lehman Trikes DYNA Installation Instructions Manual Download

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2006-2013 FXD Renegade Rev. 6

DYNA

2006-2013 H-D FXD MODELS

Installation Instructions

Excludes Fat Bob

July 2014

Summary of Contents for DYNA

Page 1: ...2006 2013 FXD Renegade Rev 6 DYNA 2006 2013 H D FXD MODELS Installation Instructions Excludes Fat Bob July 2014 ...

Page 2: ...ng the Carrier Pulley Unit in the Differential Belt Tensioning and Tracking Attaching Adjusting and Bleeding the Brake System Installing the Lehman Frame Suspension Installing the Exhaust Body Prep Lights and Wiring Fitting the Body Door Install and Adjstment Neck Race Preload Renegade Torque Specifications Replacement Parts 2006 Dyna models use a 66 tooth pulley assembly 2007 2013 Dyna models use...

Page 3: ...tory trained installers A few steps may require special skills using power tools These steps should be completed by qualified personnel only These instructions do not include information specifications or repair procedures relating to the motorcycle itself Please reference a factory service manual for motorcycle information The information in these instructions is provided to Lehman Trikes dealers...

Page 4: ...the following 1 Differential with brakes 6 Hardware box small parts bolt bags 2 Wheel kit 7 Shock absorbers 3 Renegade Body 8 Warranty Book 4 Swingarm 9 Owners Manual 5 Lehman frame 10 Packing parts list Check your kit to the parts list and the order when it arrives 3 ...

Page 5: ...2006 2013 FXD Renegade Rev 6 4 MODULAR DIFFERENTIAL ...

Page 6: ...confirm bike is straight Locate a reference point on frame that is level 6 Remove side stand and side covers 7 Disconnect rear wiring harness 8 Remove rear turn signals from fender These will be reused with Lehman body 9 Remove rear fender assembly from motorcycle 10 Remove mufflers and heat shields from motorcycle save all exhaust hardware these parts will be reused 11 Remove muffler support from...

Page 7: ...g 1 3 Install motor mount braces LB6111 and aluminum spacers Long spacer LS6126 will go on RH side and short spacer LS6125 will go on LH side 4 See Fig 2 Fasten transmission brace and spacers with supplied CB1270 GR 8 bolts and CN3053 stake nuts Using Loctite 262 install bolt with head on RH side of motorcycle Torque to 33 ft lbs 5 Use new pivot shaft bolt LP6105 to align brace plates The pivot bo...

Page 8: ...rm collar facing upward 9 See Fig 4 Place swingarm pivot bolt spacer LS6129 on RH side of swingarm between swingarm bearing and LB6110 bracket 10 On pivot bolt LP6105 install a new CW2032 washer against bolt head 11 Holding swingarm in place insert pivot bolt assembly through RH side and into swingarm and transmission case Start stock flange nut as bolt emerges from bearing on LH side Use Loctite ...

Page 9: ...garm as shown Leave hardware loose 2 See Fig 2 Attach RH adapter plate to swingarm 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 Fig 2 Fig 1 8 ...

Page 10: ...2006 2013 FXD Renegade Rev 6 4 See Fig 3 and 4 Loosely install hardware to pinch blocks before installing differential to swingarm Fig 3 Fig 4 9 ...

Page 11: ...ential as far 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 f...

Page 12: ...The correct deflection is 5 16 3 8 7 Correct tension by adjusting tensioner bolts equally on both sides Any adjustment requires checking belt tracking again 8 Look along top of belt to check belt alignment on front pulley There should be about 0 030 clearance between pulley flange and belt If adjustment is required loosen cap screws that hold mount plate to swingarm and tap differential housing wi...

Page 13: ...tial 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 cylinder 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 See Fig 2 Ins...

Page 14: ...iper 7 Pump brake pedal to build pressure 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 8 Tighten bleeder valves and check for leaks 9 Install master cylinder reservoir cap with new screws Do not over tighten cap screws Park Brake Assembly 1 See Fig 1 Install park...

Page 15: ...ame attaching cable ties to cable and frame and install in left hole in handle mount 5 See Fig 4 Route right park brake cable up around axle and forward to right hole in handle mount 6 See Fig 4 Secure both cables to upper rear pinch block with clamp GC0108 7 See Fig 5 Secure cable retaining nuts to handle mount with 7 8 wrench 8 Check for tire clearance 9 See Fig 5 Thread one 5 16 NF nut onto eac...

Page 16: ...15 on both sides and secure with locknut CN3050 Bolt head should be toward outside of frame 3 Secure front of frame by using supplied 3 8 x 3 bolts S001080 with 1 frame spacer LS6127 between Lehman frame and H D frame and a smaller spacer LS1189 between outside of H D frame and floorboard brace LB6112 with slots to top Bolt head should be toward outside of frame Use flat washers CW2015 on both sid...

Page 17: ... adjusted 6 See Fig 4 Use 1 2 x 2 1 2 bolts to mount floor board brackets to H D frame Secure using the following hardware 2 1 2 x 2 1 2 Hex Bolts CB1417 4 1 2 Flat Washer CW2015 2 1 2 Lock Nut CN3060 7 See Fig 5 Install cross brace between frame braces and floorboard mounts using the following hardware Do not tighten floorboard mounts until later in build 1 Cross Brace LB6113 2 3 8 x 1 1 4 Bolt C...

Page 18: ... and GB0320 bushings through lower shock eye and thread it into shock plate Use 1 washer under head of bolt Lock bolt in with a lock nut 9 Raise differential and install top of shock using 1 2 x 2 1 4 bolt GB0320 bushing and one washer under head of bolt Shock should run parallel to frame tube when viewed from rear Torque shock bolts to 40ft lbs Fig 6 17 ...

Page 19: ...hman frame Use a 3 8 NC nylock nut washers and grommet GG6100 to attach sway bar to frame Leave loose Fig 7 11 Attach left hand side of sway bar to sway bar bracket S001883 using a 3 8 NC nylock nut 2 washers and 2 grommets GG6100 Shim with flat washers as needed Leave loose See Fig 8 Fig 8 18 S001883 ...

Page 20: ... at rest as this could alter power train alignment Make sure shocks are running vertical after sway bar is tightened There are 6 3 8 flat washers supplied to shim grommets on sway bar if needed Dyna Head Bolt Procedure Bolt Bag LCK5064 1 Remove existing 3 8 head bolts and washers from engine mount bracket on LH side 2 Apply Loctite 242 to threads of 3 8 x 1 hex flange locking bolts 3 Assemble bolt...

Page 21: ...ar header pipe will need to be cut approximately 3 back from center of cross over tube Install exhaust pipes LP6100 and LP6101 onto stock header pipes Slide exhaust clamps into position and leave loose Install mufflers onto Lehman exhaust pipes with muffler mounting plates pointing up NOTE Lehman pipes may need to be cut depending on muffler location Fig 1 20 ...

Page 22: ... 2 4 Insert bracket GB1200 into rubber isolator Attach bracket to Lehman frame using 2 5 16 x 1 1 2 bolts four 4 5 16 flat washers exhaust spacers LS6101 and lock nuts Fig 3 5 Adjust mufflers and pipes so they run even and parallel to one another 6 Fasten exhaust clamps to joint Position clamps so they do not squeeze a slit open on the sides and clamp opening does not line up with slits in pipe 7 ...

Page 23: ...00 4 1 4 Flat Washer CW2006 4 Lock washer Provided with light 4 Nut Provided with light 2 1 4 Flange Nut CN3007 4 If required Install female terminals and male connectors to taillight wiring Use appropriate tool for crimping terminals to wires Mac Tools TCT1028 5 Inspect crimps before installing into connector Distortion should be minimal 6 See Fig 3 Install thin weather seal CW2505 on bottom outs...

Page 24: ...2006 2013 FXD Renegade Rev 6 Fig 3 Fig 4 23 ...

Page 25: ...s 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 Fig 1 Body clips Light bar connector on RH side Taillight connector Fig 3 8 position connector on wiring harness main 6 position connector...

Page 26: ...olts and foot pocket mounting bracket 8 Tighten all foot pocket mounting hardware 9 Install rubber footpads through foot pocket and mounting bracket using washers CW2005 and locknuts CN3040 10 Verify that body is still square with motorcycle 11 From underside of body drill a hole in body through each of four mounting tabs Keep hole centered in slot of each of tabs 12 Fasten body as follows a 4 x 2...

Page 27: ...ring through lower hole in door 1 License plate light S001469 1 Support plate S001601 1 1 4 x 1 Button head bolt CB1086 2 M6 Flat washer CW2175 4 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 5 Solder and heat shrink light wiring to trunk wiring harness Attach wire ...

Page 28: ...l 2 door hinges GH0093 and stop cable brackets to body with 2 hinge gaskets FG1003 underneath hinge using 4 screws CS4024 0 and 4 plated star nuts CN1898 5 Fasten door to hinges using 4 10 32 x 3 8 screws CS4024 1 6 Attach stop cables to door using 2 1 4 20 x 438 shoulder screws CB1151 with flat washers under cable 7 See Fig 3 Torque shoulder screws to 10ft lbs using 5 32 Allen socket 8 Install la...

Page 29: ...B1320 to bottom left side of door 15 Fasten door to hinges using 4 10 32 x 3 8 screws CS4024 1 16 Attach stop cables to door using 2 1 4 20 x 1 2 hex head bolts CB1075 from body bolt bag and 4 1 4 Gr 8 washers CW2005 17 Cut license plate wire from body to length approx 12 14 18 Install shrink tubing over license plate wires 19 Strip and solder ends of license plate wires from the body and door tog...

Page 30: ...installed to body See Fig 1 Install rear reflector 3 below taillights on body See Fig 3 Install side reflectors using wheel center caps as a reference above wheel opening on body 2 Install rear wheels Torque lug nuts to 85 ft lbs wire wheels 75 ft lbs 28 Fig 3 ...

Page 31: ...2006 2013 FXD Renegade Door Adjustment Procedures Figure 0 10 Fig 1 29 ...

Page 32: ...2006 2013 FXD Renegade Fig 2 Fig 3 30 ...

Page 33: ...e approximately 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 31 ...

Page 34: ...pter plate 31 ft lbs Banjo bolts 16 ft lbs LB6111 Transmission Brace Bolts 33 ft lbs LB6110 Swingarm Pin Brace 20 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 38 ft lbs Axle tube bolts 38 ft lbs Differential housing plate bolts 17 ft lbs 32 ...

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