Evo Sportster 200 Kit Installation Instructions


1. Remove seat, rear fender, rear shocks, wheel and swing arm. 

   See Rear Fork Assembly/Disassembly Diagrams

2. Remove battery box.

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3. On the frame cross-member tube, under the seat...Remove the Ignition Module from the cross member (If Applicable to your bike)

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The  cross-member must be cut in two, on each side of the fender mounting bracket, in the middle of the cross-member. This mounting bracket is a metal tab with a hole in it welded to the center of the cross-member tube. The tab holds a bolt that is attached to the center front of the rear fender. The cross-member section to be cut out should be 1 long.

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Figure 2

4.The fender rail area of the frame must be spread apart to 8 wide to accept the wider rear fender. After the cross-member is cut, the frame can be spread with a port-a-power, hydraulic jack, scissor jack, etc.*

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5. When the cross-member has been spread apart to 3, install spreader tube (supplied in kit) and drill two (2) holes through cross-member tube to bolt in spreader tube.

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NOTE:  When the cross-member is spread apart to 3, the fender rails appear to be wish-boned or Vd (veed). (see photo below) 

6. After the spreader tube is installed, the rear of the fender rails must be bent inward to become parallel with the fender. Heating with an oxy-acetylene torch can be used to help in the bending of each side of the fender rails. When completed, fender rails must measure 8 wide to accommodate the new wide tire fender.  Use the "Alignment Template:, (supplied in the kit & shown above) to help with alignment.

7. Install new swing arm, tire and wheel. Position fender with seat to determine where fender mounting holes must be drilled.

8. Remove transmission pulley cover from engine, and transmission pulley. Replace with offset pulley and install pulley cover mounting bolts and supplied spacers to space pulley cover out from engine.

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NOTE: On 1999 and previous model years, the rear brake caliper bracket must be milled out to 2 1/16 to go over the larger swing arm tubing.  The manufacture  provides this service for you at no cost, if you ship us your caliper bracket.

* Sometimes it is easier to install the swing arm, tire, and wheel prior to spreading the fender rails. You can then conform the rails to location of the tire. The tire will not run in the center of the fender.

Parts List

  • Wide heavy-duty swing arm

  • Offset pulley (1)

  • Offset pulley spacers (4) & bolts (4)

  • Frame spreader tube (to replace cross member under seat)

  • 8 rear fender

  • 200mm tire

  • Axle adjuster plates (2)

  • Axle (1)

  • Axle nut & washers (2 flat)




Figure 2-92

  1. Pivot Bolt

  2. Rear Fork

  3. Frame

  4. Pivot Bushing

  5. Pivot Spacer

  6. Dust Shield (2)

  7. Inner Race (2)

  8. Outer Race (2)

  9. Lock Ring

  10. Bearing Spacer

  11. Socket Screw

Mark all hardware as it is removed so that it may be returned to it's orginal location.

  1. See Figure2-92 Avove.  Remove rear wheel 
  2. Remove rear brake caliper assembly. See Rear Brake Caliper.
  3. Remove rear shock absorber nuts & washers from rear fork.
  4. Remove rear belt guard and debris deflector. Remove belt.
  5. Remove socket screw (#11)
  6. Remove pivot (#1). Support rear fork and pull fork assembly from frame.


Carefully mark all bearing components as they are removed so that they may be returned to their original locations.  Do Not intermix bearing components.



  1.    Carefully press bearing outer races (8) from from fork. Remove lock ring (9).

  2. Remove pivot spacer (5). Press pivot busing (4) from fork assembly.


  1. Clean all components in solvent and blow dry. Carefully inspect all bearing components for wear and/or corrosion.  Replace complete bearing assembly if any component is damaged.

  2. Check that rear fork is not bent or twisted. Replace if damaged.


  1. See Figure 2-92 If necessary install new lock ring (9) and press new outer races (8) into position.

NOTE- Roller bearing assemblies are shipped assembled as a unit. Do not intermix components.  Mark all components so they may be correctly installed.

   2.  Coat bearing components with bearing grease and assemble.


Bearing space (10) must be installed between inner races (7) or bearing failure can result.

   3. Press dust shields (6) ovr bearing inner races (7) with the lipped side in.
   4.  If pivot bushing (4) must be replaced, press it into rear fork (2)
   5.  Insert pivot spacer (5) into pivot gushing (4) with chamfered end facing outward thoward socket head screw.


Pivot spacer (5) must be installed with chamfered end outward toward socket head screw (11) or  insufficient clamp load between rear fork pivot and frame may adversely affect handling which could result in death or serious injury.

  1. See Figure 9-92 above. Slide rear fork assembly into position.
  2. Holding fork assembly in position, install povot bolt (1). Apply two or thre drops of Coctite 242 Blue on threads of screw (11). Thread screw into internal treds of pivot bolt (1) and thighten to 50 ft-lbs.(68Nm) torque.
  3. Install belt guard and debris deflector.
  4. Install shock absorbers onto rear fork.
  5. Install rear brake caliper assembly.
  6. Install rear Wheel.
Transmission Pulley Cover

The rear compartment of the left and right crankcase halves for the transmission case.  An access cover (door) allows removal of transmission components without removing the engine or disassembling (splitting) the crankcase.


  1. Remove exhaust system.
  2. See Figure 6-20 below. Remove footrest, brake pedal, sprocket cover (5) and rear brake master cylinder from right side of motorcycle.

  1.    Place a drain pan under the engine. Remove drain plug, and drain lubricant from primary drive/transmission.
  2. See Figure 6-21 right. Place transmission in first gear. Remove two socket head screws (5) and lockplate (4).

NOTE: Transmission sprocket nut has left-hand threads. Turn nut clockwise to loosen and remove from main drive gear shaft.

  1. Remove transmission sprocket nut (3) from main drive gear shaft (1).