lehman Trikes DYNA Installation Instructions Manual

2006-2013 FXD Renegade Rev. 6

DYNA

2006-2013 H-D FXD MODELS

Installation Instructions

*Excludes Fat Bob

July 2014

2006-2013 FXD Renegade Rev. 6

Table of Contents

SECTION

INTRODUCTION AND GENERAL INFORMATION

Unpacking Your Kit

Preparing the Motorcycle

Installing Lehman Swingarm

Carrier Assembly and Pulleys

Installing the Differential

Assembling 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 a 70 tooth pulley assembly

1

2006-2013 FXD Renegade Rev. 6

INTRODUCTION AND GENERAL INFORMATION

Statements in these instructions preceded by the words WARNING, CAUTION, or NOTE and printed

in bold face are important. ** WARNING **

Indicates a strong possibility of severe personal injury or loss of life if instructions are not

followed.

** CAUTION **

Indicates a possibility of personal injury or equipment damage if instructions are not

followed.

** NOTE **

Gives helpful information to make a step or procedure easier or more clear.

Throughout these instructions, “Front” or “Forward” refers to the front of the bike. The “Left” and “Right

hand” sides refer to the position of the parts as viewed by a rider sitting on the seat, facing forward.

All of the procedures covered in the manual should be performed by Lehman factory-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. It is proprietary to

Lehman Trikes, Inc. and provided solely for use by dealers. Any unauthorized duplication or distribution is a

violation of international copyright law.

** NOTE **

Compliance with national (DOT-USA, MOT-Canada), State, Provincial, and local vehicle

standards is the responsibility of the installer. Installation of the parking brake is

necessary to achieve compliance with DOT/MOT.

** NOTE **

The symbol H-D refers to Harley-Davidson.

The symbol LH refers to left hand side while seated on the bike.

The symbol RH refers to right hand side while seated on the bike.

2

2006-2013 FXD Renegade Rev. 6

Unpacking Your Kit The crate contains 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

2006-2013 FXD Renegade Rev. 6

4

MODULAR DIFFERENTIAL

2006-2013 FXD Renegade Rev. 6

Preparing Motorcycle

Note: During installation you will use various products on different areas of the trike. The following

are products to have on hand before starting the conversion.

Loctite 242- Medium strength blue

Loctite 262- High strength red

Loctite 5920- High temp sealer

Note: Refer to H-D service manual for detailed instructions on the removal of the following parts:

1. Note motorcycle year, model and VIN number, as well as Lehman serial number located inside body, on

left side of swingarm and on warranty registration form in owner’s manual.

2. Place motorcycle on center stand, preferably on a motorcycle lift. Secure front wheel to lift with

compression strap.

3. Remove seat and disconnect battery.

Note: Always disconnect negative battery cable first. If positive cable should contact a grounded

object while the negative cable is installed, the sparks may cause an explosion.

4. Raise motorcycle so that rear wheel is off lift.

5. Use a level on HD frame to 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 transmission. Save hardware.

12. Remove belt cover.

13. Remove master cylinder cover. Evacuate brake fluid from system through bleeder screw on caliper.

14. Cover master cylinder to prevent contamination.

15. Remove brake line from caliper. Save banjo washers for use on Lehman brake system.

16. Remove shocks.

17. Remove rear tire and brake assembly.

18. Remove swingarm pin, discard pin and save flange nut.

19. Remove swingarm from motorcycle.

20. Remove snap ring and bearing from left side

of swingarm.

21. Remove inner race, dust cap and bushing

from right side of swingarm. Note position

of parts for reassembly.

22. Support rear of motor with a jack and

remove (2) top rear motor mount bolts

through transmission case.

Caution: See Fig. 1. Plates will spring apart;

hold with clamp before removing nuts.

Fi

g

. 1

5

2006-2013 FXD Renegade Rev. 6

Installing Lehman Swingarm

Note: Provided they are in good working order, all original components of Harley-Davidson

swingarm may be re-used.

1. Clean and inspect original components, replace if necessary.

2. See Fig. 1. Install components into Lehman swingarm in same orientation as original swingarm.

Fig. 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 bolt should be free to rotate or pull out when

locknuts are tight.

Fig. 2 LB6111

Motor Mount

Brace

(RH Side)

6

LB6111 Brace- LH Side

2006-2013 FXD Renegade Rev. 6

6. 06-07 Models: See Fig. 3. Install swingarm pin brace

(LB6110) to RH side of transmission housing with

original hardware from case. Leave bolts for this bracket

loose until swingarm installation is complete.

7. 08-13 Models: See Fig. 4. Install swingarm pin brace

(LB6110) to RH side of transmission housing with

original hardware from case. Install (S001057- Fig. 4)

spacer between case and pin brace. Leave bolts for this

bracket loose until swingarm installation is complete.

All Models

8. Install Lehman swingarm with word “TOP” (stamped into

swingarm 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 242 on threads.

Torque to 150 ft. lbs.

Note: Make sure bolt end does not contact primary

case.

12. See Fig. 3. Using Loctite 242 tighten all fasteners for LB6110 swingarm pin bracket. Torque to 20 ft.

lbs.

13. Be sure swingarm moves freely up and down with no side to side movement.

Fi

g

. 3 LB6110 Pin Brace

,

06-07 Models

S001057 Space

r

-

2008+ Models

LS6129

CW2032

Fi

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. 3

7

Fi

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. 4

2006-2013 FXD Renegade Rev. 6

Differential Installation

1. See Fig. 1. Attach LH adapter plate (LP1038) to

swingarm 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

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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

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2006-2013 FXD Renegade Rev. 6

5. Support swingarm with jack stands.

6. See Fig. 5. With differential assembly on lift, slide

belt over LH axle tube and against center housing.

7. See Fig. 5. Set differential assembly on swingarm

adapter plates. Slide differential 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 ft. lbs.

Install belt

Fig. 6

Fig. 5

Remove plates

10

2006-2013 FXD Renegade Rev. 6

Belt Tensioning and Tracking

1. See Fig. 1.Center differential to motorcycle frame.

Make sure distance is equal on both sides. This is

critical for proper body and seat pan alignment.

2. See Fig. 2. Using adjusters, push differential

assembly back until belt has about 3/8” slack with 10

lbs. pressure at midpoint of bottom run

3. Measure between mount plates on swingarm and

welded pinch blocks on differential to ensure equal

distances.

4. Rotate pulleys forward at least 3 revolutions of rear

pulley by pulling backwards on bottom run of belt.

Pull belt straight back to get an accurate reading.

Check that belt is running about 0.030” from flange on

rear pulley. Tap differential left or right to achieve this

reading.

5. Tighten socket head screws (8) that hold mount plates

to swingarm. Leave bolts loose to adjust differential.

6. Once tracking is obtained, re-check belt tension.

Raise and lower differential assembly slowly with a

jack while checking belt tension. When tightest position is determined, apply 10lbs. of force at

midpoint of lower strand of belt. 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 with a rubber mallet in desired direction. Check rear alignment

and belt tension again if adjustment is required.

Note: If necessary, apply chalk to edge of belt to aid in getting proper clearance between belt and

pulley flanges. If visible clearance cannot be obtained, be sure belt is not climbing up side of pulley

or squeaking as belt is rotated.

9. After all adjustments are made, tighten adjuster lock nuts. Tighten left adapter plate bolts first. Then

tighten left-hand pinch block in a criss-cross pattern.

10. Tighten right hand adapter plate bolts and right hand pinch block bolts in a criss-cross pattern.

11. After all adjustments are made, tighten adjuster lock nuts and tighten pinch block bolts. Tighten pinch

blocks in a crosswise pattern. Go over both sides at least 2 times to seat blocks over pins. Torque

bolts to 25 ft. lbs.

Figure H-1

Drive belt deflection

Fig. 2

Fig. 1

11

2006-2013 FXD Renegade Rev. 6

Brake System

CAUTION: Brakes are a critical safety component 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. Brake pads

will need to be seated in during initial test ride.

Brake System

1. See Fig. 1. Attach brass tee 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 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. Install (2) braided brake lines to rear calipers

as shown. Torque bolts to 16 ft. lbs.

(2) M10 Banjo Bolt– CB6001

(4) M10 Banjo Washers- GC6002

4. Secure brake lines to swingarm with cable ties.

Fi

g

. 2

Install brake lines to LH/RH

Fi

g

. 1

12

2006-2013 FXD Renegade Rev. 6

Park Brake Assembly

Note: Verify all brake lines and hardware are tight before bleeding system.

5. Add brake fluid (refer to OEM reservoir cap for brake fluid requirements) to brake system and work

brakes to fill lines.

6. Remove rubber caps on bleeder valves. Install clear brake bleeder hose over bleeder valve on caliper.

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 brake cable to caliper brackets. Secure cable to bracket with cir-clip provided on

cables.

13

Fig. 1

RH Side

Secure to

bracket

Attach to

caliper

2006-2013 FXD Renegade Rev. 6

1. See Fig. 2. Remove snap ring from one side of large clevis pin

on brake lever. Hold park brake lever on its side and push

release button at end of park brake lever to allow clevis pin to

slide out.

2. See Fig. 2.Place park brake lever within park brake bracket,

ensuring ratchet is secure on cross brace. Attach with large

clevis pin.

3. See Fig. 2. Attach park brake cable pulling bracket to brake

lever using small clevis pin and cotter pin.

(1) Cable Pulling Bracket– LB1294

(1) Clevis Pin– CC3106

(1) Cotter Pin- CC4017

4. See Fig. 3. Route left park brake cable above differential

and under motorcycle frame, 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 each brake

cable. Place threaded end of brake cables through holes in

cable bracket. Thread second nut onto each brake cable.

10. Adjust park brake cables at handle to engage at 3–4 clicks.

Note: Take up slack in cables before tightening ends to

ensure good adjustment range with threaded end of brake

cables.

Fig. 6

Cable retaining nuts

Adjuster nuts

Left park brake cable

Fi

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. 4

Cable routin

g

Attach clamp

14

Fi

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. 3

Fi

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. 2

Fi

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. 5

2006-2013 FXD Renegade Rev. 6

Installing Lehman Frame & Suspension

1. See Fig. 1.Insert (4) small frame spacers (LS6130) into H-D

frame where trike frame will attach.

2. See Fig. 2.Set frame in place by using 3/8” x 2 1/2” bolts with

.875 rear frame spacers (LS6128). Use flat washers (CW2015)

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 sides and secure with a locknut (CN3050).See Fig. 2.

Small s

p

acer

Fi

g

. 1

15

Fig. 2

2006-2013 FXD Renegade Rev. 6

4. See Fig. 3. Install front frame mounting tab bolt

through trike frame, spacer and H-D using the

following hardware.

(1) Spacer- S001050

(1) 1/4” x 1-3/4” Hex Bolt- CB1100

(2) 1/4" Flat Washers- CW2005

(1) 1/4” Lock Nut- CN3040

5. Tighten rear bolts and lower front tab bolt. Leave

upper front bolts until floorboard mounts are

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- CB1240

(2) 3/8” Lock Washer- CW2050

(2) 3/8” Flat Washer- CW2015

Fig. 3

Front frame tab

S001050 Spacer

16

Fig. 4

Cross Brace

Floorboard Mount

Fig. 5

2006-2013 FXD Renegade Rev. 6

Note: The lower shock eye is offset to one side. Be sure to install correctly.

8. See Fig. 6.Install 1/2” x 2 1/4” bottom shock bolt 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

2006-2013 FXD Renegade Rev. 6

10. See Fig. 7. Install stabilizer bar LB6101 into tab on right side of Lehman 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

2006-2013 FXD Renegade Rev. 6

12. See Fig. 9. Sway bar bracket is attached to upper rear of differential housing.

Fig. 9

13. Tighten 3/8” nuts on stabilizer bar until there is no play in grommets. DO NOT COMPRESS

GROMMETS.

Caution: Make sure sway bar is not pulling or pushing on Lehman frame when trike is 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 ½” hex flange locking bolts.

3. Assemble bolt, spacer (LS1189) and external tooth lock washer in appropriate order.

4. Torque bolts to 42 ft.-lbs.

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lehman Trikes DYNA Installation Instructions Manual

lehman Trikes DYNA Installation Instructions Manual

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