lehman Trikes TRAMP 2009 Service Information
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lehman Trikes TRAMP 2009 Service Information

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2009 SERVICE INFORMATION
2009 SERVICE INFORMATION
SERVICE PROCEDURES
SERVICE PROCEDURES
PARTS/PRICE LIST
PARTS/PRICE LIST
FLAT RATE TIMES
FLAT RATE TIMES
PUB0020

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  • Page 1 Powered by Suzuki™ 2009 SERVICE INFORMATION 2009 SERVICE INFORMATION SERVICE PROCEDURES SERVICE PROCEDURES PARTS/PRICE LIST PARTS/PRICE LIST FLAT RATE TIMES FLAT RATE TIMES PUB0020...
  • Page 2 THIS IS YOUR MANUAL - HELP US MAKE IT BETTER Reader’s Comments Lehman Trikes continuously strives to improve the quality and use- fulness of its publications. To do this effectively, we need your feed- back—your critical evaluation of this manual.
  • Page 3 FOR PREVIOUS MODEL YEARS, PLEASE CONTACT LEHMAN TRIKES USA This service supplement is designed for use by authorized Lehman Trikes dealer technicians. Online copies of this supplement may be printed for internal use in your shop. This supplement is for use in a properly equipped shop and should remain available for reference in the shop area.

  • Page 4: Table Of Contents

    Jump to Flat Rate Times Jump to Parts and Pricing TABLE OF CONTENTS SAFETY INFORMATION........................5 AXLE BEARING ..........................6 AXLE SEAL ............................7 BODY ............................. 8-11 BRAKE BLEEDING .......................... 12 BRAKE SHOES ..........................13 DIFFERENTIAL ........................... 14-17 DIFFERENTIAL COVER GASKET ....................18 EXHAUST, MUFFLER ASSEMBLY....................

  • Page 5: Safety Information

    Jump to Parts and Pricing Jump to Flat Rate Times SAFETY INFORMATION UNDERSTANDING SAFETY LABELS & INSTRUCTIONS READ AND BECOME FAMILIAR WITH ALL WARNING, CAUTION SYMBOLS AND STATEMENTS LISTED BELOW AND IN THE TEXT OF THIS MANUAL BEFORE YOU BEGIN WORK. DANGER, WARNINGS &...

  • Page 6: Axle Bearing

    Jump to Flat Rate Times Jump to Parts and Pricing R & R AXLE BEARING REMOVAL Fig. 1 1. Place trike on lift. 2. Loosen lug nuts with 11/16” shallow socket. 3. Lift trike using a jack under differential carrier housing and two safety jack stands under left and right rear axles.

  • Page 7: Axle Seal

    Jump to Flat Rate Times Jump to Parts and Pricing R & R AXLE SEAL R & R AXLE SEAL REMOVAL Fig. 1 1. Place trike on lift. 2. Loosen lug nuts with 11/16” shallow socket. 3. Lift trike using a jack under differential carrier housing and two safety jack stands under left and right rear axles.

  • Page 8: Body

    Jump to Flat Rate Times Jump to Parts and Pricing R & R BODY Fig. 1 REMOVAL Remove footpads 1. Loosen lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support with jack stands or center stand. 3.
  • Page 9 Jump to Flat Rate Times Jump to Parts and Pricing R & R BODY CONTINUED 3. Insert (2) original fender washers saved from Fig. 4 disassembly to inside frame rails (front loca- tion). CAUTION: Use caution when placing body as rear fender braces may cause paint damage.
  • Page 10 Jump to Flat Rate Times Jump to Parts and Pricing R & R BODY CONTINUED 9. Center body to motorcycle using a framer’s Fig. 7 square. 10. See Fig. 7. Obtain a height measurement for both sides, adjusting body until equal measure- ments are obtained on both sides.
  • Page 11 Jump to Flat Rate Times Jump to Parts and Pricing R & R BODY CONTINUED 14. See Fig. 10. Insert (2) M6 x 1 x 30 bolts Fig. 10 through left and right front body mount holes and fasten with (2) M6 x 1 plated flange locking nut and (2) washers.

  • Page 12: Brake Bleeding

    Jump to Flat Rate Times Jump to Parts and Pricing BRAKE BLEEDING 1. Remove operator and passenger seat. Fig. 1 2. See Fig. 1. Remove reservoir cover screws, gasket and reservoir cover. 3. See Fig. 2. Fill brake fluid reservoir with DOT 4 brake fluid.

  • Page 13: Brake Shoes

    Jump to Flat Rate Times Jump to Parts and Pricing R & R REAR BRAKE SHOES Fig. 1 REMOVAL Green spring White spring 1. Loosen lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support with jack stands or center stand.

  • Page 14: Differential

    Jump to Flat Rate Times Jump to Parts and Pricing R & R DIFFERENTIAL Fig. 1 REMOVAL 1. Loosen lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support with jack stands and center stand under motorcycle frame. 3.
  • Page 15 Jump to Flat Rate Times Jump to Parts and Pricing R & R DIFFERENTIAL CONTINUED REPLACEMENT Fig. 5 1. See Fig. 5. Support new differential under rear of motorcycle with jack stands. 2. See Fig. 6. Position differential with pinion shaft to left of motorcycle centerline and vent tube pointing upward.
  • Page 16 Jump to Flat Rate Times Jump to Parts and Pricing R & R DIFFERENTIAL CONTINUED Fig. 8 8. Ensure adequate clearance between drive shaft and tunnel in swingarm. 9. See Fig. 8. Install (2) u-bolts, (4) lock washers and (4) nuts to install yoke to pinion shaft. 10.

  • Page 17: Differential

    Jump to Flat Rate Times Jump to Parts and Pricing R & R DIFFERENTIAL CONTINUED Fig. 10 BRAKE BLEEDING 18. Fill brake fluid reservoir with DOT 4 brake fluid. 19. Bleed brakes until air bubbles are eliminated (See Brake Bleeding). 20.

  • Page 18: Differential Cover Gasket

    Jump to Flat Rate Times Jump to Parts and Pricing R & R DIFFERENTIAL COVER GASKET Fig. 1 REMOVAL 1. Place drain pan under differential housing. 2. See Fig. 1. Remove (8) differential cover bolts. 3. Use a flat blade screwdriver or small pry bar to separate cover from housing.

  • Page 19: Exhaust, Muffler Assembly

    Jump to Flat Rate Times Jump to Parts and Pricing R & R EXHAUST, MUFFLER ASSEMBLY Fig. 1 REMOVAL 1. Remove RH side cover. 2. Protect edge of RH foot pocket area above exhaust using masking tape. 3. Remove head pipe mounting bolts. 4.

  • Page 20: Park Brake Cables

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PARK BRAKE CABLES Fig. 1 REMOVAL 1. Loosen lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support with jack stands or center stand. 3.
  • Page 21 Jump to Flat Rate Times Jump to Parts and Pricing R & R PARK BRAKE CABLES CONTINUED Fig. 4 8. See Fig. 4. Place a round file (or equivalent), inside brake drum, under end of park brake Release cable from lever cable and release park brake cable from u- shaped lever.
  • Page 22 Jump to Flat Rate Times Jump to Parts and Pricing R & R PARK BRAKE CABLES CONTINUED R & R PARK BRAKE CABLE CONTINUED REPLACEMENT Fig. 6 1. Route new cables through backing plate slot and connect ends of park brake cables to park Short cable, outside hole brake levers inside drum brake assemblies.

  • Page 23: Park Brake Cables

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PARK BRAKE CABLES CONTINUED R & R PARK BRAKE CABLE CONTINUED 8. See Fig. 9. Re-install park brake cables to Fig. 9 park brake cable pulling bracket and fasten with hardware.

  • Page 24: Park Brake Lever

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PARK BRAKE LEVER Fig. 1 REMOVAL 1. See Fig. 1. Cut cable ties attaching park brake boot to lever; remove boot. 2. See Fig. 2. Loosen hardware on cable pulling bracket.

  • Page 25: Passenger Footpads

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PASSENGER FOOTPADS Fig. 1 REMOVAL 1. See Fig. 1. Remove RH side cover. 2. See Fig. 2. Remove LH side cover with igni- tion key and remove tool box cover. 3.

  • Page 26: Passenger Grab Handles

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PASSENGER GRAB HANDLES Fig. 1 REMOVAL 1. See Fig. 1. Remove mounting hardware from frame rails and grab handles. 2. Carefully remove grab handles. REPLACEMENT 1. Install new grab handles with same hardware. Remove grab handles...
  • Page 27 Jump to Flat Rate Times Jump to Parts and Pricing R & R PINION SEAL REMOVAL Fig. 1 1. Loosen lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support motorcycle frame with center stand and differential with jack stands.

  • Page 28: Pinion Seal

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PINION SEAL CONTINUED Fig. 4 REMOVAL CONTINUED 9. Tilt front of differential downward to access front pinion nut. Apply silicone 10. Apply park brake and remove pinion nut with a Pinion 1 1/16”...

  • Page 29: Swingarm

    Jump to Flat Rate Times Jump to Parts and Pricing R & R PINION SEAL CONTINUED REMOVAL CONTINUED Fig. 6 20. Using original hardware, attach differential to swingarm. 21. Torque differential mounting bolts to 47 ft.-lbs. 22. See Fig. 6. Install (2) u-bolts, (4) lock washers and (4) nuts to install yoke to pinion shaft.

  • Page 30: Rear Wheel(S)

    Jump to Flat Rate Times Jump to Parts and Pricing R & R REAR WHEEL(S) R & R REAR WHEELS Fig. 1 REMOVAL CAUTION: Do not use impact tools to re- move or install lug nuts. 1. See Fig. 1. Loosen lug nuts with 11/16” shal- low socket.
  • Page 31 Jump to Flat Rate Times Jump to Parts and Pricing R & R SWINGARM REMOVAL Fig. 1 1. Remove rear wheels (See R&R Rear Wheel). 2. Remove operator and passenger seats located behind battery box. 3. Disconnect main wire harness. 4.
  • Page 32 Jump to Flat Rate Times Jump to Parts and Pricing R & R SWINGARM CONTINUED REPLACEMENT Fig. 4 1. Install shock link sleeve Item # Part # Description into new swingarm. Apply OEM parts LS6200 (1) Swingarm EP grease and ensure that LD1113 (1) Drive shaft sleeve moves freely.
  • Page 33 Jump to Flat Rate Times Jump to Parts and Pricing R & R SWINGARM CONTINUED Fig. 6 12. See Fig. 6. Support differential under rear of motorcycle with jack stands. 13. See Fig. 7. The pinion shaft is located to left of the motorcycle centerline and vent tube points 14.
  • Page 34 Jump to Flat Rate Times Jump to Parts and Pricing R & R SWINGARM CONTINUED Fig. 8 18. Ensure adequate clearance between drive shaft and swingarm tunnel. 19. See Fig. 8. Install (2) u-bolts, (4) lock washers and (4) nuts to install yoke to pinion shaft. 20.

  • Page 35: Tail Light

    Jump to Flat Rate Times Jump to Parts and Pricing R & R TAIL LIGHT Fig. 1 REMOVAL Disconnect tail light wiring from harness 1. See Fig. 1. Disconnect tail light wiring from main harness. 2. See Fig. 2. Remove self-tapping nuts from back of light housing and remove light and gas- ket from body.

  • Page 36: Trunk Door

    Jump to Flat Rate Times Jump to Parts and Pricing R & R TRUNK DOOR Fig. 1 REMOVAL 1. See Fig. 1. Disconnect license plate light Disconnect license plate light wiring wiring. 2. See Fig. 1. Depress release tabs on door hinges and remove hinges from door.

  • Page 37: Trunk Door Latch

    Jump to Flat Rate Times Jump to Parts and Pricing R & R TRUNK DOOR LATCH ASSEMBLY Fig. 1 REMOVAL 1. See Fig. 1. Open trunk door and loosen push- Loosen latch assembly button latch nut. 2. When latch nut reaches latch, push in button to remove nut and star washer.

  • Page 38: Trunk Door Seal

    Jump to Flat Rate Times Jump to Parts and Pricing R & R TRUNK DOOR SEAL Fig. 1 REMOVAL Remove door hinges 1. See Fig. 1. Open trunk door and disconnect license plate light. 2. See Fig. 1. Remove hinges from door. 3.

  • Page 39: Turn Signal

    Jump to Flat Rate Times Jump to Parts and Pricing R & R TURN SIGNAL Fig. 1 2009+ REMOVAL 1. Disconnect turn signal from wire harness. 2. Using an electrical pin removal tool, remove pins from connector block. 3. Remove clamp and washer from taillight; re- move turn signal.

  • Page 40: Rear U-Joint

    Jump to Flat Rate Times Jump to Parts and Pricing R & R REAR U-JOINT REMOVAL 1. Loosen lug nuts with 11/16” shallow socket. Fig. 1 2. Lift trike with jack; support with jack stands or center stand. 3. Remove lug nuts and remove wheels. NOTE: See Fig.

  • Page 41: Wire Harness

    Jump to Flat Rate Times Jump to Parts and Pricing R & R WIRING HARNESS Fig. 1 REMOVAL Disconnect main (6-pin) wiring harness 1. Loosen RH lug nuts with 11/16” shallow socket. 2. Lift trike with jack and support with jack stands or center stand.

  • Page 42: Torque Specs

    Jump to Flat Rate Times Jump to Parts and Pricing TORQUE SPECS AXLE FLANGE NUTS ....................44 ft.-lbs. DIFFERENTIAL MOUNTING BOLTS .................47 ft.-lbs. DIFFERENTIAL COVER BOLTS ................18 ft. -lbs U-JOINT U-BOLTS......................20 ft.-lbs. SHOCK LINK BOLT ....................56 ft.-lbs. DIFFERENTIAL FILL PLUG ..................40 ft.-lbs. REAR WHEEL LUG NUTS..................75 ft.-lbs.
  • Page 43 TRAMP FLAT RATE TIMES Jump to Parts Procedures Jump to Service Procedures PROCEDURE QTY. TIME BODY Trunk Door Seal R&R 0.30 Trunk Door R&R 0.50 Passenger Footpad R&R 0.20 0.40 Passenger Grab Handle R&R 0.20 0.40 Wiring Harness R&R 0.50 Trunk Door Latch Assembly R&R 0.20 Taillight R&R...
  • Page 44 u_joint_gu1072.jpg dust_shield_yoke_ls1420.jpg badge_tramp_gb1322.jpg grab-handle_lh6202.jpg...
  • Page 45 bar_spreader_lb1357.jpg bracket_master_cylinder_lb6216.jpg bracket_reservoir_lb6218.jpg differential_ld6200.jpg...
  • Page 46 swingarm_ls6200.jpg heat_shield_ls6209.jpg bracket_parkbrake_exhaust_s001361.jpg bracket_muffler_s001362.jpg...
  • Page 47 bracket_grab handle_s001364.jpg bracket_license_plate_s001365.jpg passenger_footrest-left_lp6210.jpg passenger_footrest_right_lp6211.jpg...
  • Page 48 bracket_switch_sidestand_lb6201.jpg bracket_turnsignal_S001047.JPG park-brake-handle_gb1099m.jpg bracket_cable_park_brake_lb1294.jpg...
  • Page 49 debris_shield_differential_ls1018.jpg shaft_drive_ls1404.jpg yoke_ly1002.jpg cable_park_brake_GB1115_16.jpg...
  • Page 50 badge_25year_s001532_REV_00.jpg latch_striker_ls6208.jpg...

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