Lehman Renegade 2009 Installation Instructions Manual Download Page 1

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2009-2013

H-D TOURING MODELS

INSTALLATION

INSTRUCTIONS

*FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE

December 2013

Rev. 8

Powered by Harley Davidson

Summary of Contents for Renegade 2009

Page 1: ...2009 2013 H D TOURING MODELS INSTALLATION INSTRUCTIONS FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE December 2013 Rev 8 Powered by Harley Davidson ...

Page 2: ... only the proper tools as specified If you have any doubt as to your ability to perform any of the procedures outlined in this manual please contact Lehman Trikes before you start work at 1 888 394 3357 FOREWARD 2010 All rights reserved Lehman Trikes provides this publication as is without warranty of any kind either expressed or implied While every precaution has been taken in the preparation of ...

Page 3: ...mation refer to the factory service manual 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 This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potent...

Page 4: ...ons the following parts will need to be ordered from H D for antenna and turn signal installation HD P N Description Qty 76252 86 Base antenna 1 76253 86 Reinforcement plate 1 76255 86 Gasket base 1 11486 Grommet 1 68713 94A Lamp rear signal 2 Dakota Digital offers a hidden antenna kit as an alternative Part ANT 2000 For 2010 Models the following parts are required HD P N Description Qty 73108 96B...

Page 5: ...y using proper safety glasses or goggles Read through the installation instructions before you begin Make sure you have all the proper tools parts and skill set to perform the installation safely and completely NOTE Compliance with national DOT USA MOT Canada State Provincial and local vehicle is standards is the responsibility of the installer Installation of the parking brake and grab han dles i...

Page 6: ...ADE FRAME BRACE S001266 FRAME BRACE S001268 BODY BRACE LB1235 LICENSE PLATE BRACKET LB1207 ADAPTER PLATE LP1038 SWINGARM BUSHING LT S001346 SWINGARM BUSHING RT S001347 SWINGARM BUSHING S001315 09 10 MODELS ILLUSTRATIONS 6 ...

Page 7: ...2009 2013 FLH RENEGADE LS2013 2002 SWINGARM S001271 FRAME ILLUSTRATIONS CONTINUED 7 MODULAR DIFFERENTIAL GM0142 MOTOR MOUNT LINK ...

Page 8: ...4 Disconnect battery CAUTION Always disconnect negative battery cable first If positive cable should contact a grounded object while negative cable is installed resulting sparks may cause an explosion 5 Remove tour pack 6 Raise motorcycle lift to working height 7 Remove side stand mounting bolt and separate side stand from bracket 8 Remove passenger footboards Save boards and hardware for re insta...

Page 9: ...is card LH cup washer 7 Remove outer spacer from right side of swin garm 8 Remove rubber mount from right side 2011 MODELS 1 See Fig 1 Remove 2 bolts to free swingarm fork bracket from left side of motorcycle frame 2 Release rear brake line hose and rear wheel speed sensor if ABS equipped from cable clips on right side of swingarm Remove black plastic plug from right side NOTE For best results use...

Page 10: ...om frame 1 Remove LH and RH rear heat shields 2 See Fig 4 Using an appropriate cutting tool cut 1 5 8 from end of both rear head pipes 3 Reinstall LH heat shield after cut Shield will be placed 1 4 to 1 2 forward to gain clear ance for extension pipe installation 4 Install RH heat shield Fig 4 REMOVING H D SWINGARM 10 ...

Page 11: ...r 3 See Fig 1 Fig 2 OEM cup washers will be replaced by new swingarm reinforcement bushings S001346 LH S001347 RH S001315 4 See Fig 3 Install RH swingarm reinforcement bushings S001347 S001315 into original rubber mounts Be sure to align offset in mount and bushings 5 Install Lehman swingarm with word TOP stamped into swingarm collar facing upward 6 See Fig 3 Assemble parts for LH side S001346 S00...

Page 12: ...ushings S001347 S001661 into original rubber mounts Be sure to align offset in mount and bushings 5 Install Lehman swingarm with word TOP stamped into swingarm collar facing upward 6 See Fig 4 Assemble parts for LH side S001346 S001661 as shown 7 See Fig 4 Re install LH swingarm fork bracket Apply Loctite 242 and torque bolts to 55 ft lbs 8 Apply Loctite 242 to pivot shaft bolts and install Torque...

Page 13: ...motor mount link to same dis tance from center of hole to center of hole as OEM motor mount link 1 Upper Engine Stabilizer Link GM0142 NOTE Locate position of eyelet holes and alignment of OEM link Lehman link must be adjusted same as OEM link when link is ad justed use Loctite 262 and secure lock nuts in place 5 Install Lehman link using existing OEM bolts blue Loctite 242 and supplied motor moun...

Page 14: ...wn Leave hardware loose 2 See Fig 2 Attach RH adapter plate to swin garm as shown with park brake bracket mounted to lower holes 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 DIFFERENTIAL 14 Fig 1 Fig 2 ...

Page 15: ... hardware to pinch blocks before installing differential to swingarm NOTE Shock plate orientation is different on 09 models Make sure shock mount hole on rear of plate is towards the top DIFFERENTIAL CONTINUED 15 Fig 3 Fig 4 Hole towards top Hole towards top ...

Page 16: ...forward as possible Set jack stands under axle tubes 8 Tighten pinch block hardware just enough to allow differential to slide on swingarm adapter plates 9 See Fig 5 Remove upper lower and rear housing plates 10 See Fig 6 Carefully slide belt over pulley 11 Reinstall housing plates with original hardware using Loctite 242 Install all hardware before tightening Torque hardware to 17 ft lbs DIFFEREN...

Page 17: ... front half of differential brace to top of swingarm gusset with a 3 8 x 1 bolt flat washers and lock nut Note Do not bolt down brace until belt ten sioning is completed 15 Tighten bolts in following order a Front half of brace to swingarm gusset Torque bolts to 35 ft lbs b Rear half of brace to differential housing Torque bolt to 25 ft lbs c Torque LH front plate bolts to 17 ft lbs DIFFERENTIAL C...

Page 18: ... belt tension Raise and lower differential assembly slowly with a jack while checking belt tension When tightest position is located apply 10 lbs force at midpoint of lower strand of belt Correct deflection for various models is as follows 7 Increase or reduce belt deflection by turning adjuster screw on each side in or out an equal number of turns 8 Look along top of belt to check belt alignment ...

Page 19: ... to differential brace using the following hardware 1 Brass Tee CF5105 1 Spacer S001530 2 1 4 x 1 3 4 Hex Bolt CB1100 2 1 4 Flat Washers CW2005 2 1 4 Lock Nut CN3042 2 See Fig 1 Install original brake line from master cyclinder and rear braided lines to brass tee using the following hardware Torque banjo bolt to 16 ft lbs 1 Banjo Bolt S002022 2 Banjo Washers GC6002 2 45 M10 Braided Line S001976 3 ...

Page 20: ...nes 7 Remove rubber caps on bleeder valves Install clear brake bleeder hose over bleeder valve on caliper 8 Pump brake pedal to build hydraulic pressure 9 While holding the brake pedal open bleeder valve to release pressure and remove air from system Repeat bleeding on both calipers until fluid is solid without bubbles in bleeder hose 10 Tighten bleeder valves and check for leaks 11 Install master...

Page 21: ...rame and install in left hole in handle mount 9 See Fig 9 Route right park brake cable up around axle and forward to right hole in handle mount 10 See Fig 9 Secure both cables to upper rear pinch block with clamp GC0108 11 See Fig 10 Secure cable retaining nuts to handle mount with 7 8 wrench 12 Check for tire clearance 13 See Fig 10 Thread one 5 16 NF nut onto each brake cable Place threaded end ...

Page 22: ...embly 4 See Fig 2 Re install banjo bolt with spacer S001067 in ABS unit R and tighten 5 See Fig 3 Locate ABS front wheel sensor plug un der left side of fairing and disconnect Secure longer sensor plug to fairing wire bundle with cable tie CT1026 6 See Fig 4 Locate ABS rear wheel sensor plug left side of ABS unit Disconnect plug remove sensor from right side axle and discard 7 Place ABS warning la...

Page 23: ... cruise control light 8 See Fig 5 Disable ABS warning light by cutting or ange wire with white stripe 9 See Fig 6 Install 2 heat shrink to each end of cut wire 10 Re install fairing 11 See Fig 7 Place ABS warning label above warning light indicators on fairing BRAKE SYSTEMS ABS MODELS CONTINUED 23 Fig 5 Fig 6 Fig 7 Place ABS Disabled sticker here Apply heat shrink to ends of wires ...

Page 24: ... 4 5 16 x 1 Bolts CB1161 4 5 16 Lock Washers CW2047 4 5 16 Flat Washers CW2010 5 See Fig 3 Install LH and RH frame straps to upper holes in motorcycle frame using the fol lowing hardware Torque bolts to 18 ft lbs 1 LH Frame Strap S001266 1 RH Frame Strap S001268 2 5 16 x 1 Bolts CB1161 2 5 16 Lock Washers CW2047 2 5 16 Flat Washers CW2010 6 See Fig 3 Lower frame strap mounting holes will use the f...

Page 25: ... rear shocks 11 Secure airline to frame with cable ties as needed 12 Charge system with air to 20 psi and check for leaks 13 See Fig 6 Install Shock to lower threaded shock plate Torque bolt to 40 ft lbs Secure bolt with lock nut 2 1 2 X 2 x 1 4 Bolts CB1411 2 1 2 Flat Washer CW2025 2 1 2 Lock Nut 14 See Fig 6 Raise differential and install top of shock To frame using the following hardware Shock ...

Page 26: ...ubber mount into Lehman frame 4 Slide OEM muffler mounting bracket through rubber mount 5 Slide mufflers with clamps in place over Lehman extension pipes 6 Ensure mufflers are even on both sides 7 Torque exhaust clamps to 40 ft lbs 8 Use OEM mounting hardware to secure muffler to mounting bracket on Lehman frame Torque bolts to 144 in lbs Fig 1 ITEM PART QTY DESCRIPTION 0 OEM PARTS 1 S001273 1 PIP...

Page 27: ...e to stud with flange nut after taillight mounting hardware is installed 2 Taillight Assembly S002204 2 Gaskets BG0200 4 1 4 Flat Washer CW2006 4 Lock washer Provided with light 4 Nut Provided with light 2 1 4 Flange Nut CN3007 3 See Fig s 3 4 If required Install female terminals and male connectors to taillight wiring Use appropriate tool for crimping terminals to wires Mac Tools TCT1028 4 See Fi...

Page 28: ... in door 1 License plate light S001469 1 Support plate S001601 2 1 4 x 1 Button head bolt CB1086 2 M6 Flat washer CW2175 7 See Fig 6 Install lower license plate mounting hardware into place on support bracket using 1 4 x 50 bolts and 2 lock nuts 2 1 4 x 50 Button head bolt CS4032 2 1 4 Lock nut CN3040 8 Solder and heat shrink light wiring to trunk wiring harness Attach wire as follows Black wire o...

Page 29: ...e plate and light bar optional to harness terminals and connectors will need to be installed to each before connecting to wiring harness Use appropriate tool for crimping terminals to wires Mac Tools TCT1028 Blue Point PWC47 or H D 41609 4 See Fig 5 Inspect crimps before installing into connector Distortion should be minimal 8 position connector on wiring harness main 6 position connector on wirin...

Page 30: ...0023 1 License plate connector GH0023 3 Right brake light GH0023 3 Light bar GH0023 5 Left brake light GH0023 4 Left turn signal GH0023 4 Right turn signal GH0023 4 Included in bag Wiring Diagram Purple Blue Orange White Tracer Brown Black Red White Tracer Black Orange White Tracer LIGHTS AND WIRING CONTINUED 30 ...

Page 31: ...4 Using a 7 16 drill bit drill a 7 16 hole for grom met access hole 5 Install rubber grommet S001323 in grommet access hole Secure with glue if necessary 6 Using appropriate cutting tool cut side cover along template mark 7 See Fig 3 Trim upper rear mounting peg leaving 1 4 remaining 8 Repeat steps 1 7 for other side Fig 1 Fig 2 Set template firmly against peg Mark side cover cut out Mark grommet ...

Page 32: ... 4 x 1 Studs S001343 6 See Fig 1 Install seat shell to support on frame using the following hardware Leave bolts loose 2 1 4 Fender Washers CW2108 2 1 4 Lock Washers CW2040 2 1 4 Lock Nuts CN3041 7 See Fig 2 Install left and right body support brackets with 90 bend against frame strap attach front of body mount bracket into seat shell insert ing rubber washer between bracket and body Attach bracke...

Page 33: ...Fender Washers CW2108 4 Foam Sealing Washers FG1002 4 1 4 Flat Washers CW2007 4 1 4 Lock Nuts CN3041 15 Recheck body alignment adjust accordingly 16 Tighten body mount brackets to frame straps Torque bolts to 8 ft lbs 17 See Fig 5 Install upper body braces LB1235 by attaching slotted side on top of Lehman frame us ing the following hardware Leave hardware loose 2 Body Brace LB1235 2 5 16 x 1 Bolts...

Page 34: ...ivalent 7 Remove tour pack and assembly from body 8 Drill holes in body with 5 16 drill bit and drill 9 Remove tour pack from base assembly 10 See Fig 3 Place rubber gaskets on body and install base assembly using the following hard ware 4 5 16 x 1 1 4 Button Head Bolts CB1163 4 5 16 Lock Washers CW2046 4 5 16 Flat Washers CW2009 11 Install tour pack support brackets inside trunk body and fasten p...

Page 35: ...036 2 Aluminum Crimp CC1900 3 Apply masking tape to body just below hinge mounting holes to prevent scratching of paint by hinges 4 See Fig 3 Install door hinges and stop cable brackets to body with hinge gaskets underneath hinge using 10 32 x 1 screws and plated star nuts 2 Door Hinge GH0903 2 Hinge Gaskets FG1003 4 10 32 x 1 Phillips Screws CS4024 0 4 Plated Star Lock Nuts CN1898 5 Fasten door t...

Page 36: ...2 1 4 x 1 2 Bolts CB1075 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 1 Lehman Badge GB1320 15 Cut license plate wire from body to length to reach body wiring as needed 16 Install shrink tubing over license plate wires 17 Strip and solder ends of license plate wires from the body and...

Page 37: ...2009 2013 FLH RENEGADE Fig 1 DOOR ADJUSTMENT 37 ...

Page 38: ...2009 2013 FLH RENEGADE Fig 2 Fig 18 DOOR ADJUSTMENT CONTINUED 38 ...

Page 39: ...Make sure insert in fender is free of paint before installing screw 3 Install wheels Torque wire wheel lug nuts to 75 ft lbs and aluminum wheel lug nuts to 85 ft lbs Install center caps if applicable Caution Do not use an impact wrench when installing lug nuts 4 Reflectors can be installed to body See Fig 1 Install rear reflectors 3 below taillights on body See Fig 2 Install side reflectors using ...

Page 40: ...ximately twice as tight as factory specifications for a trike conversion Refer to H D service manual for adjustment procedure Caution Do not tighten bolts past factory specifications Only bearing adjustment collar should be tightened past factory settings STEERING NECK 40 ...

Page 41: ...lbs Torque link to engine frame 33 ft lbs Lehman frame front 75 ft lbs Rear frame bolts 18 ft lbs Frame brace top 18 ft lbs Frame brace lower 52 ft lbs Shock bolts 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 Axle flange bolts 38 ft lbs Differential bearing bridge bolts 38ft lbs TORQUE SPECIFICATIONS 41 ...

Page 42: ... 6 Wheel torque 85 ft lbs 75 ft lbs wire 7 Rear tire pressure 26 psi 8 Front tire pressure 36 psi 9 Trunk clean and dry 10 Trunk door seals and operates smoothly 11 Rear shocks set 20 psi 12 Heat shields side covers 13 Renegade Lehman badge installed 14 Accessories if applicable 15 No paint defects 16 Warranty owner s manual included FINAL TRIKE INSPECTION 42 ...

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