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Lehman Crossbow 2011 Manual
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Lehman Crossbow 2011 Manual

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HITCH & MUFFLER BRACKET INSTALLATION
1. See Fig. 1. Install (1) hitch bracket to frame as
shown using (8) bolts. Hand tighten bolts only.
•
(1) Hitch Bracket (S001128)
•
(8) Bolt (CB1972)
2. See Fig. 2. Install (1) body / exhaust bracket to LS
frame as shown using (2) bolts. Hand tighten
bolts only.
•
(1) LS Body / Exhaust Bracket (S001534)
•
(2) Bolt (CB1972)
3. Install (1) body / exhaust bracket to RS frame us-
ing (2) bolts. Hand tighten bolts only.
•
(1) RS Body / Exhaust Bracket (S001535)
•
(2) Bolt (CB1972)
Bracket Installation
Fig. 1
Fig. 2

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Summary of Contents for Lehman Crossbow 2011

  • Page 1 Bracket Installation HITCH & MUFFLER BRACKET INSTALLATION Fig. 1 1. See Fig. 1. Install (1) hitch bracket to frame as shown using (8) bolts. Hand tighten bolts only. • (1) Hitch Bracket (S001128) • (8) Bolt (CB1972) 2. See Fig. 2. Install (1) body / exhaust bracket to LS frame as shown using (2) bolts.
  • Page 2 Bracket Installation RELAY/SIDE COVER BRACKET INSTALLATION Fig. 1 1. See Fig. 1. Install OEM relays to park brake bracket as shown using plastic pushpins. Relay • (2) Relay (OEM) • (2) Plastic Pushpin (S001430) 2. See Fig. 2. Install (1) Grommet to (1) Right Side Pushpin Cover Bracket as shown.
  • Page 3 Bracket Installation BRACKET INSTALLATION Fig. 1 1. See Fig. 1. Install (1) Upper Body Mount Bracket to right side of frame as shown using (1) Bolt. S001442 Hand tighten only at this point. • (1) Upper Body Mount Bracket (S001442) •...
  • Page 4 Bracket Installation 6. See Fig. 4. Install (1) Upper Body Mount Bracket Fig. 4 to left side of frame as shown using (1) Bolt. S001442 Hand tighten only at this point. • (1) Upper Body Mount Bracket (S001442) • (1) Bolt (CB1972) 7.

  • Page 5: Part Description

    Bracket Installation PART # PART DESCRIPTION TORQUE CB1982 FRONT BODY MOUNT BOLTS 22 FT LBS FRONT BODY MOUNT BRACKET INSTALLATION Fig. 1 1. See Fig. 1. Install (1) Front Body Mount to LS Rollover Brace as shown with (1) spacer using (2) Bolts.
  • Page 6 Bracket Installation PART # PART DESCRIPTION TORQUE TAKE OFF UPPER TAIL SECTION BOLTS (2) 22 FT LBS TAKE OFF LOWER TAIL SECTION BOLTS (2) 8 FT LBS TAILLIGHT INSTALLATION Fig. 1 1. Remove Left and Right side Latch Assembly Alignment Fixtures using 10mm socket. 2.

  • Page 7: Rear Frame

    Bracket Installation Bracket Installation PART # PART DESCRIPTION TORQUE CB1972 FRAME BOLTS 22 FT LBS REAR FRAME 1. Torque and mark frame bolts to 22 ft. lbs using 13mm socket as indicated Fig. 1 Leave Loose Fig. 2 Leave Loose...

  • Page 8: Exhaust Installation

    Operation 40 - Bracket Installation Bracket Installation PART # PART DESCRIPTION TORQUE CB1906 UPPER EXHAUST BRACKET BOLT (1) 10 FT LBS CB1928 LOWER EXHAUST BRACKET BOLT (1) 35 FT LBS Fig. 1 EXHAUST INSTALLATION 1. See Fig. 1. Install (1) left side exhaust pipe as shown using (1) exhaust clamp.
  • Page 9 Side Cover Modification– Reverse Models SIDE COVER MODIFICATION (REVERSE ONLY) Fig. 1 1. See Fig. 1. Using scribe lines on backside of side Scribe Lines covers, trim Left and Right side covers as shown using air saw. 2. See Fig. 2. Install GT1800 weather seal to modi- fied edges of side covers as shown.Use loctite 404 on inside edge of side covers to secure, being careful not to get glue on outside edge of side...

  • Page 10: Body Preparation

    Body Preparation, Installation, & Final Assembly Fig. 1 BODY PREPARATION 1. See Fig. 1. Drill out OEM latch assembly as Drill Out shown using 21/64” bit. 2. See Fig. 2. Install OEM latch assembly to OEM latch bracket as shown using (2) take off bolts. Tighten using 10mm socket.
  • Page 11 Body Preparation, Installation, & Final Assembly Fig. 5 5. See Fig. 5. Acquire (1) Left Side Body. Install (2) jam nuts to latch studs as shown. • (1) Body (LS - S001437, RS - S001438) • (2) Jam Nut (CN1904) 6.
  • Page 12 Body Preparation, Installation, & Final Assembly DOOR PREPARATION Fig. 1 1. Acquire (1) Painted Left Side Door. • (1) Door (LS - S001439, RS - S001438) 2. Acquire (1) section of weather seal and cut to 56” using weather seal cutting tool. •...
  • Page 13 Body Preparation, Installation, & Final Assembly 9. See Fig. 4. Install (1) left and (1) right hinge to Fig. 4 door with (1) concentric rod as shown using (6) bolts. Tighten using 10mm socket. • (1) Left Side Hinge (S001497) •...
  • Page 14 Body Preparation, Installation, & Final Assembly DOOR INSTALLATION / ADJUSTMENT Fig. 1 1. See Fig. 1. Install (1) prepped left side door to (1) prepped left side body using (1) hinge pivot re- tainer and (1) bolt. Leave a little loose for adjust- ment purposes.
  • Page 15 Operation 50 - Body Preparation, Installation, & Final Assembly 4. See Fig. 4. Install (2) bump stops to body as Fig. 4 shown. • (2) Bump Stop (ACE52728) Bump Stop 5. See Fig. 5. Install (1) U-Nut to body as indicated. Mark hole and remove U-Nut.
  • Page 16 Body Preparation, Installation, & Final Assembly PART # PART DESCRIPTION TORQUE CB1972 UPPER BODY MOUNT BOLTS (2) 22 FT LBS BODY ALIGNMENT & INSTALLATION Fig. 1 1. Using another person to help, locate left side body to trike. The body locates with the top grab han- dle contour and rests on front and rear body mounts.
  • Page 17 Body Preparation, Installation, & Final Assembly Fig. 50-25 8. Drill hole for front body mount through front body mount hole using 21/64” bit as shown (Fig. 50-25). 9. Secure front of body to front body mount as shown using (1) Bolt, (1) Flat Washer, and (1) Ny- lock Nut.
  • Page 18 Body Preparation, Installation, & Final Assembly Fig. 4 13. Drill pilot hole from bottom side of body to locate rear body mount hole using 3/16” bit. 14. Finish drilling out the rear body mount hole from topside of body using 21/64” bit. 15.
  • Page 19 Body Preparation, Installation, & Final Assembly Fig. 6 17. See Fig. 6. Drill hole for front body mount through front body mount hole using 21/64” bit as shown. 18. See Fig. 7. Secure front of body to front body mount as shown using (1) Bolt, (1) Flat Washer, and (1) Nylock Nut.
  • Page 20 Body Preparation, Installation, & Final Assembly Fig. 9 22. Drill pilot hole from bottom side of body to locate rear body mount hole using 3/16” bit. 23. Finish drilling out the rear body mount hole from topside of body using 21/64” bit. 24.
  • Page 21 Operation 50 - Body Preparation, Installation, & Final Assembly Fig. 11 26. See Fig. 11. With body aligned and secure, mark and drill mounting hole in left side lower valence as shown using 13/64” bit. NOTE: This mounting hole must line up with the u- nut located under the lower valence.
  • Page 22 Body Preparation, Installation, & Final Assembly PART # PART DESCRIPTION TORQUE S001412 EXHAUST CLAMPS (4) 35 FT LBS CB1915 EXHAUST MOUNTING BOLTS (2) 22 FT LBS CB1929 FRONT AND REAR BODY MOUNT BOLTS (4) 22 FT LBS Fig. 1 MUFFLER INSTALLATION 1.
  • Page 23 Body Preparation, Installation, & Final Assembly 13. See Fig. 4. Re-install (1) modified RS heat shield Fig. 4 to right side of trike as shown using (1) bolt and (1) hose clamp. Tighten using 10mm socket and 5/16” nut driver. •...
  • Page 24 Body Preparation, Installation, & Final Assembly FINAL ASSEMBLY Fig. 1 1. Re-install park brake lever assembly to park brake Cable Tie bracket using 1/2” wrench. NOTE: Make sure there is no interference between the park brake lever and body. 2. See Fig. 1. Install (1) Park Brake Boot to Park Brake Lever Assembly using (1) Cable Tie.
  • Page 25 7. See Fig. 3. Install (1) Reflector to each body as shown 3-1/4” from inside edge of wheel well. • (2) Reflector (S001421) 8. See Fig. 3. Install (1) Lehman Badge above each reflector as shown. • (2) Lehman Badge (GB1327) 9.
  • Page 26 Operation 50 - Body Preparation, Installation, & Final Assembly PART # PART DESCRIPTION TORQUE TOUR PACK MOUNTING BOLTS (4) 22 FT LBS Fig. 5 10. See Fig. 5. Re-Install (1) Tour Pack to trike using OEM hardware. Tighten using 13mm socket and (2) 6”...