lehman Trikes Raider XL 2014+, Installation Instructions Manual

Page 1: ...ION INSTRUCTIONS Dec 2014 2014 XL MODELS Will not fit XR1200 models Nightster Forty Eight and Iron 883 models may require additional modifications All 2014 Models require changes to the BAS settings in the Body Control Module ...

Page 2: ...d or implied While every precaution has been taken in the preparation of this manual 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 This publication describes the state of this product at the time...

Page 3: ...is involved SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator by stander or person s inspecting or servicing the vehicle WARNING Indicates a potential hazard that may result in minor per sonal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage CAUTION N...

Page 4: ...ID X 5 8 LB1294 CABLE PULL BRACKET LS6404 SHORT BODY MOUNT SPACER LS6407 BODY BUSHING LS6406 BODY SUPPORT LB6402 ENGINE LINK BUSHING LL6400 ENGINE LINK LS6405 LONG BODY MOUNT SPACER LB6410 LH REAR BODY BRACKET S001917 SWINGARM S001942 BODY SUPPORT BRACKET S002187 MASTER CYLINDER BRACKET 2014 MODELS S002189 2014 SWINGARM PIN S001928 EXHAUST HANGER LB6422 EXHAUST AND BODY BRACKET S001903 MUFFLER BRA...

Page 5: ...sors before removing head pipes 10 Remove mufflers heat shields and head pipes from motorcycle Save exhaust hardware 11 Remove chrome belt cover Save cover and hard ware for reinstallation Remove belt from motorcy cle Mark belt orientation for reinstallation 12 Remove rear brake line and remove caliper 13 Remove shocks Save LH mounting bolts 14 See Fig 1 Remove rear master cylinder and RH passenge...

Page 6: ...ing crossover section on front head pipe Secure with clamp as shown 1 Steel plug S002210 1 Clamp S001600 3 See Fig 3 Cut rear head pipe in front of cross over pipe weld as shown Discard crossover pipe EXHAUST MODIFICATION Fig 1 Cut crossover pipe here Front head pipe Fig 2 Rear head pipe Cut rear head pipe here Fig 3 Front head pipe Install plug and clamp ...

Page 7: ...6210 1 3 4 Nut CN3255 3 Screw long end of link rod with 5 16 thin jam nut into master cylinder Place 5 16 lock washer on short end and screw it into HD pushrod 1 Link Rod LR6400 1 5 16 Thin Jam Nut CN3012 1 5 16 Lock Washer CW2045 4 Extend rod to raise pedal height to top Lock jam nuts into place 5 Test full stroke of master cylinder and check for binding 6 See Fig 3 Attach OEM brake line to maste...

Page 8: ...001530 1 OEM Allen Head Bolt 1 1 4 x 1 1 4 Button Head Bolt CB1094 1 1 4 Lock Nut CN3040 9 See Fig 5 Attach rubber hose to reservoir as shown using the following hardware 16 5 5 16 Rubber Hose CH1008 1 Hose Clamp CC2010 10 See Fig 6 Route brake hose from reservoir and below swingarm to master cylinder Install hose to master cylinder with hose clamp 1 Hose Clamp CC2010 MASTER CYLINDER INSTALLATION ...

Page 9: ... seat See Fig 1 3 See Fig 2 Remove top and center bolts from rear primary cover and drill out to 1 4 4 See Fig 3 Install LH transmission brace behind primary cover Install using Loctite 242 with 1 4 x 2 3 4 bolts and flat washers into top hole and 1 4 x 2 1 2 bolt and flat washer into lower hole Both bolts will thread into bracket Torque to 110 inch lbs 1 LH Transmission Brace LB6421 1 1 4 x 2 3 4...

Page 10: ...ine up holes on both sides 7 Install new swingarm pin through swingarm from RH side Apply Loctite 242 to threads and install OEM nut Torque to 70 ft lbs 1 2014 Swingarm Pin S002189 1 OEM Pivot Shaft Nut 8 Verify swingarm moves freely up and down Place a jack stand under swingarm for support Torque RH transmission brace lower bolt to 33 ft lbs SWINGARM INSTALLATION Fig 4 Install lower bolt only Fig...

Page 11: ...ll original Torx head bolts and large 3 8 fender washer under upper and lower RH bolts Use Loctite 242 Torque to 33 ft lbs 2 3 8 Fender Washers CW2048 4 On lower mount use Loctite 242 on Torx head bolts to reconnect bracket to frame Torque to 33 ft lbs 5 See Fig 3 On upper mount use Loctite 242 on Torx head bolts to frame Torque to 33 ft lbs Reinstall the engine bracket to cylinder head Torque to ...

Page 12: ...ngarm plates will sit above differen tial plates Slide differential as far forward as possible Set jack stands under axle tubes 4 Tighten pinch block hardware just enough to allow differential to slide on swingarm plates 5 See Fig 3 Remove upper lower and rear housing plates 6 See Fig 3 Carefully slide belt over front and rear pulleys 7 Reinstall housing plates with original hardware using Loctite...

Page 13: ...sher 1 RH Shock Spacer S001941 1 1 2 x 2 3 4 Hex Bolt CB1427 1 14mm Flat Washer CW2155 3 See Fig 2 RH Shock will mount to threaded hole on RH axle tube with shoulder bolt and flat washer 1 1 2 X 1 1 2 Shoulder Bolt CB1426 1 14mm Flat Washer CW2155 4 See Fig 3 Install LH shock as shown using original H D hardware DIFFERENTIAL INSTALLATION Fig 2 Fig 8 Fig 1 Spacer Thread bolt into axle tube RH Shock...

Page 14: ... ft lbs using 16mm shallow socket and 18mm wrench 6 Adjust belt tension by loosening rear plate bolts and moving adjusters same amount on both sides If any adjustment is made you must re check belt tracking NOTE Be sure belt is not climbing up side of the pulley or squeaking as belt is rotated 8 After all adjustments are made tighten adjuster lock nuts 9 Remove rear shocks for body installation NO...

Page 15: ...wing hardware 1 M10 X 35 Bolt CB1607 1 M8 X 40 Bolt CB1975 1 Conical Spacer S001784 1 M10 Lock Nut CN3049 2 Tighten jam nuts on differential brace after final adjustments are made 3 Torque front differential housing brace bolt to 17 ft lbs 4 Torque differential brace bolt swingarm side to 36 ft lbs STABILIZER INSTALLATION Fig 1 Fig 2 Install spacer in housing Fig 3 ...

Page 16: ... and residual valve to brass tee Torque valve to 11 ft lbs 2 Brake Lines S001976 1 Residual Valve S002037 1 Banjo Washer GC6002 3 See Fig 2 Route OEM line above swingarm to residual valve as shown Secure brake line to swingarm with cable tie 4 See Fig 2 Install OEM Brake line to residual valve using the following hardware Torque banjo bolt to 16 ft lbs 1 M10 Banjo Bolt CB6001 2 Banjo Washers GC600...

Page 17: ...s 3 4 Secure brake lines to swin garm with brake line routing clips in swingarm Secure to differential with cable tie as shown 4 Brake Line Clip S001650 2 Cable Tie CT1036 WARNING Use correct DOT rated brake fluid 7 Fill brake system with fluid Bleed rear brake system with bleed screws at calipers and check for leaks Fig 3 BRAKE INSTALLATION Cable Tie Clips Clips Fig 4 Cable Tie ...

Page 18: ...l go over bolts on inside of bracket Torque to 33 ft lbs 1 Park Brake Bracket LB6412 1 RH Body Mount LB6408 2 Short Spacers LS6404 2 3 8 x 2 Bolt CB1255 2 3 8 Flat Washers CW2015 3 See Fig 3 LH body mount will use longer spacers with the following hardware Brake line clamp will be installed on lower bolt 1 LH Body Mount LB6407 2 Long Spacers LS6405 2 3 8 x 2 Bolt CB1255 2 3 8 Flat Washers CW2015 1...

Page 19: ...H cable under differ ential and into park brake bracket Attach LH and RH cables together with clamp to lower axle tube bolt as shown Check for proper clearance with other components 1 3 4 Clamp GC0108 9 See Fig 6 Attach park brake cables to bracket as shown using nuts and washers provided on cables Use one nut and washer on each side of bracket 10 See Fig 6 Thread one 5 16 NF nut onto each brake c...

Page 20: ...shers CW2010 2 5 16 Lock Nuts CN3045 3 See Fig 2 Assemble body exhaust bracket to muffler bracket as shown Insert rubber bush ing into muffler bracket first 1 Rubber Bushing GM0300 1 RH Body Exhaust Bracket LB6422 1 Exhaust Hanger Bracket S001928 2 5 16 x 1 Hex Head GR8 Bolt CB1161 4 5 16 Flat Washers CW2010 2 5 16 Lock Nuts CN3045 EXHAUST SYSTEM INSTALLATION Fig 1 Fig 2 Install adapter plate Inse...

Page 21: ...ad pipe 7 See Fig 4 Place exhaust clamps onto exhaust pipes Install Lehman pipes over H D head pipes 2 Exhaust Clamps GC1015 8 Leave all exhaust pipes and brackets loose Exhaust will be completed once body has been installed on trike 9 See Fig 5 Install RH body exhaust bracket to outside of RH H D frame rail using the following hardware 1 RH Body Exhaust Bracket LB6422 1 5 16 x 1 1 2 Bolt CB1170 2...

Page 22: ... CN3250 0 1 1 2 Nut CN3025 2 See Fig 2 Install top body support LS6406 to H D frame using the following hardware Leave bolts loose 2 5 16 x 1 3 4 Bolts CB1175 2 5 16 Flat Washers CW2010 2 5 16 Lock Washers CW2045 3 See Fig 3 Install rear LH body mount bracket to LH H D frame rail using the following hard ware This bracket should also be left loose until body is mounted RH body exhaust bracket LB64...

Page 23: ...lock nuts against bracket Install rubber washers inside trunk 1 License Plate Bracket S001039 2 1 4 x 1 1 2 Button Head CB1096 2 6 4mm x 18mm Washer CW2154 2 1 4 x 3 4 Rubber Washer FG1002 2 1 4 SS Flat Washers CW2006 2 1 4 Lock Nut CN3040 4 See Fig 3 Install license plate light to bracket using bolts washers and nuts 2 1 4 x 3 4 Button Head CB1084 2 1 4 Flat Washers CW2006 2 1 4 Acorn Nuts CN3070...

Page 24: ...200 4 1 4 Flat Washer CW2006 4 Lock washer Provided with light 4 Nut Provided with light 2 1 4 Flange Nut CN3007 2 See Fig s 3 4 If required Install female terminals and male connectors to taillight wir ing Use appropriate tool for crimping termi nals to wires Mac Tools TCT1028 3 See Fig s 3 4 Inspect crimps before in stalling into connector Distortion should be minimal BODY PREPARATION Fig 1 Fig ...

Page 25: ...t Clips GH0912 4 6 32 x 1 4 Screws CS4073 3 Install door to body by connecting door hinges to body hinges hinges will snap to gether Perform initial fitment test 4 See Fig 3 Hinges may be adjusted from side to side in or out and up and down DOOR INSTALLATION Fig 1 Fig 2 Fig 3 Use lower adjustment screw to move door in or out Use top adjustment screw to move door up or down Loosen set screw to adju...

Page 26: ...f pa 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 sembly Secure with crimps on each end 1 Cable CC0089 2 Cable Crimp CC1900 DOOR INSTALLATION Install cable through hinge Fig 4 ...

Page 27: ...ack stands to achieve proper ride height 7 Measure body from side to side and front to back Top body support may be adjusted to move body up or down Be sure to leave enough clearance for mufflers on back of body Exhaust will still be loose and need to be held in place to check clearance 8 See Fig 2 Verify there is at least a 1 4 gap be tween the body and chrome belt cover on RH side 9 See Fig 3 On...

Page 28: ...clearance along both pipes Rear head pipe may need to be pulled away from park brake bracket 12 Tighten all exhaust clamps and nuts 13 Reinstall all HD heat shields along with Leh man heat shield to lower front header pipe 1 Heat Shield GS914 11 Tighten seat center post front bracket bolts and top body support jam nut 12 Install passenger footpads using the following hardware 6 1 4 Flat Washers CW...

Page 29: ...ll male terminals to turn signals and taillight wires Install turn signal terminals into 2 pin female connector Install taillight terminals into 3 pin female connector Install all wires into main harness on body 6 Drill hole in rear trunk floor for licence plate wiring Route wiring through trunk floor and install female terminals and connectors Plug license plate light into harness Seal harness th...

Page 30: ...s the battery 2 See Fig 2 Install red wire from sensor into 3 connector position next to the violet wire in adapter harness Verify red wire mates with solid blue wire on opposite end 3 See Fig 2 Connect the black wire from the Bank Angle Sensor to negative battery termi nal 4 See Fig 3 Carefully slide BCM out of plastic housing in front of battery 5 See Fig 3 Unplug BCM connector and tempo rarily ...

Page 31: ... plastic cover to BCM connector Re install connector to BCM Verify connector locks into place 9 Reinstall BCM into plastic housing NOTE Once conversion is complete and BCM has been reprogrammed verify that red secu rity light on speedometer stays off Any BCM fault codes may need to be cleared BANK ANGLE SENSOR INSTALLATION Fig 4 Install Green wire to B4 location Route Green wire to backside connec...

Page 32: ...senger section of seat 3 Evenly locate grab handles on body and mark for drilling Drill holes using 1 4 drill bit CAUTION Make sure LH rear hole does not interfere with front trunk wall when lo cating handles 4 Place rubber standoff S001701 between grab handle and body 5 Install grab handles to body using the following hardware 2 Grab Handles S001035 4 5 16 x 1 Socket Bolts CB1159 4 5 16 Lock Wash...

Page 33: ...3 Last two red reflectors will be centered 3 below rear taillights on body 4 Install Lehman and Raider badges to body as shown 1 Lehman Badge GB1327 1 Raider Badge GB1323 5 Install wheels Torque wire wheel lug nuts to 75 ft lbs and aluminum wheel lug nuts to 85 ft lbs CAUTION Do not use an impact when in stalling lug nuts WARNING Verify Bank Angle Setting has been changed before operating trike FI...

Page 34: ...olts 3 See Fig 2 Loosen fork stem clamp bolt located in center of steering head 4 Tighten fork stem bolt 1 4 turn past H D factory adjustment 5 Torque fork stem clamp bolt to 35 ft lbs 6 Torque lower fork bracket pinch bolts to 35 ft lbs NOTE Do not tighten fork bracket pinch bolts past factory specifications Only fork stem bolt should be tightened past factory setting STEERING NECK Stem bolt Clam...

Page 35: ...evels Belt tension 5 16 3 8 Wheel torque 85 ft lbs 75 ft lbs wire Rear tire pressure 26 psi Front tire pressure Refer to OEM psi Trunk clean and dry Trunk door seals and operates smooth Shocks set at mid setting Heat shields installed Side covers installed Lehman Raider badges installed No paint defects Warranty Owners manual with bike ...

Page 36: ...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 lbs Shock bolts 45 ft lbs Shock bolt LH lower bolt 23 ft lbs Wheels wire 75 ft lbs Wheels aluminum 85 ft lbs TORQUE SPECIFICATIONS ...

Page 37: ... BOLT BAG DIFFERENTIAL PART QTY DESCRIPTION CB1426 1 1 2 x 1 1 2 x 3 8 THREAD SHOULDER BOLT Lower RH shock mounting CB1427 1 BOLT 1 2 X 2 3 4 GRADE 8 Upper RH shock mounting CB1607 1 M10 X 35 GRADE 8 Stabilizer to swingarm CB1608 2 M10 x 100 GRADE 8 Differential adjuster bolts CB1929 1 M8 x 30 SOCKET HEAD BOLT Brake cable clamp to differential housing top CB1975 1 M8 X 40 GRADE 8 Stabilizer to dif...

Page 38: ...ort bracket CN3070 2 NUT ACORN 1 4 License plate light to bracket CN3250 0 1 NUT JAM NYLOCK 1 2 NC Top body support CN3400 1 NUT WELL 1 4 Seat mounting CS4031 2 SCREW BH SK CAP 1 4X1 5 Front body mount CS4080 1 SCREW MACH 1 4 X 1 PAN HD PHILLIPS Seat mounting CW2005 18 WASHER FLAT 1 4 GRADE 8 Foot pad 6 front body mount 4 rear body mount 4 ECM mounting 2 U bolt top body support 2 CW2006 5 WASHER F...