Step 1. PAINTING - We suggest that the first step after uncrating your Sportster Kit be a COMPLETE PAINT JOB of your color choice. The body of the has been carefully prepared for painting, having been dipped in two solutions, caustic for cleaning and a zinc phosphate solution to protect the metal from rusting. This forms an ideal base for the primer which your Sportster us delivered with. By painting the Sportster as the first step, much time normally taken up in masking is eliminated. A better job can be done if the headlights, front nose and hood are removed and sprayed separately, along with the wheels.

Step 2. WIRING - After the paint is thoroughly dry, the next step is INSTALLING THE WIRING HARNESS. As the Sportster is wired in the same manner as the VW sedan, the normal sedan wiring diagram may be used. If you buy the EMPI No. 983 wiring loom for the Sportster you will find all wires plainly color coded and a wiring diagram enclosed. (Refer to page 8) The wiring harness by EMPI is made up for the latest model turn signal switch with three wire outlets. The main wiring loom is passed through the tunnel to lessen the chance of damage to the wiring from use over rough terrain. After you have installed the wiring loom, connect the headlights, dimmer switch, all instruments. Then connect turn signal lights and tail lights. The front fenders are drilled for VW sedan flasher lights, Part No. 113-953-041A, of any year from 1958 up. The rear fenders on the Sportster have been drilled for 1962 or later tail lights, Part No. 111-945-095G (left) and Part No. 111-945-096G (right). In order to make the tail lights fit the fender at the proper angle, it will be necessary to trim the tail light housing on the long side with tin snips. Any year model VW battery will fit the battery box. Just use the VW battery cover to fit the battery you choose. Place the ½" wood spacer included in the kit under the battery.

Step 3. STEERING - This step is the INTSTALLATION OF THE COMPLETE FRONT AXLE ASSEMBLY with steering gear box, steering wheel and front shocks. The front axle assembly is bolted in position with the four standard axle mount bolts as are used on the VW sedan. Make sure the steering gear box is in proper alignment with the steering column. Mount the steering column, just under the top edge of the cowl, using the stock sedan steering column clamp and bolts.

Step 4. BRAKES - Install the BRAKE FLUID RESERVOIR as shown in Step 4 picture, install the master cylinder and connect the front brake lines. The brake fluid reservoir is a normal late model VW sedan component.