RE-PRELOAD THE VOYAGER KIT

HONDA : 250cc to 600cc should not require preload. 700cc to 800cc should not require preload. Preload would be required if the riders weight is over 150 pounds. Use 1/4” preload. 900cc to 1800cc cruiser motorcycles will use 1/4” preload. Goldwings all require 1/2” preload.

HARLEY DAVIDSON MOTORCYCLES: Sportster 883cc & 900cc should not require preload. Preload would be required if the riders weight is over 150 pounds. Use 1/4” preload. Sportster 1000cc to 1200cc use 1/4” preload. All Dyna’s use 1/4” preload. All Softails use 1/4” preload. All Dresser models including Road King and Road Glide require 1/2” preload.

KAWASAKI MOTORCYCLES: 500cc to 1100cc use 1/4” preload. 1200cc to 1500cc use 1/2” preload.

YAMAHA MOTORCYCLES: 535cc to 750cc should not require preload. Preload would be required if the riders weight is over 150 pounds. Use 1/4” preload. 920cc to 1850cc use 1/2” preload.

SUZUKI MOTORCYLES: 650cc should not require preload. 800cc use 1/4” preload. 1400cc to 1800cc use 1/2” preload.

POLARIS VICTORY MOTORCYCLES: Use 1/2” preload.

MOTO GUZZI MOTORCYCLES: 1000cc to 1100cc use 1/4” preload.

BMW MOTORCYCLES: 800cc-1100cc use 1/4” preload. 1200cc use 1/2” preload.

INDIAN MOTORCYCLES: Use 1/4” preload.

AMERICAN IRON HORSE: Use 1/4” preload.

RIDLEY MOTORCYCLES: 700 & 740 does not require preload.

Boss Hoss 3/4” preload

Tank Vision Does not require preload

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SECTION 7 Re - Preload the Voyager Kit On Voyagers with the shocks on the inside of the rear mud guard, remove the mud guard. On Voyagers with the shocks to the outside of the rear mud guard, removal of mud guard is not necessary. (See page 13 for pre-load needed for a specific bike. Some bikes do not require preload.)

RE-PRELOAD INSTRUCTIONS

1. Tools needed: 3/4”, 7/16”, & 9/16” sockets or wrenches and a torque wrench.

2. Loosen the (8) 1/2” U-bolt nuts, and (2) 3/8” suspension lock nuts.

3. Remove the 1/2” Short Shock Tower Bolts, nuts, washers, spacers completely from top of shock and shock tower.

(Make sure that rear air shocks are at 80% capacity. Normal tire pressure on both motorcycle tires.)

4. Roll motorcycle rear tire onto 1/4”, 1/2”, or 3/4” preload plate. (See pg. 15) (Preload plate can be wood, metal, or plastic.) (Make sure motorcycle is in first gear when tire is on top of preload plate.) The more preload the less lean you will have with the motorcycle inside the Voyager Kit.

5. Now tighten (8) U-bolts to 35 foot lbs. (torque wrench is needed) Then, tighten completely the (2) suspension lock nuts. Reinstall short shock tower bolts, washers, nuts, & spacers (as shown in picture) and tighten completely.

6. Only 20 PSI on Voyager tires.

7. Now you are ready to ride again. 12 SECTION 6

THE RIDE of the VOYAGER READ CAREFULLY

5. The Voyager system makes braking safer. We have tested the Voyager attached to a number of motorcycles and have found when braking at 70 mph or lower speeds abruptly the motorcycle tracks straight down the road.

6. The Voyager will steer much like a trike. You have to push and pull the front handlebars of your motorcycle. By leaning into the turns (both the driver and passenger) makes the steering of the Voyager easier. It also keeps the driver and passenger from feeling that they are being pushed to the outside of the turn. You may experience front-end shake on the motorcycle handlebars, same as a trike or conversion. You are the steering dampener of your motorcycle with the Voyager unit attached. Remember to hang on to the handlebars and use the braking power of your motorcycle. The shake will dissipate rapidly, braking and/or slowing down will help if this situation occurs. Keep your hands on the handlebars at all times.

7. You need to have your two wheel motorcycle drivers license in most states, to be able to drive your motorcycle with the Voyager unit attached, because it can be easily and quickly unattached. In some states you can use the Voyager to attain your trike drivers license. Because we are so new to the motorcycle market place, some insurance companies will not insure the Voyager. We have a listing of insurance companies that will take care of your insurance needs. In most cases involving the Voyager it is considered an add on to your motorcycle. We are presently involved in changing the vehicle identification code for motorcycles in the United States through the U.S. Department of Transportation. Since we make a two wheel motorcycle safer and we are being pulled like a trailer we fit into other areas of the Vehicle Identification Codes of the United States and the individual states with differing codes.

8. Many of the Motorcycle Tour Conversion, Inc. customers purchase the Voyager Kit for the stabilization of their two-wheel motorcycle. The Voyager Convertible Kit attached to your motorcycle does not improve your motorcycle riding ability. If you feel that physical limitations and/or limited riding experience is why you purchased the Voyager Kit then you need to be extremely careful while riding for the first 2000 miles. PRACTICE, PRACTICE, PRACTICE. A large parking lot with very little obstructions is the place to PRACTICE.

For more information please call (815) 434-7900

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SECTION 6

THE RIDE of the VOYAGER READ CAREFULLY

Thank you for your recent purchase of your Voyager system. We at Motorcycle Tour Conversion, Inc. would like to share the following information with you.

The Voyager is not a trike. It is a unique attachment that is designed to improve the stability of your motorcycle by adding two outrigger wheels to your stock motorcycle. Therefore the Voyager is totally unique in itself.

Because of the Voyager’s uniqueness, it has unique characteristics. These are as follows:

1. When the belly bracket is installed on your motorcycle, the motorcycle will lose considerable ground clearance. The loss of ground clearance will reduce the ability to lean into turns on some motorcycles when the Voyager is removed.

(Be sure to check your motorcycle for the clearance change after the belly bracket is installed. Speed bumps, angle of pavement changes need to be watched.)

2. When cornering the inside wheel on the Voyager may raise off the ground. This is a perfectly normal function and will cause no difficulty. For the Voyager to function properly this must occur.

3. When on rough road you will experience some bouncing of the Voyager. This is a normal function. This will not alter the normal function of your Voyager. The bounce you may experience on your Voyager may appear worse than it is because the fenders are attached rigidly on the Voyager and move with the wheels. Remember you are the dampener. Hold on to the handlebars and slow the motorcycle with Voyager Kit down and the bouncing will go away rapidly.

NOTE: The fenders on your car are independent of the wheels therefore do not reflect the bounce of the wheels. However the wheels are bouncing.

4. When pulling a trailer the tongue weight limit is 450 lbs. Your trailer is being pulled by the center of your motorcycle and not the rear end of the motorcycle. This makes towing safer on the highway.

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SECTION 5

TROUBLE SHOOTING YOUR VOYAGER PROBLEMS: SOLUTIONS: 1. Things just don’t go together Read and follow instructions the way you think they should. carefully.

2. Bike leans to the right or left. Place shims in between frame and belly bracket (for one piece brackets) or in between the 2 pieces of the belly bracket.

3. Bike pulls to the right or left. Bike and Voyager are not aligned. Loosen Belly Bracket and align unit.

4. Bike has front end shake. Check tire pressure. Voyager tires 20 lbs. Motorcycle tires should have normal air pressure. Check air pressure on shocks of motorcycle - front should have from 5-10lbs. Rear should be almost at max. air pressure. Front tire could be worn or cupped or out of balance. Motorcycle front springs could be worn. Front Fork Bearings are loose on your motorcycle. Make sure all hub bolts are tight. Due to a light front end on some H-D Sportsters and Dynas and some other motorcycle makes you may experience more front end shake. Motorcycle Tour Conversion, Inc. recommends wider handle bars (buckhorn style) and a steering damper or stabilizer.

5. Voyager unit is making noise. Check and tighten all bolts. Tighten jam nuts.

6. Voyager ride seems too loose. Make sure main mounting bolts & lock washers are tight. Check pre-load. (Refer to page 1 of Section 2 Part C for preload instructions)

9 SECTION 4

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WARRANTY

Your new Voyager carries a warranty on all parts and labor for the period of one year from date of original purchase. This warranty covers repair or replacement of all parts on Voyager or attachment hardware defective due to manufacturing. Any damage due to abuse, road hazard, or collision will not be covered under this warranty.

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WARNING

The installation of the Voyager kit is very critical. Failure to follow installation manual and video (when available) cancels all factory warranties. Liabilities are with the installer if not properly installed. The owner is responsible for normal maintenance. Make sure all bolts are tightened before each riding season.

8 SECTION 3 5 MIN. ON - 5 MIN. OFF

5 Min. On: 1) Place portable kickstand in position at the rear of Voyager frame. (Insert portable kickstand into the holes on both sides of the hitch ball. Ref. page 8) Portable kickstand should be in an upright position and tight with surface. Make sure the portable kickstand is in place on the rear of the Voyager so that the front of the Voyager is in the down position. Then roll motorcycle backwards over cross bar of Voyager.

2) Lower side kick stand of motorcycle in the down position. Install jack stand into the belly bracket on the opposite side of the kickstand. With the jack stand installed, push motorcycle on to the jack stand, raise motorcycle’s side kickstand and install second jack stand. Motorcycle should be level with surface, adjust jack stands to level motorcycle with surface.

3) Remove portable kickstand from rear of Voyager. Slide suspension forks over the k.prene bearing on bearing receiver attached to brackets. Attach 3/4” x 3 3/4” bolt to belly bracket on both sides with 1 1/8” socket, (second 3/4” x 3 3/4” bolt will need some adjusting to attach, use jack stand to adjust). Make sure that both 3 3/4” bolts are tightened on belly bracket as firm as possible. Remove jack stands and you are ready to ride.

5 Min. Off: 1) Make sure the motorcycle is on a flat level surface. Install the jack stands into the belly bracket, one on each side. Adjust jack stands to touch the floor.

2) Remove the left 3/4” x 3 3/4” bolt with a 1 1/8” socket, then remove the right bolt. With the main bolts and spacers removed, walk to the back of the Voyager Kit. At this point you will take hold of the hitch ball and slide the Voyager frame off the k.prene bearings. Then pull the Voyager frame back until the cross bar of the Voyager frame hits the rear tire of the motorcycle.

3) Place portable kickstand in position at the rear of Voyager frame. (Insert portable kickstand into the holes on both sides of the hitch ball. Ref. page 8) Portable kickstand should be in an upright position and tight with surface.

Lower side kick stand of your motorcycle in the down position. Remove the left side jack stand and let your motorcycle rest on its kickstand. Then remove the right jack stand. Roll motorcycle over cross bar of Voyager frame.

WARNING Any after market products that hang below side bags or rear of motorcycle (ex: light bars, long muffler extensions, tow bars, or mud flaps) must be removed or they might be in danger of colliding with suspension or frame of Voyager. Rear suspension of motorcycle will need to be set at maximum travel height and in good condition. If there is play in the rear of the motorcycle then your suspension needs to be adjusted. Lift up the rear of your motorcycle, if it travels more than 2 in., your needs to be adjusted. 7 FOR ILLUSTRATION ONLY MAY NOT BE YOUR MOTORCYCLE BRACKETS

Jackstand Installation Picture

6 FOR ILLUSTRATION ONLY MAY NOT BE YOUR MOTORCYCLE BRACKETS

5

PICTURE OF UNIVERSAL VOYAGER HARDWARE

4

14) Grease the receiver bearings, using the grease zerk in the bolt holding the bearings. (Ref. page 5)

15) Torque lug nuts on tires to 70 ft. lb.

16) Voyager tire pressure should be at 20 p.s.i.

17) Paint all U-Bolt nuts of suspension after all preload tightening.

When to re-preload your Voyager Conversion Kit

If you replace the rear tire on your motorcycle or have any service work done on the rear of your motorcycle you need to re-preload the Voyager Kit to your motorcycle. Voyager Conversion Kit may need to be re-preloaded before each driving season. Refer to page 1 of Section 2 part C for preload instructions.

3

4) Remove jack stands.

5) Roll motorcycle rear tire onto the 1/4” or 1/2” pre-load plate.

6) Block the Voyager tires to keep it from rolling.

7) For ease of installation, remove the rear mud guard. Measure the outside of motorcycle drive wheel rim to inside of the Voyager frame. There should be no more than an 1/8” off. Then tighten the belly bracket nuts or U-bolts.

8) Slide the suspension under the Voyager, (one on each side) and slide the suspension forks over the receiver bearings. (Receiver bearings are attached to Bearing Receivers, Ref. page 5) Note: lock washers on the Bearing Receiver are used as spacers. Do not tighten and prevent receiver bearing from moving.)

9) The shock tower is placed to the outside of the leaf springs. Install the shock towers & suspension u-bolts in this order. Shock tower - U-bolt - U-bolt - Shock tower. (Ref. page 4)

10) Next raise and support the suspension so that the leaf springs are touching the bottom of the suspension lock. Now install the two 4” x 4” x 1/2” shock tower u-bolt plates. Place them on the U-bolts under the leaf springs with the lock washers and nuts, do not tighten at this time. Next slide the suspension forks back until the receiver bearings are 3/16”- 1/2” back of the tapered end of the suspension fork. Make sure that suspension fork tapered end is over receiver bearing no more than 3/16” to 1/2”. ( Refer to page 5 - Top picture)

11) Torque the U-bolts to 35 foot lb. After Torquing U-bolt nuts make sure to paint all U-bolts black each time you torque. This prevents rusting of nuts. Be aware of the possibility that the rear frame tubing could flatten with continuous pre-loading and torquing of suspension bolts.

12) Tighten the lock nuts on the suspension lock.

13) Install shock absorbers as in picture (Page 4). The large bolts and large spacers go on the top of the shock and bolt to the shock tower. The short bolts go on the bottom of the shock and bolt to the suspension arm. (tighten nuts) Note: Flat washer goes on the bolt, then slide bolt through shock, then add a flat washer, then spacer, then either suspension arm or shock tower, then lock nut.

2

SECTION 2 INSTALLATION OF JACKSTANDS, FRAME, AND DUAL SHOCK SUSPENSION ON OUTSIDE OF MUD GUARD

A) Assembly

1) Remove all hardware, tires, and frame from crate.

2) Install tires, tighten lug nuts and air up tires to 20 p.s.i..

B) Jack Stands

1) Place portable kick stand in position at the rear of Voyager frame. Insert portable kickstand into one of the holes either side of the hitch ball. Portable kick stand should be at a 45 degree to 60 degree angle and tight with surface.

2) With motorcycle in neutral, push backward over the cross bar and rest the motorcycle on it’s kick stand. NOTE: You may need to hold motorcycle tightly and give it a hard push over the crossbar.

3) The first jack stand must be adjusted by unscrewing it with the bike held level so it touches the ground. Then place motorcycle back on motorcycle’s side kick stand.

4) Place the adjusted jack stand into the right side receiver of the motorcycle belly mount opposite the kick stand. ( Jack stand receiver nut is at the front of belly bracket on both sides.)

5) Push the motorcycle over onto the first jack stand and steady firmly by hand as you place the other jack stand in the left side receiver of the motorcycle belly mount. Adjust the jack stand same as the first. Raise motorcycle’s side kick stand.

6) You can now bring the motorcycle and Voyager into alignment by adjusting the jack stands.

7) Motorcycle is now completely supported by the jack stands.

C) Frame and Rear Suspension (Suspension Preload Instructions)

1) Make sure jack stands are stabilizing motorcycle completely. (Ref. Page 5)

2) Remove the Voyager portable kick stand.

3) Push the Voyager into place and install main attachment bolts 3/4” x 3 3/4” by

screwing them in all the way into the belly bracket. Tighten completely. (Second 3/4” x 3 3/4” bolt will need adjustment to attach, use jack stand to adjust.) If there exists a gap between main shaft of belly bracket and Voyager frame, use spacers provided with hardware. One spacer may be needed or both on each side.

1

NOTE FOR ALL KITS THAT RECEIVE A NEW CASTLE NUT AND COTTER PIN:

A new castle nut and cotter pin has been provided. Due to variances in the motorcycles, it is necessary for the installer to drill the cotter pin hole after the axle brackets have been installed and the castle nut tightened.

1a

Motorcycle Tour Conversions, Inc. RIDING DISCLAIMER

READ CAREFULLY BEFORE OPERATING

This is a warning to all Voyager Customers and/or operators of Voyager converted motorcycles. Understand that motorcycles, and similarly saddled vehicles, are inherently dangerous. Any motorcycle rider, with or without a Voyager attached, should use extreme caution while riding, and only ride when mentally and physically able to make quick decisions and react appropriately to the necessary decisions.

We want to thank you for purchasing the Voyager Convertible Kit. Most of our customers purchase the Voyager because they need help with stabilizing their motorcycle. The Voyager is going to keep your motorcycle in an upright position. The Voyager, when installed properly on your motorcycle, makes the entire unit one of the fastest stopping or braking motorcycle units on the road today. When applying both the front and rear brakes on flat surface road, under safe operating conditions, the full unit will track straight, stopping in 3 seconds or 30 ft when traveling 30 mph, and 6 seconds or 60 ft when traveling 60 mph.

DO NOT attach any aftermarket products to the frame, fenders, or guards of the Voyager. These products may interfere with the normal, intended movement of the Voyager around the motorcycle. Check for any possible interferences between the motorcycle and Voyager Convertible Kit natural movement.

If you feel the ride, while the Voyager is attached, at any time feels out-of-control or hazardous for any reason (road conditions, animals, wind, going too fast for conditions, drive error, etc.) all you have to do is:

HANG ON TO THE HANDLE BARS (while releasing the throttle)

APPLY BOTH FRONT AND REAR BRAKES (as needed)

DO NOT PANIC & STAY IN CONTROL (remember with the Voyager attached the motorcycle will stop straight)

TABLE OF CONTENTS

SECTION 1 INSTALLATION OF HARDWARE

SECTION 2 INSTALLATION OF JACK STANDS, FRAME, AND REAR SUSPENSION

SECTION 3 5 MIN. ON - 5 MIN. OFF

SECTION 4 WARRANTY

SECTION 5 TROUBLE SHOOTING

SECTION 6 RIDE OF THE VOYAGER

SECTION 7 RE-PRELOAD OF THE VOYAGER KIT