At the heart of the Air Ride system are the two Kevlar bags that are set into a 6061-T6 billet aluminum cradle. A compressor inflates the bags that, in turn, allows the ride height to be adjusted. Even with all the adjustment available from the system, it is designed to keep the suspension from bottoming out, while at the same time maintaining a comfortable ride.
The Legends System can be installed on H-D Softails from ’86 to ’02, and on almost every custom frame on the market.

e’ve all heard the saying “If you want something done right, you have to do it yourself.” Well, as much as we try to be that way, sometimes you gotta go straight to the source and learn how to do it. This is one of those times.
While at a big show, we found ourselves hanging around the Legend Air Suspension booth listening to the questions about how an air-ride would install on a Softail chopper, and we realized a “How To” article needed to happen. Jesse Jurrens, owner of Legend Air in Rapid City, South Dakota, said, “How about I do it in my shop on a partially completed bike? That way, the readers will have a clear view of the installation by having fewer parts getting in the way.” Before he could get another word in, we jumped all over his offer.
     Follow along as the crew from Legend shows you just how easy it is to make your custom Softail ride better than you ever imagined. Not to mention, it will give you an adjustment of the ride height with more than a 3-inch range.

Dan and Jeff lift the Legend unit into place and secure the rear of it to the swing arm using two shoulder bolts.

Dan secures the front of the unit to the frame with two more shoulder bolts. The rear wheel will need to be raised or lowered to line up the bolts. Unlike H-D shocks, the Legend unit uses no washers on the shoulder bolts, because they can hinder proper operation of the shocks. Some blue Locktite should be applied to these bolts prior to installation and tightening.

A small, lightweight, oil-less air compressor bolts to a billet mounting bracket that lines up with the two lower muffler bracket holes on the right side of the frame. Holding the bracket in place are two Allen-head cap screws. Output of the compressor is 150 psi; the Kevlar bags are pressure tested at 950 psi, so there is no possibility of the compressor over-pressurizing the bags.

Legend offers the system with two different styles of gauge mounts: The standard one is designed to mount on the handlebar clamp…

… and the optional style is set up for mounting on the rocker box. Since you’re building a custom chopper, there’s nothing that says you must use the mount. Depending on your tastes, the gauge, the release valve, and the switch can be located in less conspicuous areas on the bike. The gauge is liquid-filled for accuracy and to ensure long-life by battling the effects of vibration. Located next to the gauge is a switch that operates the compressor (to raise the suspension), and a chrome-covered air release valve that is used to lower the suspension.

Once the gauge, the release valve, and the switch are mounted, it’s time to run the air lines. The lines are made from 5/32-inch high-temp nylon. To be certain that a good, tight seal is obtained, it is important to get a clean, straight cut on the end of the line. A new razor blade works great for this.

A quick-release nut and ring are slid onto the air line before it gets tightened to the compressor.

Here is a good look at the “Y”s that allow the tubing to be connected to the various components located around the bike.

A check valve is installed in the air line coming from the compressor. Be sure to observe proper direction of the valve before securing it with the quick-release fittings.

Since the frame is bare, finding an inconspicuous place to run the air lines is easy. Take care to route them away from high-heat areas such as the exhaust system. Knowing where your sheetmetal and seat will be positioned will make this step a lot easier, not to mention, give your finished bike a cleaner look.

Once the air lines are in place, trim them for a proper fit, making sure there will be no binding on them as you move the handlebars. Then connect the ends to the fittings at the gauge mount, and at the air bags.

Securing the lines to the frame will ensure they stay put and do not become tangled with any other parts on the bike. Given that you’re building a custom chopper, why not run the air lines through the frame tubes to give your ride a real clean look.

A little blue Loctite on the female threads of the chrome air release cover and you’re ready to screw it down over the valve assembly.

Jeff wires an in-line fuse between the battery and compressor switch. Two more wires complete the electrical connections; one between the compressor and the battery, and the second connects the switch to the compressor.

Be certain to leave adequate slack in the wiring before making the final connections to the battery.

The Legend Air Suspension, in the raised position, puts the frame about 4 inches off the ground…

…in the lowered position the frame is dropped within 2 inches of the pavement; with just the flip of a switch, the ride height can be adjusted high, low, or anywhere in between. No matter what the load or road conditions, the Legends Air Ride System will give you just the ride and look you’re after.