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lehman Trikes Renegade Installation Instructions Manual

1997-2001 h-d touring models
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1997-2001
H-D TOURING MODELS
INSTALLATION
INSTRUCTIONS
*1997-01 MODELS REQUIRE BELT UPGRADE
December 2013
1997-2001 FLH Renegade– Rev. 3

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  • Page 1 1997-2001 H-D TOURING MODELS INSTALLATION INSTRUCTIONS *1997-01 MODELS REQUIRE BELT UPGRADE December 2013 1997-2001 FLH Renegade– Rev. 3...
  • Page 2 Renegade Torque Specifications Final Trike Inspection *Notes before starting conversion *For 1997-01 models, the standard Lehman Renegade conversion will not accommodate the original 1-1/2” final drive belt. The following belt replacement is required to properly complete the Renegade installation. Model...
  • Page 3 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. 1997-2001 FLH Renegade– Rev. 3...
  • Page 4 Califor- nia. 2. Label should be placed on left side of swingarm 1/2” from rear weld. 3. Make sure label correlates with correct model year. 1997-2001 FLH Renegade– Rev. 3...
  • Page 5 • Differential with brakes • Tires mounted on rims • Boxed swingarm • Lehman frame • Hardware box containing smaller parts and bolt bags • Warranty Book • Owner’s Manual • Packing/parts list Fig. 1 1997-2001 FLH Renegade– Rev. 3...
  • Page 6 MODULAR DIFFERENTIAL LS2009– 1997-2001 SWINGARM LF2084-FRAME 1997-2001 FLH Renegade– Rev. 3...
  • Page 7 22. Remove pivot shaft nut from LH side of bike. Remove two swingarm brackets. Tap shaft out of swingarm and remove from RH side. Swingarm may now be removed. 23. For 1997-2001 models, fuel tank must be removed. Refer to HD service manual for procedure. 1997-2001 FLH Renegade– Rev. 3...
  • Page 8 242 on threads. Torque rear swingarm (fork) pivot shaft to 45 ft.-lbs. 4. Re-install rear swingarm (fork) brackets. Apply Loctite 242 and torque bolts to 42 ft.-lbs. 5. Be sure swingarm moves freely up and down with no side to side movement. Light resistance is normal. 1997-2001 FLH Renegade– Rev. 3...
  • Page 9 A slightly rough sur- face is desirable. Note: Use a generous amount of glue (Loctite 330) to fill between bracket and frame. Apply glue to plate and spray activator onto glue rather than frame. Fig. 2 Fig. 3 1997-2001 FLH Renegade– Rev. 3...
  • Page 10 Use 2-3 “C” clamps to hold bracket to frame. Use 1 “C” clamp to hold side reinforce- ment plates (LP1200) to frame 7. Allow adhesive to cure for 24 hours. 8. Installation may proceed while glue cures. 9. Attach link assembly to upper frame mounting bracket. Fig. 4 1997-2001 FLH Renegade– Rev. 3...
  • Page 11 13. Reroute any wire harnesses around or behind bracket. The coil wire on a fuel-injected model will run over top edge of bracket. Note: Make sure harnesses are not pinched when fuel tank is reinstalled. Fig. 5 1997-2001 FLH Renegade– Rev. 3...
  • Page 12 6. Apply Loctite to supplied 3/8” x 1 1/2” flanged head bolt. Install supplied bolt with original flat wash- ers to frame. Torque bolt to 42 ft.-lbs. 7. Remove front engine mount; apply Loctite to threads and re-install nut. Torque bolt to 45-54 ft.-lbs. 1997-2001 FLH Renegade– Rev. 3...
  • Page 13 Leave hardware loose. 3. See Fig. 1 and 2. Install 3/8” nut to adjuster bolt and thread into adapter plate from backside. Run bolt completely into adapter plate. Fig. 2 1997-2001 FLH Renegade– Rev. 3...
  • Page 14 4. See Fig. 3 and 4. Loosely install hardware to Fig. 3 pinch blocks before installing differential to swingarm. Fig. 4 1997-2001 FLH Renegade– Rev. 3...
  • Page 15 10. See Fig. 6. Carefully slide belt over pulley. Fig. 6 Reinstall housing plates with original hardware us- ing Loctite 242. Install all hardware before tighten- ing. Torque hardware to 17 ft. lbs Install belt 1997-2001 FLH Renegade– Rev. 3...
  • Page 16 9. After all adjustments are made, tighten adjuster lock nuts and tighten pinch block bolts. Tighten pinch blocks in a crosswise pattern. Go over both sides at least 2 times to seat blocks over pins. Torque bolts to 25 ft. lbs. 1997-2001 FLH Renegade– Rev. 3...
  • Page 17 3. See Fig. 2. Install (2) braided brake lines to rear calipers as shown. Torque bolts to 16 ft. lbs. • (2) M10 Banjo Bolt– CB6001 • (4) M10 Banjo Washers- GC6002 4. Secure brake lines to swingarm with cable ties. 1997-2001 FLH Renegade– Rev. 3...
  • Page 18 11. Install master cylinder reservoir cap with new Attach cable screws. Do not over tighten cap screws. Park Brake Assembly 1. See Fig. 4. Install park brake cable to caliper brackets. Secure cable to bracket with cir-clip provided on cables. 1997-2001 FLH Renegade– Rev. 3...
  • Page 19 11. Adjust park brake cables at handle to engage at 3–4 clicks. Note: Take up slack in cables before tightening ends to ensure good adjustment range with Attach clamp threaded end of brake cables. Fig. 8 Cable retaining nuts Adjuster nuts 1997-2001 FLH Renegade– Rev. 3...
  • Page 20 6. See Fig. 3. Raise differential and install top of shock using 1/2” X 2 1/4” bolt, lock washers and (1) washer under head of bolt. Shock should run parallel to frame tube when viewed from rear. Torque shock bolts to 40 ft.-lbs. Fig. 3 1997-2001 FLH Renegade– Rev. 3...
  • Page 21 14. Attach grab handle to imitation fender using 1/4” X 1” bolts, 1/4” fender washers and original flanged nuts. • (1) Grab Handle– LH1026 • (2) 1/4” x 1” Bolts– CB1085 • (2) 1/4” Fender Washers– CW2108 • (2) OEM Flange Nuts 1997-2001 FLH Renegade– Rev. 3...
  • Page 22 Note: Pipe length may need to be adjusted accord- ing to the following: • With or without light bar • Rare occurrences of body alignment Fig. 3 RH Drop pipe 1997-2001 FLH Renegade– Rev. 3...
  • Page 23 Fig. 4 Item Part # Qty. Desc. Oem Part Right Exhaust Pipe Left Exhaust Pipe GC1001 Exhaust Clamp CB1164 5/16” x 1 1/4” NF Gr. 8 Bolt CN3009 5/16” NF Gr. 8 Bolt 1997-2001 FLH Renegade– Rev. 3...
  • Page 24 Use appropriate tool for crimping terminals to wires. (Mac Tools– TCT1028). 4. See Fig’s 3 & 4. Inspect crimps before installing into connector. Distortion should be minimal. Fig. 3 Female Terminal Insulation crimp Wire core crimp 1997-2001 FLH Renegade– Rev. 3...
  • Page 25 Attach wire as follows- • White wire on light to Black wire on trunk harness • Gray wire on light to Red wire on trunk harness 9. Seal wiring through door with silicone (Ultra Black). 1997-2001 FLH Renegade– Rev. 3...
  • Page 26 (Mac Tools– TCT1028, Blue Point– PWC47 or H-D 41609). 4. See Fig. 5. Inspect crimps before installing into connector. Distortion should be minimal. Fig. 4 Fig. 5 Insulation crimp Male terminal Wire core crimp Female terminal 1997-2001 FLH Renegade– Rev. 3...
  • Page 27 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. 6 Wiring Diagram Orange/White Tracer Red/White Tracer Brown Black Purple Orange/White Tracer Blue Black 1997-2001 FLH Renegade– Rev. 3...
  • Page 28 • (2) Foam Sealing Washers FG1002 • (2) 1/4” Flat Washers- CW2007 • (2) 1/4” Lock Nuts- CN3041 10. Tighten 5/16” hardware into place on trike frame. 11. Verify all body mounting hardware is tight. 1997-2001 FLH Renegade– Rev. 3...
  • Page 29 M6 flat washer under cable end. cable end • (2) 1/4” x .438 Shoulder Screws– CB1151 • (2) M6 Flat Washer– CW2172 7. See Fig. 3.Torque shoulder screws to 6 ft-lbs using 5/32” Allen socket. 1997-2001 FLH Renegade– Rev. 3...
  • Page 30 • (2) 1/4” x 1/2” Bolts– CB1075 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 •...
  • Page 31 Door Adjustment Procedures Fig. 6 1997-2001 FLH Renegade– Rev. 3...
  • Page 32 Fig. 7 Fig. 8 1997-2001 FLH Renegade– Rev. 3...
  • Page 33 1997-2001 FLH TOUR PACK MOUNTING 1. Bottom of tour pack has ribs that match up with ribs on Renegade body. 2. Take flat weather seal (1/16” X 1 1/2” X 24”) and cut two pieces 10 1/2” long. Place foam seals on three center ribs with short left-over piece on middle rib.
  • Page 34 3. Reflectors can be installed to body. See Fig. 1. Install rear reflectors 3” below taillights on body. See Fig. 2. Install side reflectors using wheel center caps as a reference, 1/4” above wheel opening on body. Fig. 1 Fig. 2 1997-2001 FLH Renegade– Rev. 3...
  • Page 35 The front and top motor mounts may need to be adjusted to achieve correct vertical alignment, and to center differential housing to frame. To do this, trike must be sitting on a level surface. Refer to H-D service manual for correct procedure on adjusting motor mount assemblies. 1997-2001 FLH Renegade– Rev. 3...
  • Page 36 40 ft. lbs. Wheels/aluminum 85 ft. lbs. Wheels/wire 75 ft. lbs. Caliper to bracket bolts 38 ft. lbs. Caliper bracket to axle flange bolts 38ft. lbs. Differential housing plate bolts 17ft. lbs. Axle tube bolts 38ft. lbs 1997-2001 FLH Renegade– Rev. 3...
  • Page 37 11. Shocks set @ mid setting □ □ 12. Heat shields, side covers □ □ 13. Renegade/Lehman badge installed □ □ 14. Accessories (if applicable) □ □ 15. No paint defects □ □ 16. Warranty/owner’s manual included □ □ 1997-2001 FLH Renegade– Rev. 3...

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