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lehman Trikes CrossBow Victory Vision 2009 Installation Instructions Manual
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lehman Trikes CrossBow Victory Vision 2009 Installation Instructions Manual

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2009+
Victory Vision Models
Installation Instructions
April 2014
125 Industrial Drive | Spearfish, SD 57783 | Toll Free 888.3WHEELS
w w w . l e h m a n t r i k e s . c o m

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Summary of Contents for lehman Trikes CrossBow Victory Vision 2009

  • Page 1 2009+ Victory Vision Models Installation Instructions April 2014 125 Industrial Drive | Spearfish, SD 57783 | Toll Free 888.3WHEELS w w w . l e h m a n t r i k e s . c o m...
  • Page 2 CLUTCH VALVE Fig. 1 CLUTCH MODULATION VALVE INSTALLATION 1. Rotate the handlebars all the way to the right (full left hand turn position). 2. Remove push pins in front edge of side covers (save). 3. Remove side covers (L & R). 4.
  • Page 3 CLUTCH VALVE PART # PART DESCRIPTION TORQUE S001502 BANJO BOLT 16 FT LBS Fig. 4 10. See Fig. 4. Using a silver sharpie, mark the loca- tion of the cross-drilled holes on the assembled banjo bolt as shown. 11. Remove OEM banjo bolt from clutch reservoir us- ing 12mm wrench.
  • Page 4 DISASSEMBLY REAR DISASSEMBLY Fig. 1 1. See Fig. 1. Remove rear license plate bracket using 4mm Allen head socket. • 2 screws and bracket (save) 2. Remove seat. 3. Disconnect wire harness from tour pack. 4. See Fig. 2. Remove tour pack using 13mm socket and 12”...
  • Page 5 DISASSEMBLY Fig. 1 SADDLE BAG REMOVAL ( RH SIDE FIRST ) 1. See Fig. 1. Remove lower saddle bag access panels (L & R) using 4mm Allen head socket. • 5 screws each side L & R (save) 2. See Fig. 2. Remove (5) bolts from rear of sad- dle bag as shown using 10mm socket and 4mm Allen socket (front bolt).
  • Page 6 DISASSEMBLY Fig. 4 5. See Fig. 4. Remove (4) latch assembly bolts. Remove latch assembly using 10mm socket. • 4 bolts (save) 6. See Fig. 5. Remove (3) bolts from front of sad- dle bag using 13mm socket. 7. See Fig. 6. Remove (2) bolts from upper sad- dle bag using 13mm socket.
  • Page 7 DISASSEMBLY Fig. 7 8. See Fig. 7. Unhook wire harness as shown. 9. Remove top bolt from saddle bag using 13mm socket (located behind latch assembly). 10. Remove rear-most bolt from saddle bag using 10mm socket (lower outside of taillight). 11.
  • Page 8 DISASSEMBLY 13. Repeat steps 1 thru 13 for removal of left side Fig. 10 saddle bag. 14. See Fig. 10. Remove air shock fill valve using 7/8” socket. 15. Re-install nut to fill valve. 16. See Fig. 10. Remove and save left and right side cover grommets as shown.
  • Page 9 DISASSEMBLY DISASSEMBLY Fig. 1 1. Remove LS heat shield using 10mm socket. • (2) Band Clamp (save) 2. See Fig. 1.Remove and save RS heat shield us- ing 10mm socket. • (1) RS Heat Shield (save) • (1) Clamp (save) •...
  • Page 10 DISASSEMBLY Fig. 4 9. See Fig. 4. Remove taillights using 4mm allen head socket. Disconnect and place on top of tail section as shown • (5) Bolts (save) 10. See Fig. 5. Remove reinforcement plate using 10mm socket (Fig. 10-20). •...
  • Page 11 DISASSEMBLY Fig. 6 12. See Fig. 6. Remove brake line from swingarm as shown using 10mm socket. 13. Remove side stand using 15mm socket and 6mm allen head socket. 14. Remove rear axle nut using 27mm socket. 15. See Fig. 7. Loosen belt tension with adjuster bolts as shown using 13mm socket.
  • Page 12 DISASSEMBLY Fig. 10 23. See Fig. 10. Remove lower shock mount bolts (2) using 15mm socket and 15mm wrench. Bolts • (2) Lower Shock Mount Bolts (save) • (4) Bushings (save) 24. See Fig. 11. Remove swingarm pin on RH side using 24mm deep socket.
  • Page 13 TAIL SECTION MODIFICATION Fig. 1 TAIL SECTION MODIFICATION 1. See Fig. 1. Secure tail section to trim fixture as shown 2. See Fig. 2. Mark areas to be trimmed on tail section using left and right trim splashes as shown. Mark using silver sharpie in indicated areas.
  • Page 14 TAIL SECTION MODIFICATION Fig. 1 CENTER VALENCE MODIFICATION 1. See Fig’s. 1 & 2. Mark center valence for trim- ming as shown using masking tape. 2. Trim masked off portion of center valence us- ing cut off wheel. 3. See Fig. 2. Trim approximately 1/4” from bot- tom corner as indicated.
  • Page 15 EXHAUST Fig. 1 EXHAUST MODIFICATION 1. See Fig. 1. Using Header Pipe Cutting Fix- ture, mark on the right side exhaust pipe where it is to be cut. 2. See Fig. 2. Cut exhaust header pipe 4” from the rearmost weld of crossover pipe using band saw.
  • Page 16 EXHAUST Fig. 4 6. See Fig. 4. Drill new mounting hole in RS heat shield as shown using 1/4” bit 7. See Fig. 5. Add a 1-1/2” slot to the upper left side of RS heat shield as shown using cutoff wheel.
  • Page 17 EXHAUST Fig. 1 CATALYTIC CONVERTER RELOCATION 1. See Fig’s 1 & 2. Using cutting wheel, score the exhaust pipe the length of the catalytic con- verter. NOTE: Be careful to not cut too deeply into the exhaust pipe, so as to not damage the catalytic converter.
  • Page 18 Frame, Swingarm, & Differential Installation Fig. 1 FRAME INSTALLATION 1. Remove (4) OEM transmission bolts using 15mm socket. • (2) OEM Transmission Bolt (save) 2. See Fig. 1. Install (1) frame to motorcycle as shown using (6) bolts. Tighten using 15mm swivel socket and Loctite 243.
  • Page 19 Frame, Swingarm, & Differential Installation SWINGARM ADAPTOR PLATE INSTALLATION Fig. 1 1. See Fig. 1. Install (1) RH Swingarm Adaptor Adaptor Plate Plate with (1) Bushing as shown using (2) Bolts. Hand start bolts from the inside. • (1) RH SWA Adaptor Plate (S001200) •...
  • Page 20 Frame, Swingarm, & Differential Installation PART # PART DESCRIPTION TORQUE CB1972 UPPER SHOCK BRACKET BOLTS (2) 22 FT LBS CB1974 TRANSMISSION BOLTS (4) 45 FT LBS CB1972 ROLLOVER BRACE BOLTS (4) 22 FT LBS Fig. 1 UPPER SHOCK BRACKET PREP & INSTALLATION Shock Bracket 1.
  • Page 21 Frame, Swingarm, & Differential Installation Fig. 1 SWINGARM PREPARATION 1. Lube the bearing bores of the Swingarm (left Ball Bearing (2) and right side) with Anti-Seize. 2. See Fig. 1. Press two bearings into L.S. of swing arm, using bearing press tool; then install snap ring to outside ring of bearing.
  • Page 22 Frame, Swingarm, & Differential Installation PART # PART DESCRIPTION TORQUE S001335 SWINGARM PIN 65 FT LBS CB1971 SWINGARM ADAPTOR PLATE BOLTS (4) 35 FT LBS Fig. 1 SWINGARM INSTALLATION 1. See Fig. 1. Place protector plate in front of oil Protector Plate filter as shown.
  • Page 23 Frame, Swingarm, & Differential Installation PART # PART DESCRIPTION TORQUE LOWER SHOCK BOLTS (2) 54 FT LBS 10. Secure bottom of shock to swingarm as shown Fig. 4 using (2) OEM shock bolts, (4) OEM bushings, and (2) nylock nuts. Tighten using 17mm socket.

  • Page 24: Differential Installation

    Frame, Swingarm, & Differential Installation Fig. 1 DIFFERENTIAL INSTALLATION 1. See. Fig. 1. Install differential adaptor plates to swingarm as shown using (4) bolts on each side. Snug up bolts using 17mm socket. Leave loose enough for adjustment. • (2) Differential Adaptor Plate (S001199) Right Side •...
  • Page 25 Frame, Swingarm, & Differential Installation Fig. 4 4. See. Fig. 1. Using differential hoist, install differential assembly thorugh belt and attach to adaptor plates as shown using (3) bolts. Snug up bolts using 17mm socket. Leave loose enough for adjustment. •...
  • Page 26 Frame, Swingarm, & Differential Installation Fig. 7 See. Fig. 7. Remove LH front plate hardware and install tapered washers into holes on LH side before installing brace. • (2) Tapered Washers– S001784 • (1) Differential Brace– S001840 See. Fig. 8. Bolt rear half of differential brace to differential housing.
  • Page 27 Frame, Swingarm, & Differential Installation Fig. 1 DIFFERENTIAL ALIGNMENT & BELT TENSIONING 1. Snug up the differential to adaptor plate bolts us- ing 17mm socket then loosen for alignment pur- poses. 2. See. Fig. 1. Using square, center differential from side to side.
  • Page 28 Frame, Swingarm, & Differential Installation PART # PART DESCRIPTION TORQUE CB1973 ADAPTOR PLATE TO DIFF BOLTS (6) 55 FT LBS CB1973 ADAPTOR PLATE TO SWINGARM BOLTS (8) 55 FT LBS CB1242 FRONT DIFFERENTIAL BRACE BOLT (1) 35 FT LBS LH FRONT DIFFERENTIAL BRACE BOLTS 17 FT LBS Fig.
  • Page 29 Frame, Swingarm, & Differential Installation PART # PART DESCRIPTION TORQUE TAKE OFF SECONDARY SHOCK BOLTS (2) 35 FT LBS SECONDARY SHOCK INSTALLATION 1. See Fig. 1. Install (1) secondary shock to up- Fig. 1 per shock mount bracket as shown using (1) nylock nut, (2) spacers, and (1) take off trans- mission bolt.
  • Page 30 Brake System Installation Fig. 1 1. Disconnect the ABS connector. 2. See Fig. 1. Remove OEM rear brake line from bottom of proportioning valve as shown using 10mm tube wrench. 3. Loosen OEM reservoir cap to relieve the brake system of vacuum and to let the fluid drain us- ing 5/16”...
  • Page 31 Brake System Installation PART # PART DESCRIPTION TORQUE CB1972 ABS MODULE BOLTS (2) 22 FT LBS Fig. 4 9. See Fig. 4. Bend proportioning valve mount at weld to 90 degrees as shown using pliers. 10. See Fig. 5. Re-attach ABS module to frame as shown using (2) bolts (CB1972) and (1) nut OEM Bolt and Clamp...
  • Page 32 Brake System Installation Brake Lines Fig. 1 1. See Fig. 1. Attach OEM brake lines to swin- garm clamp as shown. 2. See Fig. 2. Install (3) cable ties (CT1015) to OEM brake lines as shown. • (3) Cable Tie (CT1015) 3.
  • Page 33 Brake System Installation PART # PART DESCRIPTION TORQUE CB1095 BRAKE “T” BOLT (1) 12 FT LBS BANJO BOLT (2) 18 FT LBS BANJO BOLT (1) 18 FT LBS Fig. 4 5. See Fig. 4. Install brake line to left side. Tighten using 7/16”...
  • Page 34 Brake System Installation PART # PART DESCRIPTION TORQUE CB1977 CABLE CLAMP BOLT (1) 22 FT LBS PARK BRAKE INSTALLATION Fig. 1 1. Install (1) Park Brake Bracket to frame using (2) Bolts. Hand tighten only at this time. • (1) Park Brake Bracket (S001357) •...
  • Page 35 Brake System Installation PART # PART DESCRIPTION TORQUE CB1977 CABLE CLAMP BOLT (1) 22 FT LBS Fig. 4 6. See Fig. 4. Route lower park brake cable to right side of trike as shown and attach to brake caliper using clevis pin washer and cotter key. Install washer under head of clevis pin.
  • Page 36 Brake System Installation Fig. 7 10. See Fig. 7. Secure brake cables to left side of trike as shown using (4) T-Stud Clips. • (4) T-Stud Clip (S001480) 11. See Fig. 8. Secure brake cables to left side of trike as shown using (2) High Temp Cable Ties.

  • Page 37: Brake Bleeding

    Brake System Installation Fig. 1 BRAKE BLEEDING Note: Before the brake bleeding process be- gins, make sure that the piston moves out so there is no clearance between the pads and ro- tor. Otherwise bleeding will not be achievable. 1. Fill brake fluid reservoir with DOT 4 brake fluid. 2.
  • Page 38 Brake System Installation PART # PART DESCRIPTION TORQUE CB1995 CALIPER BOLTS (4) 35 FT LBS Fig. 4 7. Again, using the numbered sequence as shown in. Attach 10mm wrench and brake bleeder to bleeder screw. 8. SLOWLY and EVENLY pump the brake pedal 7-8 times and hold the pedal down after the last pump.