lehman Trikes DYNA Installation Instructions Manual
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lehman Trikes DYNA Installation Instructions Manual

2006-2013 h-d fxd models
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DYNA
2006-2013 H-D FXD MODELS
Installation Instructions
*
Excludes Fat Bob
July 2014
2006-2013 FXD Renegade Rev. 6

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Summary of Contents for lehman Trikes DYNA

  • Page 1 DYNA 2006-2013 H-D FXD MODELS Installation Instructions Excludes Fat Bob July 2014 2006-2013 FXD Renegade Rev. 6...
  • Page 2 Body Prep, Lights and Wiring Fitting the Body Door Install and Adjstment Neck Race Preload Renegade Torque Specifications Replacement Parts *2006 Dyna models use a 66 tooth pulley assembly *2007-2013 Dyna models use a 70 tooth pulley assembly 2006-2013 FXD Renegade Rev. 6...
  • Page 3 Please reference a factory service manual for motorcycle information. The information in these instructions is provided to Lehman Trikes dealers. It is proprietary to Lehman Trikes, Inc. and provided solely for use by dealers. Any unauthorized duplication or distribution is a violation of international copyright law.
  • Page 4 Unpacking Your Kit The crate contains the following: 1. Differential with brakes 6. Hardware box (small parts & bolt bags) 2. Wheel kit. 7. Shock absorbers. 3. Renegade Body. 8. Warranty Book. 4. Swingarm. 9. Owners Manual. 5. Lehman frame. 10.
  • Page 5 MODULAR DIFFERENTIAL 2006-2013 FXD Renegade Rev. 6...
  • Page 6 Preparing Motorcycle Note: During installation you will use various products on different areas of the trike. The following are products to have on hand before starting the conversion. Loctite 242- Medium strength blue Loctite 262- High strength red Loctite 5920- High temp sealer Note: Refer to H-D service manual for detailed instructions on the removal of the following parts: 1.
  • Page 7 Installing Lehman Swingarm Note: Provided they are in good working order, all original components of Harley-Davidson swingarm may be re-used. 1. Clean and inspect original components, replace if necessary. 2. See Fig. 1. Install components into Lehman swingarm in same orientation as original swingarm. Fig.
  • Page 8 6. 06-07 Models: See Fig. 3. Install swingarm pin brace Fig. 3 (LB6110) to RH side of transmission housing with Fig. 3 LB6110 Pin Brace, 06-07 Models original hardware from case. Leave bolts for this bracket loose until swingarm installation is complete. 7.
  • Page 9 Fig. 1 Differential Installation 1. See Fig. 1. Attach LH adapter plate (LP1038) to swingarm as shown. Leave hardware loose. 2. See Fig. 2. Attach RH adapter plate to swingarm as shown with park brake bracket mounted to lower holes. Leave hardware loose.
  • Page 10 Fig. 3 4. See Fig. 3 and 4. Loosely install hardware to pinch blocks before installing differential to swingarm. Fig. 4 2006-2013 FXD Renegade Rev. 6...
  • Page 11 Fig. 5 Support swingarm with jack stands. See Fig. 5. With differential assembly on lift, slide Remove plates belt over LH axle tube and against center housing. See Fig. 5. Set differential assembly on swingarm adapter plates. Slide differential as far forward as possible.
  • Page 12 Fig. 1 Belt Tensioning and Tracking See Fig. 1.Center differential to motorcycle frame. Make sure distance is equal on both sides. This is Figure H-1 critical for proper body and seat pan alignment. See Fig. 2. Using adjusters, push differential assembly back until belt has about 3/8”...
  • Page 13 Brake System Fig. 1 CAUTION: Brakes are a critical safety component of the trike. Verify all brake components have been properly installed before test riding. Improper brake operation could result in death or serious injury. Do not allow dirt or debris to enter master cylinder reservoir. Brake pads will need to be seated in during initial test ride.
  • Page 14 Park Brake Assembly Note: Verify all brake lines and hardware are tight before bleeding system. 5. Add brake fluid (refer to OEM reservoir cap for brake fluid requirements) to brake system and work brakes to fill lines. 6. Remove rubber caps on bleeder valves. Install clear brake bleeder hose over bleeder valve on caliper. 7.
  • Page 15 Fig. 2 1. See Fig. 2. Remove snap ring from one side of large clevis pin on brake lever. Hold park brake lever on its side and push release button at end of park brake lever to allow clevis pin to slide out.
  • Page 16 Fig. 1 Installing Lehman Frame & Suspension Small spacer See Fig. 1.Insert (4) small frame spacers (LS6130) into H-D frame where trike frame will attach. See Fig. 2.Set frame in place by using 3/8” x 2 1/2” bolts with .875 rear frame spacers (LS6128). Use flat washers (CW2015) on both sides and secure with locknut (CN3050).
  • Page 17 Fig. 3 See Fig. 3. Install front frame mounting tab bolt Front frame tab through trike frame, spacer and H-D using the following hardware. (1) Spacer- S001050 (1) 1/4” x 1-3/4” Hex Bolt- CB1100 (2) 1/4" Flat Washers- CW2005 (1) 1/4” Lock Nut- CN3040 Tighten rear bolts and lower front tab bolt.
  • Page 18 Note: The lower shock eye is offset to one side. Be sure to install correctly. See Fig. 6.Install 1/2” x 2 1/4” bottom shock bolt and GB0320 bushings through lower shock eye, and thread it into shock plate. Use (1) washer under head of bolt. Lock bolt in with a lock nut. Raise differential and install top of shock using 1/2”...
  • Page 19 10. See Fig. 7. Install stabilizer bar LB6101 into tab on right side of Lehman frame. Use a 3/8” NC nylock nut, washers and grommet GG6100 to attach sway bar to frame. Leave loose. Fig. 7 11. Attach left-hand side of sway bar to sway bar bracket (S001883) using a 3/8” NC nylock nut, (2) washers and (2) grommets (GG6100).
  • Page 20 Make sure shocks are running vertical after sway bar is tightened. There are (6) 3/8” flat washers supplied to shim grommets on sway bar if needed. Dyna Head Bolt Procedure (Bolt Bag LCK5064) Remove existing 3/8” head bolts and washers from engine mount bracket on LH side.
  • Page 21 Installing Exhaust All heat shields should be removed. Mufflers, muffler support and rear bracket should be disassembled. Stock rear header pipe will need to be cut approximately 3 ½” back from center of cross-over tube. Install exhaust pipes LP6100 and LP6101 onto stock header pipes. Slide exhaust clamps into position and leave loose.
  • Page 22 Position exhaust system with jack stand, then install muffler bracket (LB6104) to mufflers with (2) 5/16” x 3/4” carriage bolts (CB1529) and 5/16” flange nuts. Position mount so it is pointing toward front of motorcycle. Install rubber isolator (GM0300) into slot on muffler bracket (LB6104). Fig.
  • Page 23 Fig. 1 Body Prep, Lights and Wiring Drill (2) 5/16” holes for signal mounting; (1) for wire and (1) for mounting bolt. See Fig. 1.Mount HD factory turn signals on flat below taillights. Center turn signal with inside edge of taillights.
  • Page 24 Fig. 3 Fig. 4 2006-2013 FXD Renegade Rev. 6...
  • Page 25 Fig. 1 Renegade Wiring Harness 1. See Fig.’s 1-2. Attach wiring harness to body clips on Taillight connector underside of body. 2. Connect 8 position connector on wiring harness (Fig. 3) to OEM harness, located under rider seat at rear of Light bar OEM frame.
  • Page 26 Fig. 1 Body Installation Note: To meet DOT and MOT requirements one of the following must be installed- stock grab handles, stock grab strap or Install seal Lehman-supplied grab handles. to boards Position body on frame so that wheel clearance is equal on both sides and front of each fender is an equal distance from front of each tire.
  • Page 27 License Plate Light Fig. 5 1. See Fig. 5. Install license plate bracket to door with 1/4” x 1” bolts, washers, lock nuts and rubber washers. Use Install rubber washers between bracket and door rubber washers between bracket and door. Install U-nuts to bracket (2) 1/4”...
  • Page 28 Fig. 1 Trunk Door Installation Note: Lip on weather seal will face away from door opening; top of seal is flush with top of door. See Fig. 1.Install (1) 6’ weather stripping (CW2536) around edge of body, starting at center on bottom. Trim using scissors;...
  • Page 29 Fig. 5 11. See Fig. 5. Install (1) striker pin GL2041 to (1) striker pin bracket LB1297 using (1) 5/16” plated lock nut CN3045. 12. Attach striker pin bracket to door using (2) 1/4” lock washers Striker pin and bracket CW2040 and (2) 1/4 -20 x 1/2”...
  • Page 30 Final Assembly Fig. 3 1. Reflectors can be installed to body. See Fig. 1. Install rear reflector 3” below taillights on body. See Fig. 3. Install side reflectors using wheel center caps as a reference, ¼” above wheel opening on body. 2.
  • Page 31 Door Adjustment Procedures Fig. 1 Figure 0-10 2006-2013 FXD Renegade...
  • Page 32 Fig. 2 Fig. 3 2006-2013 FXD Renegade...
  • Page 33 Neck Race Preload Steering head should be approximately twice as tight as factory specifications for a trike conversion. Refer to H-D service manual for adjustment procedure. Caution: Do not tighten bolts past factory specifications. Only bearing adjustment collar should be tightened past factory settings.
  • Page 34 Renegade Torque Specifications Park brake bracket 31 ft-lbs Pinch block bolts 25 ft-lbs Head bolts 42 ft.-lbs LP1038 adapter plate 31 ft-lbs Banjo bolts 16 ft-lbs LB6111 Transmission Brace Bolts 33 ft-lbs LB6110 Swingarm Pin Brace 20 ft-lbs Shock bolts 40 ft-lbs Wheels aluminum 85 ft-lbs...

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