Assembly of your new sidecar (continued):

The mud guard (fender) and bumper bar need to be assembled before attachment to the sidecar body. It is helpful if the wheel is not tightened at the outer axle nut, as it may need to be loosened.

This would be the opportune time to attach any lighting and electrical options you wish installed in your sidecar.

Prepare the car by removing the two 17mm bolts from the frame in front of the wheel (See Figure 3).

Carefully lay the mud guard (fender) on the floor car-side down (take care not to scratch the surface) and insert and align the inner-fender spacer into the rear of the mud guard (See Figure 4 below).

Assemble a steel and a rubber washer (rubber washer toward fender) on the fender-attaching bolt. Push the bolt into the mud guard, through the spacer, and out the other side of the guard. Place a rubber and a steel washer on the bolt (rubber washer toward fender). See Figure 5 below.

The easiest way to install the fender assembly is to loosely bolt together the components. Then, with a helper, bolt the assembly to the sidecar. Set the mud guard (fender) assembly on the tire.

We've found the following order to be helpful.

Place the rear of the bumper over the bolt and rubber gasket, which comes through the inside rear of the fender. Loosely attach the second washer and nut (See Figure 6).

Loosely bolt together the attaching arm, rubber gasket, fender and front of bumper. (See Figure 6 for the relative position of each part).

Attach the front bracket with two bolts to the frame (See figure 7 Above).

Attach the middle mud guard support to the inside of the mounting tab on the sidecar frame using the 10mm bolt. Leave bolt finger-tight. The support is shown here attached to the frame of the sidecar (See Figures 8 and 9).

Attach the upper end of the middle support using a 10mm bolt and plastic washer.
Note: We've found it easiest to loosen the wheel on the axle to provide room for your hand and wrench inside the fender to tighten this bolt.

Tighten all the bolts. Don't forget to properly tighten the castle nut and install the cotter pin on the end of the axle.

Note: Take a moment to go back over every nut and bolt on the sidecar to make sure that each is properly tightened. Be sure that all locking tabs and cotter pins are properly in place. The use of a thread-locker is strongly recommended.

Installing the optional Luggage Rack

Attach the luggage rack using the plastic isolators between the rack and the bodywork with the 10mm bolts provided.

Installing the Windshield and Cushions

Remove windshield attaching bolts from sidecar body (See Figure 1 below). 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. (See figures 3-6 below).

Installing the Optional 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.

Easy Removal Instructions

Removal of the Cozy Sidecar is as easy as removing all of the mounting brackets and steering dampner.

Final Notes

Enjoy your new sidecar. Remember, it is important for your safety, and the safety of your passenger that you conduct routine inspections to insure fittings are tight and correct.

Most importantly, make sure that you or your customer is trained and qualified in the art of sidecar riding. It is completely different than riding a solo motorcycle.

If you have questions that are not answered here, please call us at 1-800-201-7472.