Related Manuals for lehman Trikes CROSSFIRE
Summary of Contents for lehman Trikes CROSSFIRE
- Page 1 2010+ Victory Cross Country / Cross Roads Installation Guide Nov 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 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 3 Before installing your new Lehman kit, we recommend that your motorcycle be inspected and ser- viced by a qualified technician. Replace any worn or damaged parts before installing the trike kit. • If the motorcycle has more than 12,000 miles, Lehman Trikes recommends installing a new drive belt during the trike conversion. •...
- Page 4 Disassembly NOTE: Refer to the Victory service manual for detailed instructions on removal of OEM parts. 1. Load motorcycle on lift and secure front wheel. 2. Place motorcycle on center stand or scissor style jack. 3. Disconnect negative battery cable. Fig.
- Page 5 ABS Pump Relocation– ABS Models Only 1. Remove ABS Pump mounting hardware from frame. Do not remove front brake lines from pump. 2. Remove mounting bracket from pump. Remove grommets and spacers from bracket. 3. See Fig. 1. Remove entire rear brake line assembly from motorcycle. Disconnect line at master cylinder and ABS pump.
- Page 6 Fig. 3 5. See Fig. 3. Install new bracket to ABS pump using original hardware. • (1) ABS Bracket– S002350 6. See Fig. 4. Install banjo bolts, spacers and washers to block off rear brake line ports on pump. Torque banjo bolts to 16 ft-lbs. •...
- Page 7 Swingarm Installation 1. See Fig. 1. Apply grease to plastic bushings and press into swingarm. Insert steel sleeves in bushings. Fig. 1 2. See Fig. 2. Install swingarm to motorcycle and slide the pivot bolt though. Place two OEM wash- ers on the RH side as shown below.
- Page 8 Top Frame Installation 1. See Fig. 1. Mount Top Frame to the motorcycle sub-frame using the hardware indicated below. Torque hardware to 19 ft-lbs evenly across all screws. • (2) M8x35 Hex Bolt– CB1622 • (2) M8x40 Socket Head Bolt– CB1975 •...
- Page 9 Differential Installation 1. See Fig. 1. Remove 3 of the 4 cross tubes as shown below. Fig. 1 Front Leave front lower tube installed 2. Pass drive belt over differential assembly and position onto rear pulley. 3. Reinstall the cross tubes and spacers. Apply anti seize to all bolts and torque the 3/4” x 2-1/2” hex head screws to 150 ft-lbs.
- Page 10 Rear Frame and Swingarm 1. See Fig. 1. Position lower rear body frame inside of swing arm and install the 1/2” bolts through the mounting holes. • (4) 1/2” x 3-1/2” Hex Head Bolts– CB2178 • (8) 1/2” Washers– CN3060 Fig.
- Page 11 Align and Tension Drive Belt 1. Set the belt tension and alignment by moving the independent drive train unit forward or rearward as necessary using the adjuster bolts. Belt tension can be measured by total vertical movement and should be approximately ¾”-1” with a new belt. Tip: Measure from the bracket to the face of the drive train on each side to get the alignment close.
- Page 12 Install Anti-Roll Bar 1. See Fig. 1. Install Anti-Roll Bar with the short side on the LH side of trike as shown below. Fig. 1 Longer Side on RHS Shorter Side on LHS (10.80 Approximately) (10.42 Approximately) 2. See Fig. 2. Install hardware through anti-roll bar housing onto swingarm. Position the anti-roll bar on the frame so that the rod ends will be close to vertical when attached to the control arms.
- Page 13 Fig. 1 3. See Fig. 1. Attach rod-end to right control arm with the included hardware in the following order: 3/8” x2-1/4” bolt, washer, rod-end, washer, control arm, washer, and then nut. Torque to 45 ft-lbs. • (2) 3/8” x 2-1/4” Hex Head Bolts– CB2001 •...
- Page 14 Fig. 3 3. Route new brake light switch wiring to original brake light switch connector on LH side of mo- torcycle and connect. 4. See Fig. 3. Attach brake block to bolt on swing arm using 1/4” locknut and washer. Torque to 11 ft-lbs.
- Page 15 Fig. 6 5. See Fig. 6. Install new reservoir assembly to original bracket on motorcycle. New bracket will mount to the inside of the existing bracket with star washer between the two brackets. • (1) M6 x 1 Flange Head Screws– CB1905 •...
- Page 16 Fig. 1 Park Brake 1. See Fig. 1. Verify park brake cables are routed in front of rubber body mounts and se- cured to upper A-arms on both sides. 2. See Fig. 2. Verify cables are secured to bal- ance bar as shown. Fig.
- Page 17 Exhaust Installation 1. See Fig’s. 1 & 2. Install exhaust extensions onto OEM header pipes (longer extension is used on the LHS). Reuse the factory clamps plus additional clamp provide for RH side. Keep all the clamps slightly loose until the mufflers are installed. •...
- Page 18 3. See Fig. 4. Place mufflers over exhaust extensions with clamps in place. Attach mufflers to brack- ets using the original flange head bolts. Torque hardware to 20 ft-lbs. Fig. 4 4. Adjust the extensions and mufflers until the best fit is achieved. Make sure the mufflers are at the same angle relative to the body frame otherwise the gap around the muffler to the body may differ.
- Page 19 Side Panel Modification 1. See Fig’s 1 & 2. Trim both LH and RH side panels to fit around sway bar. Keep both panels loose on the Trike after cutting. Fig. 1 Fig. 2 RH panel shown RH panel shown Grab Handle Installation 1.
- Page 20 • (8) #6 Stainless Flat Washers– CW2086 • (2) Taillights– S002335 • (2) Taillight Grommets- GG0011 • (1) Crossfire Wire Harness– S002305 5. Carefully position the body to the trike frame. Fig. 3 Secure the body with the following hardware (original shipping hardware).
- Page 21 Fig. 4 5. See Fig. 4. Attach balance bar to front of body as shown using the following hardware. Bolt head, fender washer and rubber washer should be installed from inside the trunk with flat washers and lock nuts on the bracket side.
- Page 22 7. See Fig. 3. Install badges to body below trunk Fig. 3 door as shown. • (1) Lehman Badge– S001532 • (1) Crossfire Badge– S002340 • (1) LLS Badge– GB1328 8. See Fig. 4. Install terminals and connector to wiring on inside of door and connect to main Fig.
- Page 23 Fig. 1 Tour Box Installation– Touring Models. 1. See Fig. 1. Install tour box mounting brackets to top frame as shown using the following hard- ware. Hand tighten hardware until box is mounted. • (4) M8 x 25 Socket Head Bolts– CB1989 •...
- Page 24 Fig. 1 Hidden Antenna Installation– Fairing models Note: Antenna may be installed during EZ-Steer installation if applicable. Remove trim 1. See Fig. 1. Carefully remove outer headlight trim on fairing. 2. See Fig. 2. Remove headlight mounting hard- ware and carefully remove headlight from fair- ing.