-Dav son Sportster®. Legend
              arran se
                ranty servi
In the event warranty service is required, the original purchaser must
                                                                r             A Sususpe                           o war nty or
                                                                              Air Suspension Systems™ shall have no warranty o liability
            e Leg nd Air                       diately with the
call or write Legend A Suspension Systems™ immediately w th                  obliga
                                                                             obligation if a Legend Air Suspension Systems™ part is used in any
                                                                             o    atio                                 ems™ art
         Some p
          ome problems can be rectified by a telephone call a
problem. Som prob                               phone
                                               ephone      and                other application. Vehicles used in competition or off road are
                                                                                  r a                                       n
                                                                                                                         tion    o
need no further course of action.
      o fur er co                                                             exempt from all warranties. Any transmission bolts or mo
                                                                                 mpt                                          ts
                                                                                                                            olts    motorcycle

                                                                                                                                                   I N S TA L L AT I O N G U I D E
                                                                                    touching airride from top down may cause dam ge to
                                                                              parts to                                       damage
A part that is suspect of being defective must not be rep
   art    t                                      t    replaced by a
                                                        placed                suspension and will void the warranty.
  aler without prior authorization from Legend Air Suspension Sys-
Dealer wit
    er itho                                            ension Sy
                                                ir Suspe                  (5) All warranty items will require a serial number off the a ide or
                                                                              A war rra                                               airride,
                                                                                                                                   he airrid
tems™. If it is deemed necessary for Legend Air Suspension System
  ms™ f
    ™.                                             pension
                                                 uspension Systems™
                                                         n                    the orig
                                                                              t original purchase invoice.
                                                                                     gin                                                                                         XL786
   m e an
to make a evaluation to determine whether the part was defective,
                                               art     defective
  return authorization number must be obtained from Legend Air Sus-
a re n a
   eturn                                         om     nd
                                                rom Legen      Sus
                                                               S          Legend Air S
                                                                              nd r Suspension Systems™ assumes no responsibility fo dam
                                                                          Legen                                                   or dam-
                                                                                                                               y for d
pension Systems™. The parts must be packaged properly so as to not
 en n S                                        operly o        n
                                                               no                injuries which may result from the use or installation of its
                                                                          age or inju
                                                                                    uri                                            tion f it
 au further damage and be returned prepaid to Legend Air Susp
cause fu
  use urt                                                Suspen-
                                            o egend A Suspen              products, wh
                                                                                    whether or not properly installed or used. All par sold
                                                                             ducts, w                                              parts sol
  on Systems™ with a copy of the original invoice of purcha and a
   n ste
sion Sys                                        e    purchase
                                                          ase                manufactured by Legend Air Suspension Systems™ are warran
                                                                          or manuf
                                                                             m ufac                                             warranted
 eta d le
   ailed                                          m,       e
detailed letter outlining the nature of the problem, how the part was
                                                                  wa      against all                                         Should
                                                                          ag st a manufacture defects or workmanship defects. Sh d a
  ed d the
   d                                              f fter     evalua
used and t circumstances at the time of failure. If after an evaluation   product we manufacture be defective, it must be returned to Leg
                                                                                                                                    o Legend
                                                                             duct                                                       gen
  s b n made by Legend Air Suspension Systems™ and the pa was
has been m                                   ™
                                            s™         part               Air Suspension Systems™. All returns must be authorized in adv
                                                                          Ai S                                                       advance
   nd    b defective, repair will be made at Legend Air Sus
found to be d                                    nd
                                                end     Suspensi n
                                                        Suspension        with RA#. Freight must be prepaid by customer. If our product is found
                                                                          w                                                         uct
                                                                                                                                  oduc s fo
    ems disc
      s™ di
Systems™ discretion.                                                                                                             exchanged
                                                                          to be defective, it will be repaired free of charge or exc nge at
                                                                          Legend Air Suspension Systems™ discre
                                                                                     Suspensi                             rs o exchanges
                                                                                                         discretion. Repairs or ex
                                                                          will not be issued if merchandise has been d
                                                                                                   chandise as b           d, ab ed or
                                                                                                                     damaged, abuse o modi-
         L ARRA
ADDITIONAL WAR                                                            fied. Any disagree
                                                                                   disagreement which may ar
                                                                                     sagreement        a                 is agreement shall
                                                                                                      may arise out of this agre
             r Suspension Systems™ shall h
               S pens
(1) Legend Air Suspe                     have obligation in the
                               ms™ all ha no obl                          be submitted to arbitr
                                                                                mitted arbitration and sha be enforceable und the laws of
                                                                                              tration  shall b      eabl under
                                                                                                                      ble nde
              gend r Sus nsion Systems™ par is modified by any
                nd     Suspension Sys
    event a Legend Air S       on       part                                             uth Dako
                                                                                               kota. Judgement on the award sh be entered
                                                                          the State of South Dakota. Jud            e a rd shall
                    or nizatio
    other person or organiz on.
                    organization.                                         into by the said court, a
                                                                                            ourt, an the decision of the a
                                                                                                  and         ion      e arb
                                                                                                                         arbitrator shall be a
                    nsion Systems™
                       on stems™
(2) Legend Air Suspension System shall have no obligation if a Leg-       condition precedent to legal rights. The parti shall submit disputed
                                                                                                          hts.     parties
    end Air Suspension Systems™ part bec
                                     becomes defective in whole or                                       American Ar
                                                                          matters under the Rules of the Am    an Arbitration Association and
                                per inst
                                  r         tion, improper maintenance,
    in part as a result of improper installation, impro                                     hall ay bo parti
                                                                          the losing party shall pay both partiesʼ attorneysʼ fees and costs.
                                    ,    any     mis
    improper use, abnormal operation, or a other misuse or mis-
                                               ems™ pa
    treatment of the Legend Air Suspension Systems™ part.

                                                                                              MADE IN THE USA


                                         For Technical Information: (605) 720-4202 *820                                                                           HARLEY-DAVIDSON SPORTSTER™
                                                                                                                                                                  1986 - 2003
                                          For Warranty Information: (605) 720-4202 *811

           Properl Support Y
                  y         our Motorcycle Prior T Air Suspension Inst
                                                  o                   allation!                                                                                                        STEP TWO: COMPRESSOR MOUNT
                                                                                                                                                                                       A.   Remove OE Hardware for exhaust mount and right
                                                                                                                                                                                            rear motor mount as shown in DIAGRAM B.
                                                                                                                                                                                       B.   Inst                       y
                                                                                                                                                                                                all compressor assembl as shown in
                                                                                                                    *Remove Sea and saddlebags (if any).                                    DIAGRAM B, re-using OE hardware.
                                                                                                                                                                                       C.   Secure hardware using blue thread locker and
                                                                                                                                                                                            tighten to manufacturers recommended
                                                                                                                      STEP ONE: HANDLEBAR SWITCH                                            torque spec.
                                                                                                                      A.   Remove stock clutch clamp.                                  D.   Connect air tubing to the solenoid on the
                                                                                                                      B.   Re-using stock hardware, inst all Legend                         compressor assembl  y.
                                                                                                                           air switch housing making sure not to                       E.   Route air tubing and wiring to the compartment
                                                                                                                           pinch wires.                                                     undernea           t
                                                                                                                                                                                                     th the sea as shown in DIAGRAM C.
                                                                                                                      C.   Route wires down the handlebar, under
                                                                                                                           the gas tank, and to the compartment
                                                                                                                           under the sea t.
                                                                                                                      d.   Secure wiring
                                                                                                                           using cable ties.

               STEP FIVE: OPERATION
               A.   Install fuse in fuse holder and you are
                    ready to run your system.
               B.   Push top button to add air to the system.
               C.   Push bottom button to release air from
                    the system.
               D.   Check fender to tire clearance
                    to make sure nothing is rubbing.
               E.   Re-inst       t
                           all sea and saddlebags.

                                                                                                                                                                                                     DIAGRAM B

                                                                                                                                                                                                                                  DIAGRAM C

                                                                                                                            TOOLS NEEDED…
                                                                                          DIAGRAM-A                                                                                                     MAKE SURE TUBING IS
STEP FOUR: SHOCKS                                                                                                                                                                                          T
                                                                                                                                                                                                      CUT A A CLEAN 90° ANGLE

A.                            y
      With motorcycle properl supported, remove stock shocks.
                                                                                                                                                        1/4”   T27
B.    Re-use OE screws for the upper shock mounts and use supplied screws                                                                                                                    STEP THREE: WIRING
      for the lower shock mounts. Appl blue thread locker to f    astners and                                                                                                                A.                 y
                                                                                                                                                                                                  Mount the rela in the compartment
      install Legend Air Suspension giving a  ttention to sp              t
                                                             acers and bol orient tion.
                                                                                 a                                                                                                                undernea           t       tt
                                                                                                                                                                                                           th the sea using a ached Velcro.
C.    Use supplied Y fitting to split the air tubing from the compressor to the                                                                                                              B.   Connect wires from compressor, handlebar
     individual shocks. Secure air tubing with cable ties if necessary.                                                                                            T50   3/4”
                                                                                                                                                                                                  swit            y
                                                                                                                                                                                                      ch, and rela harness in the compartment
D.    Lower the bike onto rear tire so shocks are full compressed.
                                                         y                                                                                                                                                       t
                                                                                                                                                                                                  under the sea using color coded wiring.
E     Using onl compressed air, carefull sea air-spring on the shock body while
                y                          y     t
                                                                                                      Use Only
                                                                                                 Compressed Air                                                                              C.   Connect   + and - to battery.
     holding the top of the air spring in place (see Diagram-A).                                                                                                                                                                        REV 8.31.09

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