Lehman Crossbow 2011 Manual Download Page 25

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Body Preparation, Installation, & Final Assembly

5. Install (1) wheel kit (2 tires / wheels) with (8) lug

nuts.

•

(1) Wheel Kit

•

(8) Lug Nut

Torque lug nuts to 85 ft-lbs using lug nut

socket and extension. Remove center stand

before torque.

NOTE: A good check for proper park brake setting

can be done while applying torque to lug nuts.

Make sure Park brake is fully engaged and apply

torque value to lug nuts. If the wheel turns, the

park brake needs to be adjusted tighter.

See Fig. 3.

Install (1) Reflector to each body as

shown 3-1/4” from inside edge of wheel well.

•

(2) Reflector (S001421)

See Fig. 3.

Install (1) Lehman Badge above each

reflector as shown.

•

(2) Lehman Badge (GB1327)

See Fig. 4.

Install (1) Crossbow Badge as shown

between rear taillights.

•

(1) Crossbow Badge (S001396)

Fig. 3

Fig. 4

PART #

PART DESCRIPTION

TORQUE

CN3135

LUG NUT (8)

85 FT LBS

3-1/4”

Summary of Contents for Crossbow 2011

Page 1: ...lts only 1 Hitch Bracket S001128 8 Bolt CB1972 2 See Fig 2 Install 1 body exhaust bracket to LS frame as shown using 2 bolts Hand tighten bolts only 1 LS Body Exhaust Bracket S001534 2 Bolt CB1972 3 Install 1 body exhaust bracket to RS frame us ing 2 bolts Hand tighten bolts only 1 RS Body Exhaust Bracket S001535 2 Bolt CB1972 Fig 1 Fig 2 ...

Page 2: ...2 Relay OEM 2 Plastic Pushpin S001430 2 See Fig 2 Install 1 Grommet to 1 Right Side Cover Bracket as shown 1 Grommet S001427 1 Right Side Cover Bracket S001389 3 See Fig 2 Install 1 Right Side Cover Bracket as shown using 2 Bolts Tighten using 13mm socket 1 Right Side Cover Bracket S001389 2 Bolt CB1972 Fig 1 Relay Fig 1 Mounting Bracket Pushpin ...

Page 3: ...racket S001377 2 Bolt CB1907 3 See Fig 2 Install Latch Assembly and Bracket to frame as shown using 2 Bolts Tighten using 13mm socket 2 Bolt CB1972 4 See Fig 3 Install 1 Grommet to 1 Left Side Cover Bracket as shown 1 Grommet S001427 1 Left Side Cover Bracket S001389 5 See Fig 3 Install 1 Left Side Cover Bracket to the left side of the frame as shown using 2 Bolts Tighten using 13mm socket 1 Left ...

Page 4: ...S001442 1 Bolt CB1972 7 See Fig 5 Install 1 Latch Assembly Alignment Fixture to 1 LS Latch Bracket using 2 Bolts Tighten using 10mm socket Fig 40 9 1 LS Latch Assembly OEM 1 LS Latch Bracket S001376 2 Bolt CB1907 8 See Fig 5 Install Latch Assembly and Bracket to frame as shown using 2 Bolts Tighten using 13mm socket 2 Bolt CB1972 Fig 4 Fig 5 Latch Assembly Bracket S001442 ...

Page 5: ...Mount S001132 1 Spacer S001517 2 Bolt CB1975 2 Nut CN1908 2 See Fig 2 Install 1 Front Body Mount to RS Rollover Brace as shown with 1 spacer using 2 Bolts Tighten using 13mm socket with loctite 243 1 Front Body Mount S001132 1 Spacer S001517 2 Bolt CB1975 2 Nut CN1908 3 Torque and mark body mount bolts to 22 ft lbs using 13mm socket Fig 1 Fig 2 PART PART DESCRIPTION TORQUE CB1982 FRONT BODY MOUNT ...

Page 6: ...tion bolts to 8 ft lbs using 10mm socket 5 See Fig 2 Re install taillight assemblies to tail section as shown Tighten using 4mm allen head socket 2 Taillight Assembly OEM 5 Bolt take out NOTE Run taillight wire harness in tail section track 6 Connect license plate light wire harness 7 See Fig 2 Install 2 U Nuts to modified tail sec tion as shown 2 U Nut CN3302 8 See Fig 3 Install a 1 piece of 3M D...

Page 7: ...Installation Bracket Installation REAR FRAME 1 Torque and mark frame bolts to 22 ft lbs using 13mm socket as indicated Fig 1 Fig 2 PART PART DESCRIPTION TORQUE CB1972 FRAME BOLTS 22 FT LBS Leave Loose Leave Loose ...

Page 8: ...CB1928 3 Torque and mark upper exhaust bracket bolt to 10 ft lbs using 15mm socket 4 Torque and mark lower exhaust bracket bolt to 35 ft lbs using 15mm socket 5 See Fig 3 Install 1 right side exhaust pipe as shown using 1 exhaust clamp 1 Right Side Exhaust Pipe S001167 1 Exhaust Clamp S001412 6 Re install side covers with 1 push pin 1 Push Pin OEM take off 1 Non Reverse Models Side Cover Set OEM O...

Page 9: ...t and Right side covers as shown using air saw 2 See Fig 2 Install GT1800 weather seal to modi fied edges of side covers as shown Use loctite 404 on inside edge of side covers to secure being careful not to get glue on outside edge of side covers Weather Seal GT1800 3 Install modified left and right side covers to trike Fig 1 Fig 2 Scribe Lines ...

Page 10: ...f 3 See Fig 3 Install 1 latch cable to OEM latch as shown using 1 SIR Clip and 1 Hair Clip 1 Cable Door Release S001504 1 SIR Clip provided with cable 1 Hair Clip S001510 4 See Fig 4 Install 1 latch cable to OEM latch release mechanism as shown using 1 SIR Clip 1 Latch Release Mechanism OEM 1 SIR Clip S001531 NOTE Left side latch release mechanisms pull from the bottom right side latch release mec...

Page 11: ...shown 1 Body LS S001437 RS S001438 2 Jam Nut CN1904 6 See Fig 6 Install latch assembly to studs as shown using 2 jam nuts Tighten using 10mm wrench 2 Jam Nut CN1904 7 See Fig 7 Secure latch release mechanism to body as shown using masking tape 8 See Fig 8 Apply masking tape to trunk opening as shown Fig 5 Fig 6 Fig 7 Fig 8 ...

Page 12: ...the vapor hole faces the inside as shown 4 Cut weather seal along indicated notch markings using weather seal cutting tool 5 Secure V notched edges together using Loctite 404 6 See Fig 3 Install weather seal to backside of door as shown starting at V notched corner 7 Apply weather seal to outer most edge of door seal surface around perimeter of door Trim ends to fit using weather seal cutting tool...

Page 13: ...Right Side Hinge S001496 1 Concentric Rod S001409 6 Bolt CB1908 NOTE See Fig 4 Pull the hinge assembly away from the door when tightening as shown 10 Mark the center of the concentric rod with a black sharpie for alignment purposes in the body 11 See Fig 5 Install 1 striker latch to door as shown using 2 nylock nuts Tighten using 7mm socket 1 Striker Latch OEM 2 Nylock Nut CN1900 Fig 5 Fig 4 Tubin...

Page 14: ... See Fig 3 Adjusts the hinge side of the door s depth in out Latch Mechanism See Fig 3 Adjusts the latch side of the door s depth in out 3 Make adjustments to the door until A uniform gap is obtained around the pe rimeter of the door A flush surface is obtained between the body and the door The bodyline of the door and body match The door does not contact the body upon opening A consistent seal is...

Page 15: ... 1 U Nut CN3302 6 Drill out hole for U Nut using 5 32 bit Re install u nut to body 7 See Fig 6 Install GT1800 weather seal to seat pan of body as shown Use loctite 404 on inside edge of body to secure being careful not to get glue on outside edge of body Weather Seal GT1800 8 Repeat BODY PREPARATION DOOR PREPA RATION DOOR INSTALLATION ADJUST MENT sections for the right side body Fig 4 Fig 5 Bump S...

Page 16: ... Fender Washer CW2109 1 Nylock Nut CN1908 4 Repeat steps 1 through 3 for right side body 5 See Fig 3 Temporarily install 1 left and 1 right lower valence as shown for alignment purposes 1 Left Side Lower Valence S001511 1 Right Side Lower Valence S001511 6 Adjust left and right side bodies until the following clearances are achieved 1 8 between front of body and side cover 1 8 between top of body ...

Page 17: ... 13mm Socket 5mm Allen Head Socket Fig 50 26 1 Bolt CB1929 1 Fender Washer CW2109 1 Nylock Nut CN1908 10 Oversize 3 foot pad mounting holes using 21 64 bit 11 Drill indicated foot pad mounting hole through front body mount using 21 64 bit Fig 50 26 12 Install 1 LS foot pad to body using 3 flat wash ers and 4 nylock nuts Tighten using 7 16 wrench Fig 50 27 1 LS Foot Pad S001418 3 1 4 Flat Washer CW...

Page 18: ...lt 1 lock washer and 1 fender washer as shown Tighten using 5mm al len head socket Fig 50 28 1 Bolt CB1624 1 Lock Washer CW2168 1 Fender Washer CW2109 NOTE Rear body mount is the front most hole The rear most hole is used for exhaust pipe mounting 16 See Fig 5 Secure 1 latch release mechanism to latch bracket as shown using 2 bolts Tighten using 10mm socket 1 Latch Release Mechanism OEM 2 Bolts CB...

Page 19: ...Nut Tighten using 13mm Socket 5mm Allen Head Socket 1 Bolt CB1929 1 Fender Washer CW2109 1 Nylock Nut CN1908 19 Oversize 4 foot pad mounting holes using 21 64 bit 20 Drill indicated foot pad mounting hole through front body mount using 21 64 bit Fig 50 31 21 See Fig 8 Install 1 RS foot pad to body using 3 flat washers and 4 nylock nuts Tighten us ing 7 16 wrench 1 RS Foot Pad S001419 4 1 4 Flat Wa...

Page 20: ...1 bolt 1 lock washer and 1 fender washer as shown Tighten using 5mm al len head socket 1 Bolt CB1624 1 Lock Washer CW2168 1 Fender Washer CW2109 NOTE Rear body mount is the front most hole The rear most hole is used for exhaust pipe mounting 25 See Fig 10 Secure 1 latch release mechanism to latch bracket as shown using 2 bolts Tighten using 10mm socket 1 Latch Release Mechanism OEM 2 Bolts CB1907 ...

Page 21: ...ide bezel as shown using 13 64 bit 1 Left Side Bezel S001512 NOTE This mounting hole must line up with the mounting hole located on the lower valence 28 Secure bezel and lower valence to body using 1 screw Tighten using phillips screwdriver 1 Screw CS4098 29 Repeat steps 26 through 28 for right side bezel installation 1 Right Side Bezel S001513 1 Screw CS4098 30 See Fig 13 Secure left and right si...

Page 22: ...derside of the body using 19 64 bit 7 Reinstall muffler to trike with 1 exhaust clamp 1 Exhaust Clamp S001412 8 See Fig 3 Secure muffler to body through mount ing hole using 1 bolt and 1 fender washer Tighten using 4mm allen head socket 1 Bolt CB1910 1 Fender Washer CW2154 9 Repeat steps 1 through 8 for right side muffler installation 10 Torque and mark exhaust clamps 4 to 35 ft lbs using 15mm soc...

Page 23: ...f trike as shown using 1 bolt and 1 hose clamp Tighten using 10mm socket and 5 16 nut driver 1 Modified RS Heat Shield OEM 1 Bolt OEM 14 See Fig 5 Install 1 LS heat shield to left side exhaust pipe as shown using 2 hose clamps Tighten using 5 16 nut driver 1 LS Heat Shield S001402 2 Hose Clamp Take Off Fig 4 Fig 5 ...

Page 24: ...ke lever and body 2 See Fig 1 Install 1 Park Brake Boot to Park Brake Lever Assembly using 1 Cable Tie 1 Park Brake Boot S001432 1 Cable Tie CT1020 3 See Fig 2 Install OEM rear shock fill valve to right side foot pocket as shown with washer 1 Rear Shock Fill Valve OEM 1 Washer 4 Verify pressure of OEM rear shock to 28 PSI us ing Handheld Air Gauge Adjust as necessary Fig 1 Fig 2 Cable Tie Fill Val...

Page 25: ...ug nuts Make sure Park brake is fully engaged and apply torque value to lug nuts If the wheel turns the park brake needs to be adjusted tighter 7 See Fig 3 Install 1 Reflector to each body as shown 3 1 4 from inside edge of wheel well 2 Reflector S001421 8 See Fig 3 Install 1 Lehman Badge above each reflector as shown 2 Lehman Badge GB1327 9 See Fig 4 Install 1 Crossbow Badge as shown between rear...

Page 26: ...rior to re securing tour pack to trike 11 Torque mark tour pack mounting bolts to 22 ft lbs using 13mm socket 12 See Fig 6 Install 1 license plate bracket to stock mounting location as shown with 2 screws Tighten using 4mm allen head socket 13 Install 1 operator passenger seat with 2 bolts and 2 washers Tighten using 4mm allen head socket 1 Operator Passenger Seat OEM 2 Bolt OEM 2 Washer OEM 15 Re...

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