INDER EXPORTS

Installing and Aligning an Inder Sidecar for Classic

500cc and 350cc ROYAL ENFIELD.

MOUNTING KIT FOR ROYAL ENFEILD CLASSIC C5 ( 500cc and 350cc )

PARTS :

1. U – BEND with Threaded bolt. ( NOTE : IN PHOTO U BEND SHOWN Is 55 MM Now we are using 32 MM)
FITTMENT IS IN SAME MANNER for all.

2. LONG Threaded Bolt .

3. Small Threaded Bolt

4. Brakett

5. U Clamp.

6. Adjustable Center support.

FIXING OF BRAKKET and U CLAMP to Motorcycle:

STEP 1 :

1. FIX the Brakett to the Motorcycle chassie and U clamp to the Motor cycle chassie as shown in the above
Photographs.

2. Don’t full tighten the Nut bolts in the step , tightness should be that much so that you can adjust the height of
U clamp while fixing the sidecar to the motorcycle.
FIXING OF U BEND and LONG THREADED BOLT to U CLAMP And BRAKETT :

STEP 2 :

# Fix The Long Threaded bolt to the U clamp and fix the either side of long threaded bolt to the sidecar chassie .

# Fix the U Bend to the Brakett as shown in the photo and pass the either side of U bend in the chassie of sidecar
and semi tight the nut bolts of both sides.
FIXING OF SMALL THREADED BOLT TO CHASSIE:

Step 3

# Fix the Small threaded bolt in the shocker of the motorcycle and either side to the hole provied in the sidecar
chassie.

You can choose the holes in the frame according the bike.

FIXING OF ADJUSTABLE CENTER SUPPORT TO CHASSIE :

Fixing of Center Support.

Step 4

# Fix the Adjustable center support to the motorcycle and the chassie of sidecar.
SIDECAR COUPLED TO THE MOTOR CYCLE:

After Performing above 4 steps your Motorcycle is coupled to the sidecar chassie like this in the photograph.

Note : In performing above 4 steps don’t full tighten the nut bolts as tight the full bolts only when the side car
wheel is fixed on the shaft of the sidecar.

Now we perform how to fix the wheel on the sidecar shaft.

FIXING OF SIDECAR WHEEL.

1. SIDECAR WHEEL PARTS :

Wheel Rim with Hub , Break Plate , Thin washer 1 , Washer 2 , Nut , Cap , split pin lock.

Below is the Sequence in which they have to be fixed on shaft.

# Remove the excessive paint from the shaft with the help of emery paper.

# Place the Break plate on the shaft and push so that it firmly sets on the shaft collar and tighten the break plate
to the chassie of sidecar with bolt as shown.

# Now place the Thin washer 1 as shown in photo.

# After that remove the one side mudguard bolt so that mudguard lift up and then place the wheel rim with tyer
tube on the shaft and push so that it move over the break plate and break leathers, rotate the rim to check the
placement .

# Then place the Thick washer 2 and then tighten the NUT after that place the cap and lock it with split pin.

# Then down the mudguard and fix the mudguard bolt to complete the wheel fixing process.
Wheel Fixing Proceduer Photos :

Sequence :

FINAL WHEEL LOOKS LIKE THIS AFTER FIXING.

AFTER COUPLING THE CHASSIE / SIDECAR TO MOTORCYCLE and FIXING the WHEEL the final it looks like in
following pictuer :

Now remove the bike from center stand and Adjust the Lean in lean out , height of the sidecar accoring to you
need with the help of adjustable bolts like : long bolt / shor bolt treaded type , and adjustable center stand
support.

After doing all adjustements TIGHTEN all the Nut bolts.

FIXING OF BRAKE WIRE:

Break wire parts : Inner wire / outer wire / part 1 / part 2 and adjuster.

# Make 2 Holes of 8 mm drill in the Motorcycle muffler braket and Break cam as shown.

# Fix part 1 and part 2 as shown . Pass the inner wire first and then cover it with the outer sleeve and shown.
# Then pass the wire alonge the sidecar chassie and clump the wire with chassie with the help of plastic clamps or
tape it so that it wont hang.

# In the other side pas the inner wire throughthe adjuster fix on the sidecar frame near to break plate and fix the
pin and tight it to necessary with the help of wire clump provided see in picture below.

Now your Break Wire is Fixed

Installing the Windshield and Seat
Remove windshield attaching bolts from sidecar body. Leave rubber windshield gasket in place. Attach
the windshield by positioning the windshield side support bars to the body of the side car while keeping
the rubber protector inline with the windshield, then insert bolts and fasten.
Note: It is helpful to have a second person to position the windshield and help prevent damage to the
finish. It is important to insert the side-support bar bolts first, before inserting and tightening the other
bolts.
The upholstery cushions are positioned and attached with the seat portion placed first the back cushion
last. Hold the seat in place with two plastic wing nuts through the car floor. The two rubber bumper on
the bottom of the seat are placed toward the front of the sidecar.

Installing the Tonneau Cover

Drape the tonneau cover over the opening of the sidecar body. Position and pop on turn clamps to
attach cover to the body.

Removal Instructions
Removal of the Sidecar is as easy as removing all of the mounting brackets and steering dampner.
Aligning the sidecar
When the sidecar is assembled and attached you need to align the sidecar. This is not an exact science
but rather involves trial and error. These settings are general places to begin.
It is helpful to have more than one person and perhaps some jack stands and a level and carpenters
square on hand.
The goal is to make the sidecar track straight down the road and not pull in either direction when
accelerating or braking. Before you begin (if they have been tightened in the preceding steps), loosen
all of the attaching points because one interacts with the other when making adjustments. Some of the
adjustment point may be stuck together with paint. It may be necessary to break the paint loose to
facilitate alignment.
The following is only a starting point but will get you close. After this, it is trial and error to try and get
the rig so that it does not pull left or right when braking or accelerating. The process can be a little
frustrating the first time, but some patience will go a long way. After the first time it will be much
easier. Time spent aligning the car is time well spent.
Frame horizontal alignment:
Ensure that the height “A” of the frame (unladen)
is the same at the front and rear of the sidecar. The
sidecar should be level or as close to level as you
can get it both fore and aft and left to right. Left to
right can be measured by using a square with the
sidecar wheel.
Setting the toe-in:
If you make a line 6 feet in front of the bike that is
parallel to the motorcycle wheels on the left and
the sidecar wheel on the right (a chalk line tied to
jack stands or two long board along each side of
the wheels works well for this measurement) there
should be about 1½ inch of toe in. (Distance C
should be about 1½ inch less than distance B, of
course if it is 3 feet in front of the bike it would be
about ¾ inch).

Setting the Sidecar lead:

This is only neccessary if you are mounting the
sidecar to another motorcycle besides the Royal
Enfield.
The axle of the side car sheel should be approx 6
incehs to 10 inches (distance D) forward of the
axle of the rear wheel of the motorcycle. (Larger
values for larger motorcycles.)
 Setting the side car lean:
Make sure that the rig is on level ground and that
the frame is horizontal. Set the lean out of the
motorcycle for 2 to 4 degrees depending on the
location of its center of gravity and road
conditions. In no event should the bike be tilted
toward the sidecar.

Air Pressure Recommendations

Try the air pressure in tires as mentioned below. Adjust accordingly to suit your operating conditions
and any manufacturer’s recommendations.
Front : 22 psi
Rear : 35 psi
S/Car : 25 psi

Wiring a sidecar
Wiring a sidecar is a fairly straightforward operation but You should have some very basic
knowledge of electrical theory and be somewhat handy. It is worth a trip inside of your owners
manual to determine the wattage (or a close approximation) of the electrical gear that is already
installed on your bike. Headlights, taillights, ignition system etc. Don’t forget to account for
things like heated clothing. Subtract whatever number you come up with from the capacity of the
charging system and you will have a good idea of how much extra equipment you can add.

Lighting - Most people are really only interested in adding a few lights to their sidecar and generally
low wattage ones at that. Let’s say for example a taillight/brake light combination, a small wattage
marker light on the top of the fender and a turn signal.
1. The first step is to decide where you want to mount the various lights. This will usually require
some drilling. When drilling for the light mounts don’t forget to drill a hole for the wires of
your device. Allow extra room for a rubber or plastic grommet.
2. Step Two is to plan your installation. The first thing is your choice of wiring. You can buy a
pre-made wiring harness such as the ones we sell or make your own. I have seen people make
them from scratch or even use a trailer wiring harness as beginning. You generally have to
choose which size of wire to use. Wiring is a case where size does matter! Wire is sized by
gauge, the smaller the number the bigger the wire. The bigger the wire the more current if can
carry safely. Common sense goes long way here. As a rule of thumb, I go with one wire size
bigger than the wires that come from the device. On the question of color there are two schools
of thought. If you use common colors for different things like red for a hot lead and black for a
ground lead it may be easier to trace them later. On the other hand using wires of the same color
can be more visually pleasing.
The next step is to determine the routing of all the wires. A fundamental first choice is how you are
going to ground the system. Electricity needs a complete circuit from the positive terminal on the
battery (unless you are working on an old Vintage bike in which case the ground may be the positive
lead), to the electrical device and then back to the negative terminal of the battery. The ground wire on
your battery is frequently run to the frame of the vehicle. You can then use the metal of the bike as one
big ground wire. For example, to make a taillight work you would only have to run one wire
to the bulb. The other wire coming from the bulb could then be attached to the metal fender
to complete the circuit. This is a simple time tested system and uses less wire that running a
ground wire back to the battery from each device.
Experience has shown that it is good practice to have at least one good wire connection
between the ground of the bike and the steel of the sidecar body or frame.
1. Now loosely mount each of the lights you are intending to wire to the sidecar. Then lay
out the wires that will be required to complete each circuit. You must determine where
on the motorcycle you want to tap into the motorcycles electrical system. I suggest that
in the case of the taillight you tap into the wires leading to the bikes taillights so that
when you turn on the light switch on the bike it will also power the sidecar light. This
also normally puts the sidecar taillight on a fused circuit for safety. If you are installing
a turn signal you may want to run the wires from the old signal on the bike which you
have just moved or relocated. When laying out the wires be sure to place them out of
harms way, free from chafing against a moving part like the tire inside the fender etc.
Be sure to use a grommet wherever a wire has to pass through a body panel or
anything else that could cut through the insulation later. Be sure to clamp the wires or
wire tie them solidly to the sidecar so that they do not move around once they are
installed. If you are using a pre-made wiring harness the wires will be neat and clean,
if not consider wrapping them with electrical tape or shrink tubing to keep them
together and neat looking.
2. Before we tie everything together you have to decide about connections. It is a good
idea to consider that you may want to remove the sidecar at some point for one reason
or another. To make it easy you should include some disconnects somewhere between
the bike and the sidecar. Some people use a trailer wiring harness connector or several
individual connectors.
3. Now it is time to wire up each device. Again there are a multitude of connectors
available to do the job, but butt connectors that are crimped on are a good way to
connect two wires. They are available at any auto parts or hardware store. A small kit
with a crimper is a good investment.
4. Consider where they are and how exposed to the elements they are. This is also a good
place to consider some dielectric grease or shrink tubing to protect them from future
corrosion.
5. After you are finished, turn the switch and admire your handiwork, with any
luck at all everything will work and be ready for years of service.

Sidecar Safety
It is important for your safety, and the safety of your passenger that you conduct routine
inspections to insure fittings are tight and correct.
Safety should be the first thing that comes to your mind when it comes to the purchase and
installation of a sidecar. There is not much else in the motorcycling world that you can do to
provide as much fun and enjoyment as the addition of a sidecar.
Driving (notice the term driving instead of riding) a sidecar rig is significantly different than
riding a motorcycle alone. We think that there are at least three components to sidecar
safety. In no particular order:

Training
We highly recommend that you seek sidecar training. With the rapid increase in the
popularity of sidecars many states are adding sidecar safety training to their safety
foundation training schedules.
Read as much as you can about sidecar safety, installation and handling characteristics.
We cannot stress enough how important we think this is.

Installation
The correct mounting and adjustment of your sidecar is very important. Most dealers that hold
themselves out to be sidecar specialists will be able to do a good job for you. There is a lot to
be said for having someone with the necessary experience do the work for you. It can be done
yourself, but be very meticulous in following instructions and other recommendations. There
is a lot of good information available on the internet about the art of sidecar mounting.

Sidecar choice
Pick a good quality sidecar and the right sidecar for your particular application. For example
our rocket or Classic sidecar would not be a good match with a Honda Goldwing as the Wing
is too large and heavy for the Cozy. On the other hand a large European type sidecar would be
too large and heavy for
a 750 Honda or a 500cc Royal Enfield.
Trouble shooting matrix
Here is a matrix of common sidecar problems. Some of the problems you may be having can
be a result of multiple solutions. Be aware that you may make the mistake of over
compensating for one problem and "cause" another. When ever you are troubleshooting,
always make small changes and then test them out, don't be in a rush and take your time.

PROBLEMS

Pulls Pulls Hard to Hard to Wheel Excessive

Wobble
Right Left turn Right turn left lifts easily tire wear
Increase toe in X X
Decrease toe in X X X
Increase lean out X X
Increase lean in X X X
Stiffer shocks X
Steering Head
X
(column) tension
Tire pressure X X X X
Swing arm bushings X
Add weight to sidecar X
Move sidecar further
X X
forward
Move sidecar further
X X X
back