2000-2006 Softail Renegade Installation Instructions
Contents
1. x 1 1 4 Socket Head Bolts e 2 3 8 High Collar Lock Washers e 2 3 8 Flat Washers Brackets will rest on the upper forward edge of the swing arm pin boss Use the factory mounting hardware to mount the foot pegs to the bracket 27 2000 2006 SFT Renegade Rev 4 Final Assembly 1 Set seat in place and align to body Mark location on body and drill hole for 1 4 20 rubber well nut 2 Install seat using 1 4 20 button head bolt 3 Install wheels Torque wire wheel lug nuts to 75 ft Ibs and aluminum wheel lug nuts to 85 ft Ibs 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 wheel center caps as a reference 1 4 above wheel opening on body 28 2000 2006 SFT Renegade Rev 4 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 1 Correct wheel stops in first swing 2 Correct wheel stops in second swing 3 Too loose wheel stops in third swing 29 2000 2006 SFT Renegade Rev 4 Renegade Torque Specifications Axle flange bolts 38 ft Ibs Park brake br2. 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 Ibs 11 2000 2006 SFT Renegade Rev 4 Disc Brakes Warning Brake pads must seat to rotors for brakes to work properly Stopping power will be very weak for first series of stops with im provements after every stop until brakes work at full capacity Brake System 1 SeeFig 1 Attach brass tee to differential brace using the following hardware e 1 Brass Tee CF5105 e 1 Spacer 5001530 e 2 1 4 x 1 3 4 Hex Bolt CB1100 e 2 1 4 Flat Washers CW2005 e 2 1 4 Lock Nut CN3042 Install brake lines to LH R 2 SeeFig 1 Install original brake line from o master cyclinder and rear braided lines to M DA brass tee using the following hardware Torque AO banjo bolt to 16 ft Ibs e 1 Banjo Bolt 5002022 e 2 Banjo Washers GC6002 e 2 45 M10 Braided Line S001976 3 SeeFig 2 Install 2 braided brake lines to rear calipers as shown Torque bolts to 16 ft Ibs e 2 M10 Banjo Bolt CB6001 e 4 M10 Banjo Washers GC6002 4 Secure brake lines to swingarm with cable ties 12 2000 2006 SFT Renegade Rev 4 6 Add brake fluid refer to OEM reservoir cap for brake fluid requirements to brake system and work brakes to fill lines 7 Remove rubber caps on bleeder valves Install clear brake bleeder hose ov
3. 8 frame bolts to 31 ft Ibs 6 SeeFig 3 Attach ECM plastic to brackets as needed ECM Fuse box will vary by year Install ECM brackets to front bolts RH bracket shown 15 2000 2006 SFT Renegade Rev 4 Shock Installation Fig 1 1 See Fig 1 Lower differential and install 1 2 X 2 1 4 bottom shock bolt with bushing GB0320 through lower shock eye and thread it into shock plate Use 1 washer under head of bolt Torque bolt to 40 ft Ibs and secure bolt with lock nut Note Do not install flat washer under lock nut 2 SeeFig 1 Raise differential and install top of shock with bushing GB0320 using 1 2 X 2 1 4 bolt lock washers and 1 washer under head of bolt Shock should run parallel to frame tube when viewed from rear Torque shock bolts to 40 ft Ibs 16 2000 2006 SFT Renegade Rev 4 Exhaust System Note Fat Boy models will use different mounting brackets 1 Reinstall rear cylinder pipe 2 Install long extension pipe LP1051 to front cylinder pipe 3 Install short extension pipe LP1351 to rear cylinder pipe 4 Mount exhaust bracket LB1247 to tab on underside of Lehman frame Use 2 3 8 bolts CB1235 flat washers CW2015 lock washers CW2050 and nuts CN3015 Note Trim extension pipes if necessary 5 Hold mufflers in place on frame bracket and measure amount to be removed from extension pipes Cut extension pipes as needed 6 Using original hardware inser
4. H D swingarm using appropriate press collar or socket Refer to H D service manual Note Make sure there is no dirt or powder coat material in bearing bore where bearing is to be started 2 Press bearings into Lehman swingarm follow ing HD service manual procedure Bearings should bottom out on stop in Lehman swingarm collar See Fig 1 Remove and discard the two cir clips and inner and outer spacers from the motorcycle swing arm Remove the swing arm bearings and press both into the Lehman swing arm LS2009 See Fig 2 For swingarm and belt clearance varies by year remove the bottom half of the plastic support and a small sections along next to the belt Relocate any wires and plugs around for adequate clearance to the swin garm See Fig 3 Lengthen the oil drain hose with the 3 hose supplied and two hose clamps for swing arm clearance e 3 Hose CH1015 e 2 Clamp CC2009 2000 2006 SFT Renegade Rev 4 8 See Fig 4 Install the inner spacers LS1186 to the inside of the swingarm collars Install the outer spacers or sleeves LS1185 through the bearings Note Apply anti seize to pivot shaft before in stalling 9 Install the Lehman swingarm with word TOP stamped in swingarm collar facing up ward Reinstall the original swingarm pivot shaft washers and nut Use Loctite 262 on nut 10 Torque swingarm bolt to 90 110 ft lbs Make sure swingarm moves freely up and down with no side to
5. LEHINAN LI HIKES leader of the Three World Renegade 2000 06 H D FLS SOFTAIL MODELS Installation Instructions Fat Boy models require separate exhaust brackets June 2014 2000 2006 SFT Renegade Rev 4 Table of Contents SECTION Introduction Unpacking Kit Preparing Motorcycle Installing Lehman Swingarm Top Motor Mount Link Carrier and Pulleys Installing Differential Belt Tensioning and Tracking Brake Systems Installing Lehman Frame and Suspension Installing Exhaust Lights and Wiring Body Neck Race Preload Motor Mounts General Information Renegade Torque Specifications Final Trike Inspection 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 e Always protect yourself when the vehicle is in the air Make sure the vehicle is properly supported anytime you use a hoist or jack e Always use the proper tools e Protect your eyes by using proper safety glasses or goggles e 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 2000 2006 SFT Renegade Rev 4 Introduction Gene
6. SHER LP1032 SHOCK MOLINT PLATE Part CB1276 3 0 X 3 NF GR 8 BOLT CB1286 3 0 X 317 GR 8 BOLT CN3016 3 0 HF GR 8 Cw 015 3 8 GR 8 FLAT WASHER CWw 050 3 0 LOCK WASHER LP1037 SHOCK MOUNT PLATE 2000 2006 SFT Renegade Rev 4 10 11 Support swingarm with jack stands See Fig 5 With differential assembly on lift slide belt over LH axle tube and against center housing See Fig 5 Set differential assembly on swin garm adapter plates Slide differential as far forward as possible Set jack stands under axle tubes Tighten pinch block hardware just enough to allow differential to slide on swingarm adapter plates See Fig 5 Remove upper lower and rear housing plates See Fig 6 Carefully slide belt over pulley Reinstall housing plates with original hardware using Loctite 242 Install all hardware before tightening Torque hardware to 17 ft Ibs 10 2000 2006 SFT Renegade Rev 4 Belt Tensioning and Tracking 1 Center differential to motorcycle frame this is Fig 2 critical for proper belt tensioning Make sure distance is within 1 16 from side to side 2 Level swingarm to motorcycle frame This will help achieve proper ride height 3 SeeFig 1 Using adjusters push differential assembly back until belt has about 3 8 slack with 10 165 pressure at midpoint of bottom run Measure between adapter plates and pinch blocks to ensure that distances are equal 4 Rotate pulleys forward
7. acket to swingarm 35 ft Ibs Pinch block bolts 25 ft Ibs Adapter plate to swingarm 35 ft Ibs Banjo bolts 16 ft Ibs Lehman frame to H D frame 31 ft Ibs Shock bolts 40 ft Ibs Wheels aluminum 85 ft Ibs Wheels wire 75 ft Ibs Caliper to bracket bolts 38 ft Ibs Caliper bracket to axle flange bolts 38ft Ibs 30 2000 2006 SFT Renegade Rev 4 Final Trike Inspection Reflectors Installed Lights and horn work Park brake operation Engine Transmission oil levels Belt tension 5 16 3 8 Wheel torque 85 ft Ibs 75 ft Ibs wire Rear tire pressure 26 psi Front tire pressure 36 psi Oo N O oa A C N Trunk clean and dry e Trunk door seals and operates smoothly Shocks set mid setting NO Heat shields side covers C2 Renegade Lehman badge installed IA Accessories if applicable C No paint defects en Warranty owner s manual included 31 Good Rework L O O O L L L L L 2000 2006 SFT Renegade Rev 4
8. ark brake cable left hole in handle mount 6 SeeFig 6 Route right park brake cable up around axle and forward to right hole in handle mount 7 See Fig 6 Secure both cables to upper rear pinch block with clamp GCO0108 8 See Fig 7 Secure cable retaining nuts to handle mount with 7 8 wrench 9 Check for tire clearance Fig 6 10 See Fig 7 Thread one 5 16 NF nut onto each n Cable routing 4 brake cable Place threaded end of brake cables LN j S through holes in cable bracket Thread second nut onto each brake cable 11 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 eI ks JN 14 2000 2006 SFT Renegade Rev 4 Frame Installation 1 See Fig 1 amp 2 Install trike frame to motorcycle frame using shim plates as needed ECM Fuse box brackets LB1117 amp LB1137 will also be installed to inside of motorcycle frame At tach using 3 8 x 2 bolts flat washers and lock nuts through front mounting holes Note FOR 2003 MOTORCYCLES Two bushing LB1288 are supplied for the rear holes in the motorcycle frame 2 Install 3 8 x 1 3 4 bolts flat washers and lock nuts through center holes 3 Install 3 8 x 1 1 2 bolts flat washers and lock nuts through rear holes 4 Level the frame to the axle before tightening the bolts 5 Torque 3
9. eated on the bike These instructions do not include information specifications or procedures relating to the motorcycle itself For this information 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 2000 2006 SFT Renegade Rev 4 Unpacking the Kit The crate contains the following Body Differential with brakes Tires mounted on rims Boxed swingarm Lehman frame Hardware box containing smaller parts and bolt bags Warranty Book Owner s Manual Packing parts list ES o Ol 2 LS1186 LB1117 LB1137 SWINGARM FUSE ECM UPAO ADAPTER SPACER BRACKETS PLATE 5 cel eL of EI lt mdi ita Lgs S TN um BRAKE BRACKET ZO 07 LB1294 CABLE SUPPORT BRACKET 80176 FOOT PEG BRACKETS 2000 2006 SFT Renegade Rev 4 Preparing Motorcycle The following instructions are a guide to preparing the motorcycle to accept the Lehman Trike Conver sion Kit This will assist you in removing the necessary parts to install the kit 1 Note motorcycle year model and serial 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 Make sure motorcycle is standing straight up and handlebars are centered S
10. er 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 eu 11 Install master cylinder reservoir cap with new screws Do not over tighten cap screws Kc Park Brake Assembly 1 SeeFig 3 Install park brake cable to caliper brackets Secure cable to bracket with cir clip provided on cables 13 2000 2006 SFT Renegade Rev 4 2 SeeFig 4 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 3 See Fig 4 Place park brake lever within park brake d al gt ent bracket ensuring ratchet is secure on cross brace uo Attach with large clevis pin D 2 4 See Fig 4 Attach park brake cable pulling bracket to brake lever using small clevis pin and cotter pin 1 GB1099 Park Brake Lever 2 LB1294 Cable Pulling Bracket e 1 Cable Pulling Bracket LB1294 3 CC3106 Clevis Pin e 1 Clevis Pin CC3106 4 CC4017 Cotter Pin e 1 Cotter Pin CC4017 5 LB1292 Park Brake Bracket 5 See Fig 5 Route left park brake cable above differential and under motorcycle frame attach ing cable ties to cable and frame and install in Pal Left p
11. for 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 Belt may ride next to flange as long as it s not trying to climb 5 Tighten socket head screws 8 that hold adapter plates to swingarm and torque to 35 ft Ibs 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 located apply 10 lbs force at midpoint of lower strand of belt Correct deflection is 5 16 3 8 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 on front pulley There should be about 0 030 clear ance between pulley flange and belt If adjustment is required loosen cap screws that hold adapter plate to swingarm and tap differential housing with rubber mallet in desired direction Check rear alignment and belt tension again if adjustment is required Drive belt deflection 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 the side of pulleys or squeaking as belt is rotated 9 After all adjustments are made
12. ing 2 1 4 x 1 bolts See Fig 5 Run wiring through lower hole in door e 1 plate light 5001469 e 1 Support plate 8001601 e 2 1 4 x 1 Button head bolt CB1086 e 2 M6 Flat washer CW2175 See Fig 6 Install lower license plate mounting hardware into place on support bracket using 1 4 x 50 bolts and 2 lock nuts e 2 1 4 x 50 Button head bolt CS4032 e 2 1 4 Lock nut CN3040 Solder and heat shrink light wiring to trunk wiring harness Attach wire as follows Install rubber washers between bracket and door e Black wire on light to Black wire on trunk harness e Red wire on light to Red wire on trunk har ness Seal wiring through door with silicone Ultra Black 20 2000 2006 SFT Renegade Rev 4 Fig 5 6 position connector for trailer GH0023 2 Erro KR irc License plate connector GH0023 3 Right brake light GH0023 3 8 position connector under seat GH0023 1 Left brake Right turn signal light GH0023 4 GH0023 4 Included in bag 4 Left turn signal GH0023 4 R Light bar GH0023 5 Fig 6 Wiring Diagram c wi itch 6 Position Connector for Trailer 2 12 Volt Switched 8 Position Connector Under Seat Tracer x 5 2 Ground Taillight _ SET 7 2 Running Light Red White ee m Tracer Brown Purple ac a x Orange White Tracer Lef
13. light wiring to trunk wiring harness Attach wire as follows e White wire on light to Black wire on trunk harness e Gray wire on light to Red wire on trunk harness Secure wiring to trunk door 24 2000 2006 SFT Renegade Rev 4 otriker pin and bracket Door Adjustment Procedures Fig 6 J Make sure Striker pin Lines up with latch up and down as well as side to side or door will not close properly and may make door leak aye S KE ge Pod y fi Latch Bracket Trunk 25 2000 2006 SFT Renegade Rev 4 L t tp Make sure cable biacketis __ 7 E nof foo for forward I the key lock will not work 2 bracket Is foo far back the a Latch wil not close to two clicks ot Moke sure striker pin ls In line with Saas The latch or door will not close property Shikex Pin l er j E ee EE mum um a nali Io make sure you have a good door seal use a piece of paper Put paper between door and weather seal Close door and then tug on The paper If the paper does not come out with ease you have a good seal and if it does adjust your door and Ty again Jado Iledo4 Paper 2 Paper Paper am Lehman 26 2000 2006 SFT Renegade Rev 4 Relocating Passenger Foot Pegs 1 Install foot peg brackets LRO176 to the frame using the following hardware e 2 3 8
14. n signal on flat below taillight Center turn signal with inside edge of taillights Mount H D turn signals using original bolts with supplied washers CW2001 NOTE Do not over tighten taillight mounting hard ware Damage to housing may occur 2 SeeFig 2 Mount taillight assemblies to body with Mount signal gaskets Attach ground wire to stud with flange to body nut after taillight mounting hardware is installed e 2 Taillight Assembly S002204 e 2 Gaskets BG0O200 e 4 1 4 Flat Washer CW2006 e 4 Lock washer Provided with light e 4 Nut Provided with light e 2 1 4 Flange Nut CN3007 3 SeeFig s3 amp 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 Fig s 3 amp 4 Inspect crimps before installing into connector Distortion should be minimal Fig 3 Female Terminal Insulation crimp Wire core crimp Fig 4 19 2000 2006 SFT Renegade Rev 4 See Fig 5 Install license plate bracket to door with Fig 5 1 4 x 1 bolts washers lock nuts and rubber wash ers Use rubber washers between bracket and door Install U nuts to bracket e 2 1 4 x 1 Button head bolt CB1086 e 2 1 4 Rubber washer FG1002 e 2 1 4 Flat washer CW2005 e 2 1 4 Lock nut CN3040 e 2 1 4 U nut CN3301 See Fig 6 Install license plate light and support plate to bracket us
15. n trike frame 9 Verify all body mounting hardware is tight 4 e 4 Fig 2 22 2000 2006 SFT Renegade Rev 4 Trunk Door Installation Note Lip on weather seal will face away from Top of seal is flush with door openinc door opening top of seal is flush with top of _ SS PA door E See Fig 1 Install door seal around edge of body starting at center on bottom and following trunk opening Trim seal ends straight with scis sors glue ends together when finished e 6 Door Seal CW2536 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 be tween the crimp and pre made end of lanyard Insert through bracket Verify both lanyards match before crimping e 2 Door Lanyard S001686 4 e 2 Cable Bracket FB1036 e 2 Aluminum Crimp CC1900 Apply masking tape to body just below hinge mounting holes to prevent scratching of paint by hinges no As 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 Fig 3 e 2 Door Hinge GH0903 e 2 Hinge Gaskets FG1003 e 4 10 32 x 1 Phillips Screws CS4024 0 e 4 Plated Star Lock Nuts CN1898 Fasten door to hinges using 10 32 x 3 8 screws e 4 10 32 x 3 8 Phillips Screws CS4024 1 Attach lanyard t
16. o door using shoulder screws f Washer under with M6 flat washer under cable end cable end e 2 1 4 x 438 Shoulder Screws CB1151 e 2 M6 Flat Washer CW2172 See Fig 3 Torque shoulder screws to 6 ft lbs using 5 32 Allen socket Shoulder Screw 23 2000 2006 SFT Renegade Rev 4 16 17 18 19 20 See Fig 4 Install large nut to rear door key See Fig 4 Attach cable to key mechanism while See Fig 5 Install striker pin to striker bracket Attach striker pin bracket to door using 1 4 Install Renegade badge to bottom right side Cut license plate wire from body to length to Fig 4 See Fig 4 Install key switch through body See Fig 4 Install latch cable bracket onto key switch switch using 7 8 wrench and adjust bracket in an upright position key is in vertical position with head of screw from cable facing out using 5 16 lock nut e 1 Striker Pin GL2041 e 1 Striker Bracket LB1297 e 1 5 16 Lock Nut CN3045 lock washers and 1 4 bolts e 2 1 4 x 1 2 Bolts CB1075 e 2 1 4 Lock Washers CW2040 of door Install Lehman badge GB1320 to bottom left side of door e 1 Renegade Badge GB1324 e 1 Lehman Badge GB1320 reach body wiring as needed Install shrink tubing over license plate wires otrip and solder ends of license plate wires from the body and door together Slide shrink tubing over soldered connections and heat oolder and heat shrink
17. ral Information UNDERSTANDING SAFETY LABELS amp 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 amp 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 h WARNING 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 N CAUTION 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 NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components Throughout these instructions Front or Forward refers to the front of the bike The front of any com ponent is the end which faces toward 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 NOTE The symbol HD refers to Harley Davidson The symbol LH refers to left hand side while seated on the bike The symbol RH refers to the right hand side while s
18. side movement Light resistance is normal Fig 4 1 PIVOT BOLT HARLEY DAVIDSON PART N A 1 2 FLAT WASHER HARLEY DAVIDSON PART N A 2 3 SLEEVE L51185 2 4 INNERSPACER L51186 2 amp SWINGARM LS2009 1 8 FLANGED NUT HARLEY DAVIDSON PART 1 2000 2006 SFT Renegade Rev 4 Differential Installation 1 See Fig 1 Attach LH adapter plate LP1038 to swingarm as shown Leave hardware loose 2 SeeFig 2 Attach RH adapter plate to swin garm as shown with park brake bracket mounted to lower holes Leave hardware loose 3 SeeFig 1 and 2 Install 3 8 nut to adjuster bolt and thread into adapter plate from backside Run bolt completely into adapter plate Part Qty Desc CB1241 3 8 x 114 NC SKT HD BOLT Cw 3 6 HIGH COL LOCK WSHR CW2D17 J 8 FLAT WASHER CN3011 3 6 NC NUT 1297 3 6 x 4 NC ADJUSTER BOLT LP 1038 ADAPTER PLATE Item Partz Desc CB1241 3 8 x 114 HC SKT HD BOLT CWI52 3 8 HIGH COL LOCK WSHR CW2U17 3 8 FLAT WASHER CB1248 38 x 11 2 NC SEKT HD BOLT LB1292 PARK BRAKE BRACKET CN3011 3 6 NC NUT CB1297 3 8 x 4 NC ADJUSTER BOLT LP 1038 ADAPTER PLATE BS loch Ch e CM 2000 2006 SFT Renegade Rev 4 4 See Fig 3 and 4 Loosely install hardware to pinch blocks before installing differential to swingarm Part Desc CB12765 3 0 X 3 NF GR 8 BOLT CB1286 30 X 312 GR 8 BOLT CH3U16 3 8 HF GR 8 HUT CW2015 3 8 GR 8 FLAT WASHER CW 050 3 6 LOCK WA
19. t Turn Signal Right Turn Signal fi Left STOP E MEME Right Lg de Black 2000 2006 SFT Renegade Rev 4 21 Fitting Body Caution Carefully set body on trike frame 1 Install side covers to motorcycle using original hardware from frame 2 Center body from side to side and front to back using a carpenter square against tire Make sure side covers have an even gap on both sides and do not rub on body 3 From underside of body drill a 1 4 hole in body through each of four mounting tabs Keep hole centered in slot of each of tabs 4 Fasten body to Lehman frame as follows Head of bolt will be inside trunk e 4 1 4 x 1 1 2 Button Head Bolts CS4031 1 4 x 1 1 4 Fender Washers CW2108 Foam Sealing Washers FG1002 4 1 4 Flat Washers CW2007 e 4 1 4 Lock Nuts CN3041 5 See Fig 5 Install upper body braces LB1235 by attaching slotted side on top of Lehman frame using the following hardware Leave hardware loose 2 Body Brace LB1235 e 2 5 16 x 1 Bolts CB1161 e 2 5 16 Lock Washers CW2047 e 2 5 16 Flat Washers CW2010 6 Slide bracket against trunk mark and drill 1 4 hole 7 Attach bracket to body using the following hardware e 2 1 4 x 1 1 2 button head bolts CS4031 e 2 1 4 x 1 1 4 fender washers CW2108 e 2 Foam Sealing Washers FG1002 e 2 1 4 Flat Washers CW2007 e 2 1 4 Lock Nuts CN3041 8 Tighten 5 16 hardware into place o
20. t mufflers onto pipes and mount to exhaust bracket Be sure to install exhaust crossover pipe LP1046 7 Position and tighten all exhaust clamps Install OEM heat shields and trim as needed 9 Install Lehman heat shield GS914 to front extension pipe Co LP1051 front extension pipe LP 1351 rear extension pipe Stock Heat Shieldu Can Be Reused install 65914 heat shield 2 to front extension pipe 17 2000 2006 SFT Renegade Rev 4 Renegade Wiring Harness 1 SeeFig s 1 2 Attach wiring harness to body clips on underside of body 2 Connect 8 position connector on wiring harness uc Fig 3 to OEM harness located under rider Light bar seat at rear of OEM frame connector RH side l License plate connector E CAR IG im pm S LM P M E s DEM e e x 3 SeeFig s 4 5 Before connecting brake lights license plate and light bar optional to harness ter minals 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 PWCA7 or H D 41609 4 SeeFig 5 Inspect crimps before installing into connector Distortion should be minimal Insulation crimp Male terminal Val Vp Wire core crimp Female terminal 18 2000 2006 SFT Renegade Rev 4 Lights and Wiring Caution Use care with painted surfaces 1 SeeFig 1 Drill 15 16 hole for tur
21. upport motorcycle with center stand under rear of transmission so it is straight up and down and handlebars are straight The front forks or handlebars should be anchored to hold bike Note Use a small level on rear wheel or disc brake to stand bike straight up Any movement of handlebars will move bike off level Locate reference point on bike frame that is level to use dur ing conversion 3 Remove seat and save mounting hardware Softail seat mounting varies by year 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 the side stand saddlebags mufflers and mounts 6 Remove all of the heat shields from the exhaust pipes except the shield located furthest forward on the front cylinder exhaust pipe 7 Remove chrome fender rails if applicable Save front mounting bolts 4 8 Remove the rear fender and then the tail lamp and wiring harness The signal lights will be used on the Lehman body 9 Remove the rear wheel assembly 10 Remove the brake line from the caliper and remove the caliper Block the line off to prevent fluid from leaking out 11 Remove the swingarm 2000 2006 SFT Renegade Rev 4 Installing Lehman Swingarm Note If all original components of H D swin garm are in good working order they may be re used 1 Press bearing assemblies out of
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