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2009-2013 H-D FLH MODELS

Limited Lean Suspension Installation Instructions

June 2014

2

• Safety Information • Specifications • Disassembly • Swingarm • Differential and Suspension Installation • Belt Alignment • Top Mount and Rocker Adjustment • Seat Mount • Sway Bar Installation • Brake System • Park Brake Installation • Exhaust • Lights and Wiring • Body Installation • Side Cover Installation • Trunk Door Installation • Final Assembly • Steering Neck Preload

© 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 this manual, Lehman Trikes® assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Lehman Trikes® reserves the right to revise and improve its products as it sees fit. This publication describes the state of this product at the time of its publication, and may not reflect the product in the future. Lehman Trikes® is a registered trademark. All other brands and product names are trademarks or registered trademarks of their respective holders. Printed in the United States of America.

SECTION BREAKOUT

3

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. Your safety is involved!

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, by-stander or person (s) inspecting or servicing the vehicle.

WARNING

Indicates a potential hazard that may result in minor per-sonal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

CAUTION

NOTE provides key information by clarifying instructions.

NOTE:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

IMPORTANT:

SAFETY INFORMATION

4

General Safety Information This kit is designed to be installed by a competent technician. Improper installation can affect the safe operation of your trike, which could also result in serious injury or death. Make sure you have a complete understanding of the work to be preformed. Unqualified installers are urged to have the unit installed by a trained technician.

• Always protect yourself when the vehicle is in the air. Make sure the vehicle is properly supported anytime you use a hoist or jack.

• Always use the proper tools.

• Protect your eyes by 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.

SAFETY INFORMATION

WARNING

5

Specifications • Verify that you have all components before assembly.

• Before installing your new Lehman kit, we recommend that your motorcycle be inspected and serviced 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.

• CAUTION: This kit is not designed for use on lowered motorcycles. Interference be-tween the tires and body may occur.

INFORMATION

Overall Width  57.5" Overall Length  103" Wheel Base  72" Curb Weight   1204lb Rear Tire Size   205/70‐15 Rear Tire Pressure  26 PSI Rear Suspension  Double A‐Arm Independent  Storage  5.75 Cubic feet 

6

Disassembly NOTE: Refer to the H-D service manual for de-tailed 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. Remove seat, save mounting hardware. 4. Remove side covers. NOTE: Save tour box mounting hardware 5. Remove tour box liner and disconnect any wir-

ing. Remove tour box. (if equipped) 6. Remove saddlebags (if equipped). 7. Remove saddlebag frames (if equipped). 8. Remove tour box frame (if equipped). 9. Remove passenger footboards. 10. Remove mufflers. 11. Disconnect air lines and remove rear shocks. 12. Remove rear wheel. 13. Disconnect rear brake line at caliper and remove

caliper. 14. Remove rear fender. 15. See Fig. 1. Remove pivot shaft nut from LH side

of swingarm. Remove swingarm frame brackets. Tap pivot shaft out of swingarm and remove from RH side. Remove swingarm from motorcycle. Bearings and spacers will be reused.

16. See Fig. 2. Remove lower swingarm/frame mounting hardware from differential assembly. Remove lower adjuster bracket hardware from each side.

17. Temporarily remove swingarm and rear frame from differential assembly.

18. See Fig. 3. Temporarily remove upper seat mount frame from differential assembly.

PREPARING THE MOTORCYCLE Fig. 1

OEM Swingarm

Fig. 2

Remove swingarm/frame hardware

Remove lower hardware

Fig. 3

Remove upper frame

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Swingarm NOTE: Trim LH & RH head pipes before install-ing swingarm. 1. Trim 2-1/4”” from RH head pipe. Trim 1-1/2” from

LH head pipe. Additional trimming may be re-quired during exhaust installation.

2. See Fig. 1. Modify original outer spacers by drill-ing to 3/4” I.D. Verify that spacers slide freely over full length of swingarm pivot shaft.

3. See Fig’s 2 & 3. Install original swingarm bear-ings into trike swingarm opposite from OEM ori-entation.

4. See Fig’s 2 & 3.Install modified spacer opposite from OEM orientation.

5. Apply Anti-Seize to OEM pivot shaft. 6. Position trike swingarm over transmission hous-

ing. Slide pivot shaft through swingarm and transmission housing.

7. Install rubber mounts, cup washer and nut to pivot shaft. Use blue Loctite on pivot shaft nut.

8. Install LH and RH swingarm frame brackets. Use blue Loctite on mounting bolts. Align rubber mount index tab with bracket slots.

9. Torque pivot shaft bolt to 45 ft-lbs. 10. Torque swingarm frame bracket bolts to 42 ft-lbs. 11. Verify swingarm has no side to side movement.

Loosen and re-torque pivot shaft if necessary.

INSTALLATION Fig. 1

Fig. 2

Fig. 3

Before After

3/4”

Bearing Modified spacer

8

Differential/Suspension Assembly WARNING: Differential assembly is ex-

tremely heavy. Verify assembly is properly sup-ported and secure while installing to motorcy-cle. Additional help may be required during in-stallation. 1. Set differential assembly on lift behind swin-

garm. 2. See Fig. 1. Remove the upper and lower rear

(3) connector tubes on differential assembly. 3. See Fig. 2. Pass the left side of differential as-

sembly through the drive belt. Place drive belt onto pulley.

4. See Fig. 2. Reinstall (3) connector tubes. Ap-ply 1-2 drops of oil to bolts. Torque hardware to 150 ft-lbs.

5. See Fig 3. Install Top seat mount frame and spacers to motorcycle frame using the follow-ing hardware. Torque 5/16” bolts to 20 ft-lbs. • (6) 5/16” x 1-3/4” Hex Head Bolts– CB2022 • (12) 5/16” Flat Washers– CW2013 • (6) 5/16” Lock Nuts– CN3045

INSTALLATION Fig. 1

Fig. 2

Fig. 3

Place belt on pulley

9

Differential/Suspension Assembly 7. See Fig. 4. Raise differential assembly and

attach to top seat mount frame using removed hardware. Temporarily tighten bolts. • (4) 1/2” x 1-1/2” Hex Bolts • (8) 1/2” Flat Washers • (4) 1/2” Lock Nuts

8. See Fig. 5. Attach swingarm and rear body frame to differential assembly using removed hardware. Leave hardware loose for belt ad-justment. • (4) 1/2” x 3-1/2” Hex Bolts– CB2017 • (8) 1/2” Flat Washers– CW2178 • (4) 1/2” Lock Nuts– CN3060

NOTE: See Fig. 5. Use rear holes in swingarm for all models. 9. See Fig. 6. Install belt adjuster brackets to

swingarm from top body mount frame using the following hardware. Mount to rear holes on swingarm. • (2) 3/8” x 1-1/4” Hex Bolts– CB2018 • (4) 3/8” Flat Washers– CW2180 • (2) 3/8” Lock Nuts– CN3051

10. Torque belt adjuster bracket hardware to 30 ft-lbs.

INSTALLATION Fig. 4

Fig. 5

Fig. 6

Use rear holes on swingarm

Body frame

Swingarm

10

Belt Alignment and Tensioning 1. See Fig. 1. Adjust belt tension and differential

alignment by moving differential assembly for-ward or rearward as needed using adjuster bolts.

NOTE: Verify adjuster bolts are equal from side to side before tightening hardware. 2. Set belt tension by measuring total vertical

movement. • New Belt- 3/4”-1” • Used Belt- 1”-1-1/2”

3. Check belt alignment by turning the pulley by hand, verifying that belt runs in the center of the pulley. Belt may ride next to flange as long as it’s not trying to climb.

4. Recheck belt alignment after making any ad-justments.

5. After all adjustments are made, tighten adjuster jam nuts

6. See Fig. 2. Torque front swingarm/frame mounting bolts to 50 ft-lbs.

7. Check belt alignment and adjust as needed. 8. See Fig. 2. Once belt alignment is correct,

torque rear swingarm/frame bolts to 50 ft-lbs. NOTE: See Fig. 3. Rear shocks are preset on the fourth setting (4 complete revolutions on lower collar) from the factory. Shocks have a total of 7 settings. Adjust shocks as needed.

INSTALLATION Fig. 1

Fig. 2

Front Rear

Adjuster bolt

Fig. 3

Soft Firm

11

Top Mount and Rocker Adjustment

INSTALLATION Fig. 1

1. See Fig. 1. Verify vibration rockers are close to vertical (within a few degrees of vertical is accept-able) before tightening upper hardware.

2. If rockers are vertical, torque upper hardware to 50 ft-lbs. 3. If rockers are not vertical, loosen belt adjuster bracket and adjust as needed. Torque adjuster

bracket hardware to 30 ft-lbs when finished.

Vibration rockers

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Seat Mount 1. See Fig. 1. Install the seat mounting bracket to

the upper trike frame using the following hard-ware. Torque hardware to 30 ft-lbs. • (1) Seat Mount Bracket– S002118

• (8) 3/8” x 1-1/4” Hex Head Bolts– CB2018

• (16) 3/8” Flat Washers– CW2180

• (8) 3/8” Lock Nuts– CN3051 2. Reuse stud plate from OEM fender. 3. See Fig. 2. Cut off end (harness guide) from

plate. 4. See Fig. 3. Install stud plate to seat mount us-

ing OEM retainers. 5. Install chrome grab handle to seat mounting

using OEM hardware.

• (1) Grab Handle– LH1026

INSTALLATION Fig. 1

Fig. 2

Fig. 3

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Sway Bar Installation 1. See Fig’s 1 & 2. Install sway bar to swingarm

using the following hardware. Short end of sway bar should be on the RH side. Torque to 30 ft-lbs.

• (4) 3/8” x 1” Hex Bolt- CB2000 • (8) 3/8” Flat Washers- CW2180

• (4) 3/8” Lock Nuts- CN3051 2. See Fig. 3. Install sway bar rod ends to LH and

RH control arms using the following hardware. Install one washer to each side of rod end. • (2) 3/8” x 2-1/4” Hex Bolt- CB2001

• (6) 25/64” Stainless Flat Washers-CW2182

• (2) 3/8” Lock Nut- CN3051 3. Adjust rod end on LH side in or out until bolt

moves freely. 4. Tighten jam nuts on rod ends.

• Tighten rod end hardware. Torque to 30ft-lbs

INSTALLATION Fig. 1

Fig. 2

Fig. 3

Install washers

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Brake System CAUTION: Brakes are a critical safety compo-nent of the trike. Verify all brake components have been properly installed before test riding. Improper brake operation could result in death or serious injury. Do not allow dirt or debris to enter master cylinder reservoir. New brake pads and rotors will have a break-in period be-fore optimum brake operation is achieved. Note: FOR ABS DISABLE, SEE PAGE 17 1. See Fig. 1. Connect residual valve to brass

block as shown using a copper banjo washer. Torque valve to 11 ft-lbs. • (1) Residual Valve– S002037

• (1) Copper Banjo Washer- GC6002 2. See Fig. 1. Connect OEM brake line to residual

valve using the following hardware. Torque banjo bolt to 16 ft-lbs. • (1) M10 x 20 Banjo Bolt-S002229

• (2) Copper Banjo Washer- GC6002 3. Remove reservoir cap. 4. Bleed rear brake system at rear calipers with

brake bleeder or hand operated vacuum pump. 5. Repeat bleeding until all air is eliminated from

brake system. Verify rear brake pedal is firm and does not bottom out.

6. Fill fluid reservoirs and install caps.

INSTALLATION Fig. 1

Valve

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Park Brake Installation 1. See Fig. 1. Attach park brake lever to bracket

as shown. 2. See Fig. 2. Install park brake bracket to sway

bar on LH side. Bracket should be 3-1/2” from outside of sway bar. Install using the following hardware. • (1) Park Brake Bracket– S002112

• (1) U-Bolt- S002047

• (2) 3/8” Thin Lock Nut- CN3055

• (2) 3/8” Flat Washer– CW2180

INSTALLATION Fig. 1

Item# Part# Description 1 GB1099M Park Brake Lever 2 LB1294 Cable Pulling Bracket 3 CC3106 Clevis Pin 4 CC4017 Cotter Pin 5 S002112 Park Brake Bracket

1

3,4

2

5

Fig. 2

3-1/2”

16

3. See Fig. 3. Route RH cable along upper con-trol arm and in front of body mount as shown.

4. See Fig. 4. Secure RH cable to frame with ca-ble ties as shown. Attach LH cable to upper control arm with cable tie. Join RH and LH ca-bles together below lower control arm.

CAUTION: Ensure RH park brake cable has enough clearance around belt and pulley. 5. See Fig. 5. Attach park brake cables to

bracket using nuts and washers provided on the cables.

6. See Fig. 5. Attach cables to pulling bracket using 5/16” nut on each side. • (4) 5/16” Nut- CN3009

7. Adjust cables until brake system holds at 3-4 clicks on lever. Tighten 5/16” nuts against bracket.

8. Install park brake boot over lever. Secure with cable tie.

CAUTION: Ensure boot does not interfere with LH muffler. Damage to boot may occur.

INSTALLATION Fig. 3

Fig. 5

Fig. 4

Route in front of body mount

RH Side

LH Side

Secure RH ca-ble along frame

Secure LH cable to upper control arm

Bring together

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ABS Systems 1. See Fig. 1. Disconnect OEM rear brake line

(black line) from ABS unit “MR”. Route brake line along lower frame tube and above swin-garm. This line will be used for the rear brake system.

2. See Fig. 2. Re-install banjo bolt with washers and spacer (S001067) in ABS unit “MR” and tighten.

3. See Fig. 1. Disconnect OEM rear brake line (silver line) from ABS unit “R” and discard (brake line was disconnected from rear caliper during motorcycle disassembly).

4. See Fig. 2. Re-install banjo bolt with washers and spacer (S001067) in ABS unit “R” and tighten.

5. See Fig 3. Locate ABS front wheel sensor plug under left side of fairing and disconnect. Se-cure longer sensor plug to fairing wire bundle with cable tie.

6. See Fig. 4. Locate ABS rear wheel sensor plug (left side of ABS unit). Disconnect plug, remove sensor from right-side axle and dis-card.

INSTALLATION Fig. 1

Fig. 2

Fig. 3

Fig. 4

From ABS to caliper (silver)

From Master Cylinder to ABS (black)

R

MR

Banjo bolt spacer

R MR

ABS front wheel sensor plug

ABS rear wheel sensor plug

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ABS Systems 7. Remove outer fairing (refer to HD service man-

ual). CAUTION: Disabling ABS light will also disable cruise control light. “ABS Disabled” label can be placed over light if you chose not to disable light. 8. See Fig. 5. Disable ABS warning light by cut-

ting orange 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 disabled label over light

on tachometer

INSTALLATION Fig. 5

Fig. 7

Apply heat shrink to ends of wires

Fig. 6

Place “ABS Disabled” sticker here

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Exhaust 1. Verify head pipes were properly trimmed during

disassembly. NOTE: Additional trimming may be required to head pipes and exhaust extensions. Aftermar-ket exhaust may require additional modifica-tions. 2. Install exhaust extensions and clamps to head

pipes. • (1) RH Exhaust Extension– S002231

• (1) LH Exhaust Extension– S002230

• (2) Exhaust Clamps– GC1016 3. See Fig’s 1 & 2. Install muffler plates to frame

using the following hardware. NOTE: Tighten muffler hardware until 2-3 threads are visible through lock nuts. Do not over tighten hardware.

• (2) Muffler Plate– S002170

• (6) Muffler Vibration Mount– S002225 4. Install mufflers to extensions using the OEM

clamps. 5. See Fig. 3. Mount mufflers to brackets using

the following hardware. • (4) 5/16” x 3/4” Hex Head Bolts– CB1154

• (4) 5/16” Flat Washers- CW2013

• (4) 5/16” Lock Washers– CW2045 6. Verify alignment on all exhaust components

and tighten exhaust clamps.

INSTALLATION Fig. 1

Fig. 2

Fig. 3

LH muffler mount

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INSTALLATION Lights and Wiring 1. Install wire harness to trike body. Route light mod-

ule and main harness connector along RH side of body.

NOTE: Module will connect to battery once body is installed. 2. Route brake wiring to rear of body following wiring

clips on each side. Route connector with yellow wires to RH taillight. Route connector with gray wires to LH taillight.

3. Route trailer harness, license plate and accessory wiring along RH side and below trunk.

NOTE: Do not over tighten taillight mounting hard-ware. Damage to housing may occur. 4. See Fig 1. Mount taillight assemblies to body with

gaskets. Attach ground wire 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 5. See Fig’s 2 & 3. If required- Install female termi-

nals and male connectors to taillight wiring Use appropriate tool for crimping terminals to wires. (Mac Tools– TCT1028).

6. See Fig’s 2 & 3. Inspect crimps before installing into connector. Distortion should be minimal.

Taillight/Body Wiring-

Attach ground wire to stud

Fig. 1

Fig. 2

Wire core crimp

Insulation crimp

Function Taillight Trike Harness Brake #1 Red Yellow Tail #2 Black Yellow (Center Terminal)

Ground #3 Green Black

Female Terminal

Fig. 3

1

2

3

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INSTALLATION Fig. 4

Fig. 5

Lights and Wiring 7. See Fig. 4. Install license plate bracket to door

with 1/4” x 1” bolts, washers, lock nuts and rubber washers. Use rubber washers between bracket and door. Install U-nuts to bracket

• (2) 1/4” x 1” Button head bolt—CB1086

• (2) 1/4” Rubber washer- FG1002

• (2) 1/4” Flat washer- CW2005

• (2) 1/4” Lock nut- CN3040

• (2) 1/4” U-nut- CN3301 8. See Fig. 5. Install license plate light and support

plate to bracket using (2) 1/4” x 1 bolts. See Fig. 4. Run wiring through lower hole 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 9. See Fig. 5. 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 10. Seal wiring through door with silicone (Ultra Black).

Install rubber washers between bracket and door

Install wire through lower hole

U-nut

22

Body Installation NOTE: The installation /alignment of the body is an important process to find the correct posi-tion of the body in relation to the wheels. The pre-drilled holes in the body are for shipping purposes. Re-drill the holes if necessary once the body is properly aligned. 1. Carefully place trike body on frame and posi-

tion using the (6) body mounts. Install the fol-lowing hardware and leave loose.

• (6) 3/8” Fender Washers– CW2180

• (6) 3/8” Thin Lock Nuts– CN3055 2. Align body to trike. Center body by checking

side to side (wheel opening) and front to back (front of fender) measurements.

NOTE: Open mounting holes if necessary to achieve proper alignment. 3. Torque all body mounting nuts to 20 ft-lbs. 4. See Fig. 1. Route emergency release cable

from trunk along RH side of motorcycle frame. Secure emergency release with cable ties to sit behind RH side cover.

5. See Fig. 1. Plug main connector from trike body harness to rear lighting connector on mo-torcycle. Install positive and negative leads from module and fuse holders to battery termi-nals.

NOTE: Module and fuse holders will sit under seat above battery. Secure harness and module as needed. 6. See Fig. 2. Drill 3/8” hole in RH trunk pocket.

Install grommet to body.

• (1) Grommet– GG0011 7. Route license plate and accessory wiring

through grommet. Apply silicone around har-ness and grommet.

8. Secure trailer hitch, license plate wiring to clips on body. Secure excess hitch wiring to rear frame bar with cable ties.

INSTALLATION Fig. 1

Connect to main harness

Module

Fuse Fuse

RH trunk pocket

Install grommet and wiring

Secure hitch wiring

Secure trunk release cable to RH frame

Fig. 2

23

Side Cover Installation CAUTION: Use care while modifying painted parts. 1. See Fig’s 1 & 2. Modify LH/RH side covers as

shown. Additional trimming may be required for proper clearance around frame brackets and sway bar.

INSTALLATION Fig. 1

Fig. 2

Trim lower section of cover

RH side cover shown

Clearance around bar and bracket

24

Trunk Door Installation Note: Lip on weather seal will face away from door opening; top of seal is flush with top of door. 1. See Fig. 1. Install door seal around edge of

body, starting at center on bottom and following trunk opening. Trim seal ends straight with scissors; glue ends together when finished.

• (6’) Door Seal– CW2536 2. See Fig. 2. Insert lanyard through top bend on

cable stop bracket. Make a small loop in the end of lanyard and crimp using aluminum clip (see inset in Fig. 2). There should be 7-1/2” between the crimp and pre-made end of lan-yard. Verify both lanyards match before crimp-ing.

• (2) Door Lanyard– S001686 • (2) Cable Bracket– FB1036 • (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 under-neath 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 to hinges using 10/32” x 3/8” screws.

• (4) 10/32 x 3/8” Phillips Screws– CS4024-1 6. Attach stop cables to door using1/4”-20 shoul-

der screws with M6 flat washer under cable end.

• (2) 1/4” x .438 Shoulder Screws– CB1151 • (2) M6 Flat Washer– CW2172

7. See Fig. 3.Torque shoulder screws to 6 ft-lbs using 5/32” Allen socket.

INSTALLATION Fig. 1

Fig. 2

Lip on weather seal

Top of seal is flush with door opening

7 1/2”

Insert through bracket

Loop and crimp

Fig. 3

Shoulder Screw

Washer under cable end

25

8. See Fig. 4. Install striker pin to striker bracket using 5/16” lock nut . • (1) Striker Pin– GL2041 • (1) Striker Bracket– LB1297 • (1) 5/16” Lock Nut– CN3045

9. Attach striker pin bracket to door using 1/4” lock washers and 1/4” bolts . • (2) 1/4” x 1/2” Bolts– CB1075 • (2) 1/4” Lock Washers– CW2040

10. See Fig. 5. 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 • (1) LLS Badge– GB1328

11. Trim license plate light wiring as needed to reach connector inside trunk door opening.

12. See Fig. 6. Install female terminals and male connector to license plate wiring and plug into body harness. Verify light wiring matches har-ness wiring as follows.

• Black wire (-) on light to Black wire on body harness

• Red wire (+) on light to Blue wire on body harness

13. Secure wiring to trunk door. 14. See Fig. 6. Install male connector to acces-

sory wiring- Black (-), Red (+). Tuck acces-sory wiring in RH trunk pocket.

INSTALLATION Fig. 4

Striker pin and bracket

Fig. 5

Accessory

License plate

Fig. 6

26

Tour Pack Installation 2009-13 Models 1. See Fig. 1. Cover painted surfaces with mask-

ing tape before locating bracket and drilling body. Place tour pack mounting bracket on top of body. • (1) Renegade Tour Pack Bracket– S002254

2. Align tour pack bracket from side to side and front to back. Carefully set tour pack on bracket and align as needed before drilling.

CAUTION: Verify that front mounting holes will not interfere with trunk wall. Front holes should be drilled on the inside of trunk. 3. See Fig. 1. Once tour box bracket is aligned in

desired location, mark (6) mounting holes on body.

4. Drill holes in body to 1/4”. 5. Install bracket to body using the following hard-

ware. Rubber gasket must be installed be-tween body and bracket to prevent paint or material damage. • (2) Rubber Gasket– S002299 • (6) 1/4” x 1-1/4” Button Head– CB1094 • (6) 1/4” Flat Washers– CW2007 • (6) 1/4” Lock Nuts– CN3040

6. See Fig. 2. Place tour pack on mounting bracket. Use the inner threaded mounting holes on bracket for 2009-13 models. Install using the following hardware Loctite 242. • (4) 1/4” x 1” Button Head– CB1096

7. Reinstall original wiring to tour box. 8. Set tour box mounting bracket on body. 9. Reinstall tour pack and fasten tour pack with all

hardware. Torque bolts to 8 ft.-lbs. 10. Reinstall all tour pack wiring in proper loca-

tions. 11. Reinstall tour pack liner.

INSTALLATION Fig. 1

Fig. 2

Front

09-13 Mounting Holes

Front

27

Trunk Release Cable Mounting 1. Before installing the tour box inner liner, route

the trunk release cable from the front of the body up through the right side grommet hole in tour box.

2. See Fig. 1. Install the trunk release cable bracket to the right or left rear corner inside of the top box using OEM hardware.

3. See Fig. 2. With the knob of the cable re-moved, lay in the top box liner. Mark the loca-tion of the cable and remove the liner. Drill a 9/16” hole for the cable to pass through and reinstall the liner.

4. Reinstall the cable knob. 5. Adjust trunk latch assembly as needed for

proper cable operation and door seal.

INSTALLATION Fig. 1

Fig. 2

28

Door Adjustment Procedures

INSTALLATION

Fig. 1

29

INSTALLATION Fig. 2

Fig. 3

30

Final Assembly 1. Install seat to mounting tab using original H-D

mounting hardware. Caution: Do not use an impact wrench when installing lug nuts. 2. 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).

3. Set rear tire pressure at 26 psi. 4. Install reflectors to body. See Fig. 1. Install rear

reflectors 3” below taillights on body. 5. See Fig. 2. Install side reflectors using wheel

center caps as a reference, 1/4” above wheel opening on body.

INSTALLATION Fig. 1

Fig. 2

31

Neck Race Preload Steering head should be 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.

INSTALLATION

Fig. 1