Haul N Ride
Kawasaki ZZR600 Leaner Sidecar Project.
Visitor - Hi. Thx
for your wonderfully helpful site! I have
fitted a leaner car (kozi) to my Kawasaki ZZR
600 but I'm having some stabilatly issues.
It's still in test stages but there is a lot
of rocking up and down of the car at the front
and rear. It's stable at 100kmh. And corners
ok but with some steering shudder. Regards
Haul N Ride - Hi
So great to hear you are going down the Leaner
path. I wonder if the rocking is somehow
related to the attachments to the bike. Rose
joints can loosen and bushes can wear. Next I
would adjust the Tow In. Then I would check
the tyres. Unbalanced or worn rubber and wheel
bearings. Just sounds like a rocking up and
down is most likely the attachment. Anyway, I
highly recommend you join and post on the
Schwenker Forum. Schwenker is German for
You will be able to chat with Leaner
enthusiasts in English. This is a post I put
They know what they are talking about because
they share and learn from each other. Good
luck with your project and enjoy the ride.
Kind Regards, Dave
Haul N Ride - Hi
Paul, Just thought I would share a sidecar
attachment email conversation I had with
"David. I looked
at some rod end bearings recently in a
bearing suppliers. I was surprised to see
there is end float within the bearings. The
supplier explained that is normal and there
must be a certain amount in all of them for
normal operation. A bit too much movement
for me. With two of them basically in line
the sidecar would tend to pull back on
acceleration and push forward during
braking. I guess brass bushes are the way to
go and would be in keeping with the age of
When you think
about it mounting a sidecar rigidly to a
bike is the worst thing you could do to a
bike frame. I had been thinking
independently about a banking sidecar for
years and figured two pivots below
axle height was the way to go. Having the
front pivot higher than the rear as
mentioned in your web page is an
improvement. Regards Terry"
Good luck, Dave
Visitor - Thx for
your prompt reply. Yes the problem is in the
mounting. The Kozi sidecar is all new. I did
replace the wheel on it with one from a
kawasaki EX 250. The original wheel had
plastic bearings! The EX wheel has disc breaks
I plan to fit later.
I'm going to try and make up some bush bearing
to replace the tie rod ends (knuckle joins) I
have on there now. I see other leaners use
them but the three dimensional play isn't
The other leaners I've seen in photos all seem
to be low slung too, maybe 6 inch off the
ground. This is a good 10 inch. Maybe the
extra hight doesn't help with balance.
Haul N Ride - Hi
Can I beg you for some photos? My website is
all about sharing projects and experiences.
The rotation is only on one axial plane on a
Leaner Sidecar. So bushes are best suited to
this task. Rose bushes are press fit and can
collapse. Probably not a good idea if you
don't want your passenger going in a different
direction to you. Can't wait to see pics of
your ride. Cheers. Dave
Visitor - Still in
early stages as yet. When I was getting the
position right I needed some weight in it and
a large tub of water was as easy option, until
my young daughter found it. The other photo
shows how easy it is to pick up blondes in
Haul N Ride - Thanks
the photos. Nice Ride! Do you still use the
Kwaka kick stand? Some leaners have a stand on
the Pivot Bars. Scroll down to Replacement
Stand on this webpage.
How does the 600cc go on top end torque on the
open road with a passenger uphill? Dave
Visitor - Sadly I
had to remove the centre stand and bolted the
undercarriage mounting frame to the stand
mounts. I still use the kick stand. At this
point in time I'm not happy with the sidecar
frame supporting the sidecar let alone the
bikes weight as well lol
Visitor - Leaner Update.
Hi David. A few photos of the
leaner so far. Still not finished but
U were asking how the 600cc pulls uphill
with weight in it. Not too many hills here
but yet I notice it. Doesn't take off like
it use to. But still not too bad. Just have
to give it more notice when u want to get up
They fit these sidecars to Vespa's. That
must knock them around.
The main changes I have made to mine are....
Leaner attached. Front wheel off a 250cc
ninja with 4 piston disc breaks. Compete
respray and fairing / windshield off ZZR600.
I've made all the attachments quick detach.
Undo two 3/4 bolts and it comes off. The
wiring is a 7 pin plug under the seat.
Hydraulic brakes are on the rear foot lever
and run off a separate master cylinder that
unbolts as a unit.
Takes about 15 min to take it off.
N Ride - Hi
I absolutely love how you put the windscreen
on the sidecar to match. Looks awesome with
that paint job too.
At least you don't have to put Leading Link
like the Vespa connected as a Rigid Hack.
Leaner is definitely the way to go.
Vespa Leading Link: http://i26.photobucket.com/albums/c127/ExonicJay/Sidecar005.jpg
I would really be interested to know the
following if you don't mind.
Width of sidecar?
Width of sidecar and bike leaning out?
(don't include mirrors and
Did you add a battery for the headlight or
is your bike power running it?
Is the front mount attachment higher than
the rear mount attachment on
your bike? Having the front higher helps to
steer the sidecar as you
lean the bike, rather than scrub the sidecar
Your answers to my questions will really
help my engineer as he is
interested in fabricating a wheelchair
accessible leaner sidecar
Here is where my Rigid Hack is up to: http://www.haulnride.com/FJ1200_Wheelchair_Sidecar.html
I so wish it was a Leaner. Oh well at least
I can take my daughter on our rides.
Look forward to your answers. Cheers Dave
Visitor - I've
tried to make the bike and sidecar extreme
lol. Over the top with the decal and mirrors
and fairing. It just got carried away from a
I've sent u some more photos from my phone
and email u from my iPad. It's easier.
In the photos I have leaned the bike over
and holding with a strap. I'm working on a
steering damper system to help take out
bounce in the sidecar from bumps and pot
holes. It could also be used to limit the
lean ether way. This could be used in your
argument about width for your licence
The original mounting frame I had made to
mount on the bike was too light and small. I
rebuilt a heavier one bolting the front
mount onto the engine mountings and
sacrificed my centre stand and bolted the
rear mounting the mounting on the frame.
I've used 3/4 tie rode ends and bolts as the
pivots. Just thru the bikes suspension
system it's surprising the amount bounce the
sidecar can get. I was going to try long
bush bearing mounts instead of the tie rode
ends but all the photos I have seen use the
tie rod ends.
Yes I designed the front mounting about 40mm
higher than the back to push the sidecar
over when leaning / turning. Works very
well! But if hitting a pothole with the
sidecar wheel it can pull the bike around a
bit. Sort of steering the bike in
reverse..... Causing some steering wobble. I
have put a small steering damper on the
handle bars and it helps. So far the dampers
I have tried from the car to the bike tends
to stabilise the bike more than the car
making leaning too slow and not safe for
cornering. Surprisingly the faster the
bike goes the less steering wobble occurs.
It handles very well at 140 km (not that I
have ever ride at the speed of course.....).
But and this will need more research and
trial and error, at higher speed, like
100km, the bike tends to pull a bit. It has
30mm toe in at the moment. I just haven't
got around to adjusting it more yet. It
seems strange but maybe it needs toe out not
In the photo of the bike leaning out I don't
think I would lean out that far when
cornering (but it would come close to it)
and even if I'm trying to I have never hit
the car with the bike on a left hand corner.
I wouldn't want the car any closer to the
bike, it seems about right. Of course with
the car attached it's no longer just a bike
so can't expect racing type performance from
In the photo the total width is 190cm. Errrr
sorry must have misread the tape because
legal width is 185cm right? :D
With the Kozi sidecar there is a lot of room
between the wheel and body of the car. I
think this could be reduced by 100mm maybe.
Meaning overall would be narrower.
I don't think it's fair the over width of
the bike and car is Max of 185cm because
cars, utes and trailers are all wider. And
so what if the bike sidecar is a little
wider on a corner because it leans out? What
is the width of a car and trailer when they
Head light and battery..... The extra
headlight is an eBay job ($70). It's three
high output LEDs. Single on low and all
three on high. I'm stunned how bright it is.
But because it's LEDs the wattage is very
low. Also I have replaced the tail lights
and blinker with LED globes. I haven't
calculated out the total wattage used but I
think it would be fine. I would like to
replace the bike headlight globe with LED
Visitor - Just
been having a read thru your set up. U have
done bloody well! I'm surprised at the
weight. Only 140 kg.
I think my sidecar weight would be about
100kg?? Just a guess. The frame is heavy but
I can easily lift it myself.
The body is just thin rolled tin and light
Good choice of bike for your car, much more
power than mine. Geez mine sucks thru the
fuel if I try and open it up on the road.
Maybe double the normal or more.
I've just picked up a '84 BMW K100 1000cc.
I'll make it into a cafe racer. Thinking
about making a trailer for it....
N Ride - Hi
My Trailer is the one with 10 bags of horse
shit on this page. It is also the one with a
log on it.
I use the same trailer to carry motorcycles.
Just have to be firmer on the handlebars
because at 110 ks she feels like little pot
holes. But not all the way, only
occasionally. Just have to be ready for it.
Considering you ride a leaner with teething
problems, I don't think a trailer will
I will add your photos to my website to
inspire others and give them ideas.
N Ride - Hi
Paul, Sorry to bother you again.
I was uploading your photos to the Haul N
Ride Community and looking at the bolt that
remove/attaches the sidecar, I thought it
really could do with a Nyloc nut. Hate the
think of vibration loosening it. Cheers Dave
U are right, good pick up! But
the way I always build things is just out of
my head and work it out as it goes.
I once built a stone building 18" x 36", a
Korean style martial arts training hall,
complete with return verandas and double
sliding doors on each side and high pitched
exposed beams roof without putting a pen to
paper. Just straight out of my head. (It was
under the $20k restriction so didn't need to
submit plans to the council)
Anyway I wielded the nuts onto the mounting
frame for the bike then later realised I
couldn't put a locking nut on it as it there
isn't room for it to turn. So what I've done
is used super strength loctite on it. I've
been meaning to also drill thru and nut and
bolt and then put in a split pin.
If u want any more photos of any bits let me
know and I'll send u some.
One bit that worked well was running the
brake line and wiring past the rear pivot
point. Stopped any looping lines problems
that occur as the bike leans one way or the
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