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Lehman Renegade 2009 Installation Instructions Manual
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Lehman Renegade 2009 Installation Instructions Manual

H-d touring models
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Powered by Harley Davidson
2009-2013
H-D TOURING MODELS
INSTALLATION
INSTRUCTIONS
*FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE
December 2013
Rev. 8

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Summary of Contents for Lehman Renegade 2009

  • Page 1 Powered by Harley Davidson 2009-2013 H-D TOURING MODELS INSTALLATION INSTRUCTIONS *FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE December 2013 Rev. 8...
  • Page 2 Read the text and become familiar with the procedures before starting any work. Some procedures re- quire the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this manual, please contact Lehman Trikes before ®...

  • Page 3: Safety Information

    For this information, refer to the factory service manual. The information in these instructions is provided to Lehman Trike dealers. It is proprietary to Lehman Trikes, Inc. and provided solely for use by dealers. Any unauthorized duplication or distribution is a vio- lation of international copyright law.
  • Page 4 SECTION BREAKOUT UNPACKING THE KIT PREPARING THE MOTORCYCLE REMOVING HD SWINGARM INSTALLING LEHMAN SWINGARM TOP MOTOR MOUNT LINK CARRIER/PULLEY DIFFERENTIAL-LEFT HALF DIFFERENTIAL-RIGHT HALF BELT TENSIONING/TRACKING BRAKE SYSTEMS FRAME/SUSPENSION EXHAUST ELECTRICAL BODY REPLACEMENT PARTS TORQUE SPECIFICATIONS FINAL TRIKE INSPECTION HARDWARE DESCRIPTION/BOLT BAG BREAKDOWN...

  • Page 5: General Information

    GENERAL INFORMATION General Safety Information This kit is designed to be installed by a competent technician. Improper installation can affect the safe operation of your trike, which could also result in serious injury or death. Make sure you have a complete understanding of the work to be preformed. Unqualified installers are urged to have the unit installed by a trained technician.
  • Page 6 ILLUSTRATIONS SWINGARM BUSHING- SWINGARM BUSHING-LT- SWINGARM BUSHING-RT- S001315 (09-10 MODELS) S001346 S001347 FRAME BRACE-S001266 FRAME BRACE-S001268 BODY BRACE-LB1235 LICENSE PLATE BRACKET-LB1207 ADAPTER PLATE-LP1038 2009-2013 FLH RENEGADE...
  • Page 7 ILLUSTRATIONS CONTINUED MODULAR DIFFERENTIAL GM0142 MOTOR MOUNT LINK LS2013-2002+ SWINGARM S001271-FRAME 2009-2013 FLH RENEGADE...
  • Page 8 PREPARING THE MOTORCYCLE The following instructions are a guide to preparing the motorcycle to accept the Lehman Trike Con- version Kit. This will assist you in removing the necessary parts to install the kit. Refer to H-D ser- vice manual for detailed procedures on motorcycle disassembly.
  • Page 9 REMOVING HD SWINGARM 2009-2010 MODELS Fig. 1 1. See Fig. 1. Remove (2) bolts to free swingarm LH Fork bracket bolts fork bracket from left side of motorcycle frame. 2. Release rear brake line hose and rear wheel speed sensor (if ABS equipped) from cable clips on right side of swingarm.
  • Page 10 REMOVING H-D SWINGARM Fig. 4 TRIMMING EXHAUST NOTE: Trimming rear head pipes is more convenient while swingarm is removed from frame. 1. Remove LH and RH rear heat shields. 2. See Fig. 4. Using an appropriate cutting tool, cut 1 5/8” from end of both rear head pipes. 3.
  • Page 11 See Fig. 3. Install RH swingarm reinforcement bushings (S001347 & S001315) into original rubber mounts. Be sure to align offset in mount and bushings. Install Lehman swingarm with word “TOP” (stamped into swingarm collar) facing upward. See Fig. 3. Assemble parts for LH side (S001346 & S001315) as shown.
  • Page 12 NOTE: Make sure swingarm bore is clean where bearing will be pressed in. 2. Press bearings into Lehman swingarm following H-D service manual procedure (H-D tool # HD- 45327). H-D tool will set bearings at correct location in Lehman swingarm collar.
  • Page 13 OEM Top motor mount link proper removal and installation procedures for all motor mounts. Fig. 2 4. Adjust Lehman motor mount link to same dis- Lehman link installed tance from center of hole to center of hole as OEM motor mount link.
  • Page 14 DIFFERENTIAL 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 swin- garm as shown with park brake bracket mounted to lower holes. Leave hardware loose. 3.
  • Page 15 DIFFERENTIAL CONTINUED Fig. 3 4. See Fig. 3 and 4. Loosely install hardware to pinch blocks before installing differential to swingarm. NOTE: Shock plate orientation is different on 09+ models. Make sure shock mount hole on rear of plate is towards the top. Hole towards top Fig.
  • Page 16 DIFFERENTIAL CONTINUED Fig. 5 5. Support swingarm with jack stands. 6. See Fig. 5. With differential assembly on lift, Remove plates slide belt over LH axle tube and against center housing. 7. See Fig. 5. Set differential assembly on swin- garm adapter plates.
  • Page 17 DIFFERENTIAL CONTINUED 12. See Fig. 10. Remove RH front plate hardware Fig. 7 and install tapered washers (S001784) into holes on RH side before installing brace. 13. Bolt rear half of differential brace to housing using bolts (CB1939). 14. See Fig. 11. Bolt front half of differential brace to top of swingarm gusset with a 3/8”...
  • Page 18 BELT TENSIONING AND TRACKING 1. Center differential to motorcycle frame– this is critical for proper body and seat pan alignment. Make sure distance is within 1/16” from side to side. 2. Level swingarm to motorcycle frame. This will help achieve proper ride height and is critical for proper belt tensioning.
  • Page 19 BRAKE SYSTEMS Fig. 1 Disc Brakes OEM line CAUTION: Brakes are a critical safety compo- nent 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.
  • Page 20 BRAKE SYSTEMS CONTINUED Note: Be sure you have correct model year res- Fig. 3 ervoir extension pack before proceeding (Reminder: packs are labeled 1997-2007 and Supplied cover screws 2008+). 5. See Fig. 3. Remove original master cylinder reservoir cap screws and discard. Install ex- tension to master cylinder with new extension screws.
  • Page 21 BRAKE SYSTEMS CONTINUED 5. See Fig. 7. Remove snap ring from one side of large Fig. 7 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. 6.
  • Page 22 BRAKE SYSTEMS-ABS MODELS Fig. 1 ABS Systems From ABS to caliper (silver) 1. See Fig. 1. Disconnect OEM rear brake line (black) From Mas. Cyl. to ABS (black) from ABS unit “MR”. Route brake line along lower frame tube and above swingarm. This line will be used for the rear brake system.
  • Page 23 BRAKE SYSTEMS-ABS MODELS CONTINUED Fig. 5 Note: Items 7-11 can be performed during Neck Race Preload check. 7. Remove outer fairing (refer to HD service manual). Caution: Disabling ABS light will also disable cruise control light. 8. See Fig. 5. Disable ABS warning light by cutting or- ange wire with white stripe.
  • Page 24 FRAME AND SUSPENSION Fig. 1 1. The holes in front of Lehman frame line up with HD shock mount holes. 2. Position Lehman frame above differential and inside motorcycle frame, lining up mounting holes. 3. See Fig. 1. Install the following hardware in the front frame mounting holes.
  • Page 25 FRAME AND SUSPENSION Fig. 4 7. Use original cross-over airline to connect “tee” to air valve. Use new air line to connect two shocks to- gether. 8. See Fig. 4. Air valve plate for front and rear shocks must be removed and relocated. Recommended loca- tion is on right side of trike behind air deflector in loca- tion shown.
  • Page 26 5. Slide mufflers with clamps in place over Lehman extension pipes. 6. Ensure mufflers are even on both sides. 7. Torque exhaust clamps to 40 ft.-lbs. 8. Use OEM mounting hardware to secure muffler to mounting bracket on Lehman frame. Torque bolts to 144 in.-lbs. Fig. 1 ITEM PART # QTY.
  • Page 27 LIGHTS AND WIRING Lights and Wiring Fig. 1 Caution: Use care with painted surfaces 1. See Fig. 1. Drill 15/16” hole for turn signal on flat below taillight. Center turn signal with inside edge of taillights. Mount H-D turn signals using original bolts with supplied washers (CW2001).
  • Page 28 LIGHTS AND WIRING 5. See Fig. 5. Install license plate bracket to door Fig. 5 with 1/4” x 1” bolts, washers, lock nuts and rubber Install rubber washers washers. Use rubber washers between bracket between bracket and door and door. Install U-nuts to bracket •...
  • Page 29 LIGHTS AND WIRING CONTINUED Fig. 1 Renegade Wiring Harness 1. See Fig.’s 1-2. Attach wiring harness to body Taillight connector clips on underside of body. The Purple turn sig- nal wire will go to the LH side. The Brown turn signal wire will go to the RH side.
  • Page 30 LIGHTS AND WIRING CONTINUED Fig. 8 6 position connector for trailer-GH0023-2 License plate connector- GH0023-3 Right brake light-GH0023-3 8 position connector under seat-GH0023-1 Left brake Right turn signal- light-GH0023-4 GH0023-4 Included in bag Left turn signal- GH0023-4 Light bar- GH0023-5 Fig.
  • Page 31 SIDE COVER MODIFICATION 1. See Fig. 1. Place side cover template Fig. 1 (S001324) as shown with a 90° bend at center; Set template firmly against peg make sure template rests firmly against mount- ing peg. 2. See Fig. 2. Mark grommet access hole and side-cover cut-out as shown.
  • Page 32 WARNING: To meet DOT and MOT require- Underside of frame-seat shell hardware ments one of the following must be installed on all Lehman Trikes: stock grab handles, stock grab strap or Lehman-supplied grab handles. Please contact Lehman Trikes if you require replacement grab handles.
  • Page 33 16. Tighten body mount brackets to frame straps. Torque bolts to 8 ft.-lbs. Fig. 5 17. See Fig. 5. Install upper body braces (LB1235) by attaching slotted side on top of Lehman frame us- ing the following hardware. Leave hardware loose. • (2) Body Brace– LB1235 •...
  • Page 34 TOUR PACK Fig. 1 NOTE: See Fig. 1. Adapter plate (S001307) Rearward angled ears determine rearward position and straight and 90° edges determine forward position. 1. Install tour pack adapter plate to base plate us- ing button head bolts. Torque bolts to 8 ft.-lbs. •...
  • Page 35 TRUNK DOOR Fig. 1 Trunk Door Installation Note: Lip on weather seal will face away Top of seal is flush with door opening from door opening; top of seal is flush with top of door. 1. See Fig. 1. Install door seal around edge of body, starting at center on bottom and fol- lowing trunk opening.
  • Page 36 Striker pin and bracket • (2) 1/4” Lock Washers– CW2040 14. Install Renegade badge to bottom right side of door. Install Lehman badge GB1320 to bottom left side of door. • (1) Renegade Badge– GB1324 • (1) Lehman Badge– GB1320 15.
  • Page 37 DOOR ADJUSTMENT Fig. 1 2009-2013 FLH RENEGADE...
  • Page 38 DOOR ADJUSTMENT CONTINUED Fig. 2 Fig. 18 2009-2013 FLH RENEGADE...
  • Page 39 FINAL ASSEMBLY Final Assembly 1. Install grab handle to seat shell using the following hardware. Torque bolts to 8 ft.-lbs. • (1) Grab Handle– LH1026 • (2) 1/4” x 3/4” Bolts– CB1081 • (2) 1/4” Lock Washers– CW2040 • (2) 1/4” Flat Washers– CW2005 2.
  • Page 40 STEERING NECK 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 41: Torque Specifications

    25 ft. lbs. LP1038 Adapter Plate 35 ft. lbs. Banjo bolts 16 ft. lbs. Torque link to engine/frame 33 ft.-lbs. Lehman frame, front 75 ft. lbs. Rear frame bolts 18 ft. lbs. Frame brace, top 18 ft. lbs. Frame brace, lower 52 ft.
  • Page 42 10. Trunk door seals and operates smoothly □ □ 11. Rear shocks set @ 20 psi □ □ 12. Heat shields, side covers □ □ 13. Renegade/Lehman badge installed □ □ 14. Accessories (if applicable) □ □ 15. No paint defects □ □...

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Renegade 2013