lehman Trikes CrossBow Victory Vision 2009 Installation Instructions Manual Download

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2009+

Victory Vision Models

Installation Instructions

April 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

Summary of Contents for CrossBow Victory Vision 2009

Page 1: ...2009 Victory Vision Models Installation Instructions April 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: ...rcycle tank as shown 5 Remove clutch reservoir cap using Phillips screwdriver 6 Using brake bleeder suck out all clutch fluid from reservoir 7 See Fig 2 Using brake bleeder and 6mm wrench suck out remaining clutch fluid from the system as shown 8 See Fig 3 Install 1 ball to 1 modified banjo bolt 1 Ball S001508 1 Modified Banjo Bolt S001502 9 See Fig 3 Install 1 seat to banjo bolt using 1 8 Allen w...

Page 3: ...applied make sure that the cross drilled holes are lined up with the banjo adaptor as shown Fig 00 13 If the holes are not lined up with the adaptor the clutch will not oper ate properly 14 Fill clutch reservoir with DOT 5 1 15 See Fig 6 Bleed the clutch system as shown us ing brake bleeder 16 Depress the clutch lever slowly and repeatedly making sure all air bubbles are out of the system This can...

Page 4: ...ct wire harness from tour pack 4 See Fig 2 Remove tour pack using 13mm socket and 12 extensions 4 Bolts save 5 Open saddlebags Remove and save owners manual 6 Remove taillight valence Ensure clips are re tained with valence 7 See Fig 3 Remove exhaust valence as shown using 4mm long Allen head socket Save 6 bolts 8 Fig 1 Fig 2 Fig 3 DISASSEMBLY ...

Page 5: ...t 5 screws each side L R save 2 See Fig 2 Remove 5 bolts from rear of sad dle bag as shown using 10mm socket and 4mm Allen socket front bolt 3 bolts save 3 See Fig 3 Remove 2 lower bolts from rear of saddle bag as shown using 10mm socket 4 Remove 2 lower nuts from front studs using 10mm socket and 6 extension Fig 1 Fig 2 Fig 3 ...

Page 6: ... 4 latch assembly bolts Remove latch assembly using 10mm socket 4 bolts save 6 See Fig 5 Remove 3 bolts from front of sad dle bag using 13mm socket 7 See Fig 6 Remove 2 bolts from upper sad dle bag using 13mm socket Fig 6 Fig 4 Fig 5 ...

Page 7: ...g using 13mm socket located behind latch assembly 10 Remove rear most bolt from saddle bag using 10mm socket lower outside of taillight 11 See Fig 8 Remove 2 relays from saddle bag using 10mm socket 12 See Fig 9 Remove striker from saddle bag as shown using T 20 Torx Bit Fig 8 Fig 9 Fig 7 ...

Page 8: ... air shock fill valve using 7 8 socket 15 Re install nut to fill valve 16 See Fig 10 Remove and save left and right side cover grommets as shown 17 See Fig 11 Remove diagnostic cable and grom met as shown 18 Remove main wire harness connector from frame 19 Remove saddlebag from bike Fig 10 Fig 11 ...

Page 9: ...ft Side extension pipe using 15mm socket Save clamp 1 Clamp save 5 See Fig 2 Remove left and right side pivot shaft nuts as shown using 24mm socket Save 1 nut and 2 washers Fig 10 16 1 Pivot Shaft Nuts save 2 Pivot Shaft Washer save 6 See Fig 3 Remove Left Side rollover brace using 10mm socket and 6mm allen head socket 7 See Fig 3 Remove rollover brace from floor board using 6mm allen head socket ...

Page 10: ...allen head socket Disconnect and place on top of tail section as shown 5 Bolts save 10 See Fig 5 Remove reinforcement plate using 10mm socket Fig 10 20 2 Bolts save 11 Remove tail section using 13mm socket Set aside for modification 2 Bolts save Fig 4 Fig 5 ...

Page 11: ...sing 13mm socket 16 Remove rear axle and wheel assembly 17 Dismount rear caliper from swingarm Set aside for later disassembly 18 Remove shock fill hose from splash guard 2 plastic inserts 19 See Fig 8 Remove and discard splash guard using 6mm allen head socket 20 Remove 2 splash guard brackets using 13mm socket 21 Remove OEM shock hose from splash guard bracket 22 See Fig 9 Remove ABS module and ...

Page 12: ...ve 24 See Fig 11 Remove swingarm pin on RH side using 24mm deep socket 25 Tap out swingarm pin using rubber mallet and re move swingarm 26 See Fig 12 Remove and save LH RH swingarm washers RH steel bushing and LH bronze bushing 27 See Fig 13 Remove 2 screws that hold cruise control module using 10mm socket Fig 10 Fig 11 Fig 12 Bolts Fig 13 ...

Page 13: ...ark areas to be trimmed on tail section using left and right trim splashes as shown Mark using silver sharpie in indicated areas 3 See Fig 3 Finish straight line over the top of tail section using masking tape as shown 4 Trim marked areas using jig saw and dremel 5 Set aside for later installation Fig 1 Fig 2 Mark Mark Fig 3 ...

Page 14: ... as shown using masking tape 2 Trim masked off portion of center valence us ing cut off wheel 3 See Fig 2 Trim approximately 1 4 from bot tom corner as indicated 4 See Fig 3 Trim approximately 1 8 from va lence as indicated 5 De burr cut edges and set aside for later instal lation Fig 1 Fig 2 Fig 3 1 4 1 8 ...

Page 15: ... exhaust header pipe 4 from the rearmost weld of crossover pipe using band saw 3 Using flapper wheel de burr the remaining end of the header pipe 4 See Fig 3Using RS Heat Shield Cutting Fix ture mark the RS heat shield where it is to be cut 5 Using band saw cut RS heat shield at marked location saving the front half Fig 1 Fig 2 Fig 3 Mark Cut Here Save ...

Page 16: ... slot to the upper left side of RS heat shield as shown using cutoff wheel 8 Set aside modified RS heat shield for later in stallation 9 See Fig 6 Remove front and rear mounting tabs from OEM mufflers 2 as shown using cutoff wheel 10 Set aside modified mufflers for later installation Fig 4 Fig 5 Fig 6 Slot Drill ...

Page 17: ... catalytic converter 3 Check the fitment of the newly removed cata lytic converter to the shortened upper header pipe 4 If the catalytic converter does not fit the header pipe will need to be expanded slightly using the exhaust expansion tool 5 See Fig 3 Install catalytic converter to short ened upper header pipe as shown NOTE The use of a rubber mallet may be re quired to fully seat the catalytic...

Page 18: ...re hand started on the left side of frame 4 See Fig 2 Hand start 1 upper bolt CB1972 to left side of frame as shown 5 Repeat steps 2 3 to hand start 2 bolts CB1974 and 1 upper bolt CB1972 on right side of frame 6 Remove bungee strap from frame 7 See Fig 3 Install OEM Rollover Brace with Reinforcement Bracket to left side of frame as shown using 2 bolts Hand tighten only using 6mm Allen socket 1 Ro...

Page 19: ...10x30 CB1971 2 See Fig 2 Install 1 LH Swingarm Adaptor Plate as shown using 2 Bolts Hand start bolts from the inside 1 LH SWA Adaptor Plate S001201 2 Bolt M10x30 CB1971 3 See Fig 3 Temporarily install 1 swingarm pin with 2 bushings for alignment purposes only as shown 1 Swingarm Pin S001335 4 Snug up swingarm adaptor plate bolts using 15mm socket 5 Remove swingarm pin and bushings Fig 1 Fig 2 Fig ...

Page 20: ... 3 8 Nylock Nut CN3052 3 See Fig 3 Install upper shock bracket to frame as shown using 4 bolts Hand start bolts only at this time 4 Bolt CB1972 4 Torque and mark upper shock bracket bolts to 22 ft lbs using 13mm socket 5 Torque and mark transmission bolts to 45 ft lbs using 15mm swivel socket Torque and mark left and right side rollover brace bolts to 22 ft lbs using PART PART DESCRIPTION TORQUE C...

Page 21: ...n press a seal on each side of the bearing with hammer and seal press tool making sure the open side of the seal faces toward the bearing 1 Needle Bearing GB1032 2 Seals S001338 4 See Fig 2 Press 1 spherical bearing with loctite 609 to LS of lower swingarm using bearing press tool as shown 1 Spherical Bearing S001385 5 See Fig 2 Press 1 spherical bearing with loctite 609 to RS of lower swingarm us...

Page 22: ...ivot shaft nut IN ORDER OF INSTALL 1 Swingarm Pin S001335 1 Washer OEM 1 Bronze Bushing LS OEM 1 Steel Bushing RS OEM 1 Washer OEM 1 Nut OEM 5 Torque and mark swingarm pin to 65 ft lbs using 24mm end wrench on RS and 27mm socket on LS 6 Torque and mark swingarm adaptor plate bolts to 35 ft lbs using 15mm swivel socket and 12 extension 7 Remove floor jack from swingarm 8 Move swing arm up and down ...

Page 23: ... using 2 OEM shock bolts 4 OEM bushings and 2 nylock nuts Tighten using 17mm socket 2 Shock Bolt OEM Shock Bolt 4 Bushing OEM 2 Nylock Nut CN3049 Torque and mark lower shock bolts to 54 ft lbs using 15mm socket 17mm wrench PART PART DESCRIPTION TORQUE OEM LOWER SHOCK BOLTS 2 54 FT LBS Fig 4 ...

Page 24: ...daptor Plate S001199 8 Bolt CB1973 2 See Fig s 2 3 Install adjuster bolts to both sides of differential as shown Leave loose for future adjustment 2 Bolt 3 8x2 CB1263 2 3 8 Jam Nut CN3017 3 See Fig 3 Using differential hoist install RS of differential to adaptor plate as shown using 3 bolts Snug up bolts using 17mm socket Leave loose enough for adjustment 3 Bolt CB1973 Fig 1 Fig 2 Fig 3 Adjuster B...

Page 25: ...s using 17mm socket Leave loose enough for adjustment 3 Bolt CB1973 5 Slide differential as far forward as possible 6 See Fig 2 Remove upper lower and rear housing plates Fig 20 20 7 See Fig 3 Carefully slide belt over pulley 8 Reinstall housing plates with original hardware using Loctite 242 Install all hardware before tightening Torque hardware to 17 ft lbs Fig 4 Fig 5 Left Side Fig 6 ...

Page 26: ...ers S001784 1 Differential Brace S001840 10 See Fig 8 Bolt rear half of differential brace to differential housing 1 Flange Head Bolt M8 x 35 CB1939 11 See Fig 8 Bolt front half of differential brace to top of swingarm gusset 1 Bolt 3 8 x 1 1 4 CB1242 1 3 8 Flat Washer CW2015 1 3 8 Lock Washer CW2049 Note Do not bolt down brace until belt ten sioning is completed Fig 7 Fig 8 ...

Page 27: ... 2 Install wheel crank tool on wheel studs Install diff stop tool on other side of diff in the same manner 5 Using wheel crank manually move belt around pulley to ensure belt is located properly on pulley 6 See Fig 3 Measure belt deflection at 10 lbs us ing a tape measure and belt tensioning tool NOTE Belt deflection should initially be set to 7 8 at 10 lbs Check at 4 locations on belt Measure at ...

Page 28: ...ng 17mm socket 13 Torque and mark Front Differential Brace to Swingarm Bolt to 35 ft lbs using 9 16 socket 14 Torque and mark LH front Differential Brace to housing bolts to 17 ft lbs 15 Tighten jam nuts on adjuster bolts using 9 16 wrench 16 Verify belt deflection is still set to 3 4 at 10 lbs Check at 4 locations on belt Fig 4 PART PART DESCRIPTION TORQUE CB1973 ADAPTOR PLATE TO DIFF BOLTS 6 55 ...

Page 29: ...See Fig 2 Secure secondary shock to lower shock mount bracket as shown using 1 nylock nut 2 spacers and 1 take off transmission bolt Tighten using 15mm socket and 17mm wrench 1 Secondary Shock S001233 1 Nylock Nut CN3049 1 Flat Washer CW2015 2 Spacer S001236 1 Bolt take off transmission NOTE Floor jack may be needed to raise differ ential slightly to line up bottom shock mount with secondary shock...

Page 30: ... and to let the fluid drain us ing 5 16 wrench 4 Remove OEM rear caliper Let fluid drain into oil pan 5 Place caliper in bag and place in designated box 6 See Fig 2 Remove upper proportioning valve line from ABS module as shown using 10mm wrench 7 Remove and discard proportioning valve 8 See Fig 3 Re attach OEM rear caliper brake line to ABS module where upper proportioning valve was just removed ...

Page 31: ...ABS module to frame as shown using 2 bolts CB1972 and 1 nut CN1908 with Loctite 242 Tighten using 13mm socket 2 Bolt CB1972 1 Bolt CB1929 Front Hole 1 Nut CN1908 Front Bolt Only 11 Torque and mark ABS module bolts to 22 ft lbs using 13mm socket Fig 4 PART PART DESCRIPTION TORQUE CB1972 ABS MODULE BOLTS 2 22 FT LBS Fig 5 OEM Bolt and Clamp ...

Page 32: ...n 3 Cable Tie CT1015 3 See Fig 2 Secure OEM rear brake line to ABS module as shown using 1 p clamp from relays and 1 bolt take off as indicated Tighten using 10mm socket 4 See Fig 3 Install brake lines to left right calipers as shown using 1 banjo bolt and 2 supplied copper washers Tighten using 14mm wrench 2 Banjo Bolt 4 Copper Washers GC6002 Fig 1 Fig 2 Fig 3 P Clamp ...

Page 33: ...sher 1 4 CW2005 8 Torque and mark brake T bolt to 12 ft lbs using 7 16 socket 9 Attach left and right side brake lines to brake T 10 See Fig 6 Attach OEM brake line to brake T mount using 1 banjo bolt and 2 copper wash ers Tighten using 14mm wrench 1 OEM Brake Line 1 Banjo Bolt 2 Copper Washer GC6002 11 Re Check all brake line fittings using a 7 16 wrench to make sure they are tight 12 Torque and ...

Page 34: ...ke cable to left side of trike as shown and attach to brake caliper using clevis pin washer and cotter key Install washer under head of clevis pin 1 Clevis Pin CC3108 1 Washer CW2160 1 Cotter Key CC4018 4 See Fig 3 Secure park brake cable to outer un derside of left front body mount as shown using 1 cable clamp and 1 bolt Tighten using 13mm socket 1 Cable Clamp GC0112 1 Bolt CB1977 5 Torque and ma...

Page 35: ... to outer un derside of right front body mount and differential housing as shown using 2 cable clamps and 1 bolt Tighten using 13mm socket 2 Cable Clamp 1 Bolt CB1977 8 Torque and mark cable clamp bolt to 22 ft lbs using 13mm socket 9 See Fig 6 Using park brake lever torque fix ture adjust the park brake until a value of 14 15 ft lbs is obtained upon engagement Fig 4 Fig 5 Fig 6 Torque Fixture PAR...

Page 36: ...ike as shown using 2 High Temp Cable Ties 2 High Temp Cable Tie CT1026 12 See Fig 9 Verify brake cables are secured to right side of trike as shown using 2 T Stud Clips and 3 High Temp Cable Ties 2 T Stud Clip S001480 4 High Temp Cable Tie CT1026 13 Remove park brake lever assembly from bracket and lay down on differential This needs to be removed for body installation Fig 7 Fig 8 Fig 9 ...

Page 37: ...nce shown in Fig 1 attach brake bleeder to the first bleeder screw as shown making sure to install the 10mm wrench to the bleed screw first 4 Suck out all air from brake line with the brake bleeder until fluid begins to come through by turning on the brake bleeder and opening the bleeder screw slightly 5 Tighten the bleeder screw and remove the brake bleeder and 10mm wrench Note Be sure to keep an...

Page 38: ...ew with a 10mm wrench 11 Turn on the brake bleeder to suck up any fluid that may have collected in the hose 12 Repeat steps 7 11 for each bleeder screw until no bubbles emerge from the brake system This includes tiny bubbles as well as large 13 Repeat steps 7 11 to bleed the front brake cali pers until no bubbles emerge from the brake system This includes tiny bubbles as well as large 14 Fill rese...

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lehman Trikes CrossBow Victory Vision 2009, Installation Instructions Manual

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