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lehman Trikes Raider XL 2014+ Installation Instructions Manual

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2014+ XL MODELS
*Will not fit XR1200 models
*Nightster, Forty-Eight and Iron 883 models may require additional modifications
INSTALLATION INSTRUCTIONS
Dec, 2014
*All 2014 Models require changes to the BAS settings in the Body Control Module
2014+ XL Raider

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Summary of Contents for lehman Trikes Raider XL 2014+

  • Page 1 2014+ XL MODELS *Will not fit XR1200 models *Nightster, Forty-Eight and Iron 883 models may require additional modifications INSTALLATION INSTRUCTIONS Dec, 2014 *All 2014 Models require changes to the BAS settings in the Body Control Module 2014+ XL Raider...

  • Page 2: Brake System

    Lehman Trikes® assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Lehman Trikes® reserves the right to revise and improve its products as it sees fit.

  • Page 3: Safety Information

    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 & CAUTION SYMBOLS This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
  • Page 4 ILLUSTRATIONS LB6404 LB6421 RH TRANSMISSION LH TRANSMISSION BRACE BRACE S001917 SWINGARM S001928 S002187 MASTER EXHAUST CYLINDER BRACKET HANGER 2014+ MODELS LB6408 RH FRONT BODY LB6407 BRACKET LH FRONT BODY LB6412 BRACKET PARK BRAKE BRACKET LS6404 LB6422 SHORT BODY EXHAUST AND MOUNT SPACER BODY BRACKET LB1294...
  • Page 5 PREPARING THE MOTORCYCLE NOTE: Refer to H-D service manual for detailed instructions on the proper removal of OEM parts. Fig. 1 1. Place motorcycle on motorcycle lift. Make sure bike is standing straight up and handlebars are RH foot peg centered.
  • Page 6 EXHAUST MODIFICATION 1. See Fig. 1. Cut crossover pipe even with end Fig. 1 of front head pipe as shown. 2. See Fig. 2. Install steel plug with high temp silicone into remaining crossover section on Cut crossover pipe here front head pipe.
  • Page 7 MASTER CYLINDER INSTALLATION Fig. 1 1. See Fig. 1. Install master cylinder bracket to motorcycle frame using the following hardware. Use Loctite 242 and Torque to 20 ft. lbs. At- Attach bracket to frame tach OEM brake line and clamp to LH side as shown.
  • Page 8 MASTER CYLINDER INSTALLATION Fig. 4 7. See Fig. 4. Remove Allen bolt from RH side of frame below side cover. Remove OEM bolt 8. See Fig. 5 . Install master cylinder reservoir and mounting bracket to motorcycle frame us- ing the following hardware. Reuse OEM Allen bolt to mount bracket to frame.

  • Page 9: Swingarm Installation

    SWINGARM INSTALLATION Fig. 1 1. Press bearing assemblies out of HD swingarm using an appropriate press collar or socket. Re- fer to HD service manual for proper procedures. 2. Press bearings into Lehman swingarm. Bearings should bottom out inside swingarm collar. NOTE: Make sure there is no dirt or powder coat material in the bearing bore where the bearing needs to seat.
  • Page 10 SWINGARM INSTALLATION Fig. 4 5. See Fig. 4. Install RH transmission brace (LB6404) using Loctite 242 with original bolt in lower hole only. Leave this bolt loose until swingarm is in place. 6. Slide swingarm over transmission braces and line up holes on both sides. 7.
  • Page 11 MOTOR MOUNT INSTALLATION 1. Remove original upper and lower stabilizer links Fig. 1 from front of motorcycle. Remove lower bracket at frame. Remove upper bracket at cylinder head. LB6402 2. See Fig. 1. Install two bushings into each side of new motor mounts.
  • Page 12 DIFFERENTIAL INSTALLATION 1. See Fig. 1. Install adjuster bolts and jam nuts to Fig. 1 each side of swingarm as shown. Bolt head will face front of bike. Thread bolt into swin- garm just enough to thread nut on backside. •...
  • Page 13 DIFFERENTIAL INSTALLATION NOTE: Once proper belt tracking is achieved the Fig. 1 shocks will need to be removed. RH Shock 1. Temporarily install shocks to trike as shown. 2. See Fig. 1. Install spacer between shock and Spacer frame on upper RH side. Use 1/2” x 2-3/4” bolt and 14mm flat washer.
  • Page 14 BELT TENSIONING 1. Using adjuster bolts, push differential assembly back until belt has about 3/8” slack with 10 lbs. Fig. 1 pressure at midpoint of bottom run. Measure between swingarm and differential to ensure that both sides are equal distance. 2.
  • Page 15 STABILIZER INSTALLATION 1. See Fig’s 1 thru 3. Install differential brace to Fig. 1 trike as shown adjusting as necessary for fit- ment. Attach to housing and swingarm using the following hardware. • (1) M10 X 35 Bolt- CB1607 • (1) M8 X 40 Bolt- CB1975 •...
  • Page 16 BRAKE INSTALLATION 1. See Fig. 1. Attach brass block to swingarm Fig. 1 using the following hardware. Insert spacer under brass block. • (1) Brass Block– S002123 • (1) 1/4” x 3/4” Bolt– CB1100 • (1) 1/4” Flat Washer- CW2005 •...
  • Page 17 BRAKE INSTALLATION 5. See Figs. 3 & 4. Install brake lines to calipers Fig. 3 with the following hardware. Torque banjo bolts to 16 ft. lbs. • (1) M10 Banjo Bolt– CB6001 • (2) Banjo Washer– GC6002 6. See Figs. 3 & 4. Secure brake lines to swin- garm with brake line routing clips in swingarm.
  • Page 18 PARK BRAKE INSTALLATION Park Brake Assembly Fig. 1 1. See Fig. 1. Install park brake cables to caliper brackets. Secure cable to bracket with cir-clip provided on cables. 2. See Fig. 2. Attach park brake bracket with RH body mount bracket to trike using original foot peg mounting holes using the following hard- ware.
  • Page 19 PARK BRAKE INSTALLATION 4. See Fig. 4. Remove snap ring from one side of Fig. 4 pin on park brake lever. Hold handle on its side and push release button at end of handle to allow pin to slide out. •...
  • Page 20 EXHAUST SYSTEM INSTALLATION Fig. 1 1. Reinstall H-D head pipes onto bike. 2. See Fig. 1. Install adapter plate to muffler bracket using the following hardware. Leave hardware loose. • (1) Muffler Bracket– S001903 • (1) Adapter Plate– S002175 • (2) 5/16”...
  • Page 21 EXHAUST SYSTEM INSTALLATION 4. See Fig. 3. Install mufflers to bracket using Fig. 3 original mounting hardware. 5. Install Lehman pipes into H-D mufflers. Short pipe will go on RH muffler (rear head pipe) and long pipe will go on LH muffler (front head pipe).
  • Page 22 BODY MOUNT INSTALLATION 1. See Fig. 1. Attach rubber bumper to body sup- Fig. 1 port bracket using 1/2”bolt. Place a 1/2” washer on both sides of rubber bumper and secure with thin 1/2” lock nut. Place a 1/2” jam nut on bolt Lock nut and thread bolt into bracket until distance be- 1-1/4”...
  • Page 23 BODY PREPARATION 1. See Fig. 1. Remove base from turn signals and Fig. 1 mount to body in designated holes using the following hardware. • (2) Turn Signals– OEM • (2) 5/16” x 1-1/4” Bolts– CB1165 • (2) 5/16” Lock Washers– CW2045 •...
  • Page 24 BODY PREPARATION NOTE: Do not over tighten taillight mounting Fig. 1 hardware. Damage to housing may occur. 1. See Fig 1 & 2. Mount taillight assemblies to body with gaskets. Attach ground wire to stud with flange nut after taillight mounting hard- ware is installed.
  • Page 25 DOOR INSTALLATION 1. See Fig. 1. Install door hinges to body using Fig. 1 8/32” oval-head screws. • (2) Door Hinges– GH0910 • (4) 8/32” x 5/8” Oval Screws– CS4021-1 2. See Fig. 2. Install door hinge mount clips to door using 6/32”...
  • Page 26 DOOR INSTALLATION 5. Test door seal by closing door with a strip of pa- Fig. 4 per at various locations around door. Door seals properly when paper has significant drag. 6. See Fig. 4. Install stop cable to one hinge as- Install cable sembly.
  • Page 27 BODY INSTALLTION 1. Lay down top body support so that it is level with Fig. 1 frame. 2. See Fig. 1. Slide body around RH bracket and up over HD frame. Install seat center post with sup- plied 5/16” fender washer on bolt head. Leave this bolt loose.
  • Page 28 BODY INSTALLTION 10. See Fig. 4. Before drilling RH bracket holes, Fig. 4 push exhaust away from differential hous- ing. Exhaust pipes should be at least 1” away from housing (verify pipes are straight). A wedge can be used to hold pipes in place while you tighten bracket to frame and drill two 1/4”...
  • Page 29 BODY WIRING NOTE: Use appropriate tool for crimping terminals to wires. (Mac Tools– TCT1028, Blue Point– PWC47 or H-D 41609). 1. See Fig. 2. Inspect crimps before installing connector. Distortion should be minimal. 2. Install trike wire harness (S001922) to body clips on underside of body. Fig.
  • Page 30 BANK ANGLE SENSOR INSTALLATION Fig. 1 WARNING- 2014+ Models: Before the trike in- Mount BAS stallation is complete, the Bank Angle Sensor bracket to seat (BAS) setting must be changed in the Body post under body Control Module (BCM) from “Internal” to “External”.
  • Page 31 BANK ANGLE SENSOR INSTALLATION Fig. 4 6. See Fig. 4. Route green wire along wire to backside off BCM connector. Route Green wire to backside connector 7. See Fig. 5. Install green wire to B4 location in BCM connector as shown. Verify the terminal locks into place.
  • Page 32 GRAB HANDLE INSTALLATION 1. See Fig. 1. Once body is in place and Fig. 1 secure, install support bracket to motorcy- cle frame using the following hardware. Attach support • bracket to frame (1) Support Bracket- S001942 and top support •...
  • Page 33 FINAL ASSEMBLY 1. Install reflectors to body. Fig. 1 • (4) Reflectors– S001045 2. See Fig. 1. Two red reflectors will be cen- tered on side of fenders and a 1/4” up from edge. They should be located directly above wheel center cap on body. 3.
  • Page 34 STEERING NECK NOTE: Steering head should be adjusted after Fig. 1 conversion is complete. Consult H-D service manual for proper adjustment procedure. 1. Check steering to ensure it has not been previ- ously adjusted. 2. See Fig. 1. Loosen lower fork bracket pinch bolts.
  • Page 35 FINAL TRIKE INSPECTION Good Rework Reflectors installed Light operation □ □ Park brake operation □ □ □ □ Engine/Transmission oil levels Belt tension 5/16”-3/8” □ □ Wheel torque 85 ft-lbs. (75 ft. lbs-wire) □ □ Rear tire pressure 26 psi □...
  • Page 36 TORQUE SPECIFICATIONS Engine stabilizer links 33 ft. lbs LH transmission brace 110 in. lbs RH transmission brace-lower bolt 33 ft. lbs Swingarm pin 70 ft. lbs Caliper mounting bolts 38 ft. lbs Body mount brackets to frame 33 ft. lbs Banjo bolts 16 ft.
  • Page 37 HARDWARE GB6401 BOLT BAG- SWINGARM/BRAKES PART # DESCRIPTION CB1116 BOLT 1/4 X 2 1/2 NC SOCKET HD Primary cover- center hole 2004-2005 models CB1122 BOLT 1/4X2 3/4 NC SOCKET HD ZN Primary cover- top and bottom holes CB1255 BOLT 3/8 X 2 NC PLATED Front body mount brackets CC3106 CLEVIS PIN 5/16 X 19/32...
  • Page 38 HARDWARE GB6403 BOLT BAG BODY/EXHAUST 04+ XL RAIDER PART # DESCRIPTION CB1084 BOLT, 1/4 X 3/4 NC BUTTON HEAD SS License plate light to bracket CB1086 BOLT, 1/4X 1 NC BUTTON HEAD SS Rear body mounts LH & RH CB1096 BOLT, 1/4X 1 1/2 NC BUTTON HEAD SS License plate bracket to door CB1161...