2001-2010 Monarch II Installation Instructions
Contents
1. Fig 4 gt gee 10 Driveline and Suspension Disassembly Special tools e Snap On A26 drag link socket e Honda pivot lock nut wrench 07ZMA MCAA100 e 19mm Allen socket Swingarm Parts e Swingarm LS6300 e Right swingarm pin LP6000 e Left swingarm pin LP6001 NOTE Temporarily leave brake lines attached to caliper 1 See Fig 1 Remove rear caliper mounting bolts with 14mm socket Free brake lines from final drive assembly clips 2 See Fig 2 Remove front and rear brackets holding brake lines to swingarm Save front mounting bracket 3 See Fig 3 Remove final drive assembly from swingarm using 17mm wrench 4 Remove driveshaft from swingarm tunnel Re move and discard rubber driveshaft boot Final drive 11 a Hemove from clips Driveline and Suspension Disassembly CAUTION Do not disconnect oil line from shock to pump Contents of Honda shock are under pressure and shock is non serviceable D Remove and save LH swingarm pin lock nut Remove rubber boot from transmission and See Fig 4 Temporarily remove shock com pressor mounting bolts Disconnect compres sor from wiring harness to allow more slack in line See Fig 5 Remove upper shock nut through RH side of frame using a 17mm socket and 6 extension Hold bolt head through LH side of frame with 8mm Allen socket and 6 extension See Fig 6 Remove rear linkage bolt with 17mm and 19mm sockets Remove front link2. 50
3. sl Fig 3 Crossbar S Consistent spacing 36 5 See Fig 4 Install trunk door to body using the following hardware Leave hardware loose e 6 M6 x 16 Button Head Bolts CB1904 e 6 M6 Fender Washers CW2107 CAUTION Slowly close door and ensure strik ers clear top of trunk opening Bend strikers down if necessary Strikers should just clear opening 6 Slowly close door do not try to latch door at this time Adjust door from side to side and up and down to match body Once door is in place slowly open and tighten mounting hard ware 7 See Fig 5 Lower door and check for consis tent spacing between door and body 8 Pull latch assembly towards rear of body and tighten hardware Align strikers from side to side to match opening on each latch 9 Latch door Verify that both side latch when closed Adjust latch assembly in or out as needed 10 See Fig 6 Door adjustment is made using the following e Moving hinges upward in trunk results in the top of door tilting outward and away from body e Moving hinges downward will bring door closer to body e Latch can be slide in or out to adjust gap on top and take out any excessive play in door and adjust as needed 37 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 1 Carefully place body on trike frame 2 Insta
4. LS6305 e 1 Set Screw CS3978 4 See Fig 3 Install collar and spring to OEM driveshaft as shown e 1 Driveshaft Collar S002091 e 1 Driveshaft Spring S002201 5 Grease all internal splines on Honda motorcy cle yoke NOTE Ensure that centers of universal joints are aligned in phase as closely as possible centers may not line up exactly 6 SeeFig 4 Assemble drive shaft as shown 7 Install drive shaft through swingarm tunnel and onto output shaft of transmission Ensure drive shaft is fully engaged on transmission output shaft Fig 1 ez Secure with a set screw Fig 3 Fig 4 Align U joints Differential Installation 8 See Fig 5 Mount differential to swingarm us ing the following hardware Apply Red Loctite to threads Align rear u joint to differential yoke during installation NOTE Do not torque differential mounting hardware until stabilizer and driveshaft have been properly adjusted e 4 M12 x 100 Bolts CB1612 e 4 7 16 Flat Washers CW2022 e 4 M12 Lock Nuts CN1916 9 See Fig 6 Attach driveshaft to differential yoke using the following hardware Use Blue Loctite and Torque nuts to 18 ft lbs e 1 U Bolt kit 5002202 22 14 10 See Fig 7 Assemble new stabilizer bar with jam nuts and rod ends Install LH threaded rod end into end of stabilizer bar with groove as shown See Fig 8 Install stabilizer to bracket on diff
5. age bolt from motorcycle frame using 19mm socket and 10mm Allen socket See Fig 6 Remove lower shock bolt with 14mm and 17mm sockets See Fig 6 Raise swingarm and remove swin garm linkage bolt with 19mm socket and 10mm Allen socket Remove LH and RH swingarm pins with 19mm Allen socket Remove OEM swingarm Feed shock through Access to upper top of swingarm during removal shock nut discard Spring Replacement Special tools e Spring compression tool wn i 1 See Fig 1 Loosen set screw on spring and mark orientation of adjuster to shock body wa 2 See Fig 2 Install spring tool to compress spring 3 See Fig 2 Compress spring and remove re taining ring 4 Remove old spring and install new heavy duty spring e 1 Heavy Duty Spring 150625 5 Compress new spring with compression tool 6 Align orientation marks while compressing 7 Re install retaining ring and slide ring into groove 8 Tighten set screw 13 PREPARING THE MOTORCYCLE Brake System Modification OEM brake system and trike modifications The original Honda motorcycle brake system utilizes both front and rear brakes when the foot brake is applied During the trike conversion the brake system will be modified Once modification is complete the rear brake pedal will maintain front and rear linked braking The front brake lever will operate the front brakes only The anti dive valve feature is mainta
6. Verify rear brake pedal and front brake lever are firm and do not bottom out Fill fluid reservoir and install cap NOTE New brake pads and rotors will have a break in period before optimum brake opera tion is achieved 8 Heinstall front fender and wheel covers 24 w mg li Front LH upper bleeder Park Brake Cables 1 See Fig 1 Install park brake cable to caliper brackets Secure cable to bracket with cir clip on cables 2 See Fig 2 Route LH cable around axle tube as shown towards RH side of trike Secure to axle tube with cable ties as needed 3 See Fig 3 Route RH cable around axle tube as shown Secure to LH cable with cable ties as needed 25 12817 Se Ys I 2 D Es RH side w e yc ap r 1 Sei oof Se d e et CT e E Park Brake Installation 1 See Fig 1 Remove one snap ring from either side of park brake handle pin and remove pin 2 Align pivot hole with holes in bracket Make sure ratchet catch is in place over tab on park brake bracket 3 Install pivot pin through assembly and reinstall snap ring Itemz 4 Assemble park brake lever to park brake bracket e 1 Park Brake Lever 1099 e 1 Park Brake LB6322 5 Attach cable pulling bracket to park brake lever assembly using clevis and cotter pin e 1 Cable Pulling Bracket LB1294 6 See Fig 2 Attach park brake bracket LB6322 to swingarm using th
7. clamps and all mounting hard ware 43 Exhaust tips centered in cut outs Fig 1 Final Assembly 1 Set tour box in place on frame Make sure all wiring is routed in the proper location before attaching tour box to frame 2 Attach tour box to frame with original hard ware NOTE Leave mounting hardware loose until lower trim panels are installed 3 Attach trunk release cable to tour box latch assembly on RH side 4 See Fig 1 Cut 1 1 2 1 4 slot into lower cover as shown for cable clearance 5 Reinstall all tour box trim and lights into OEM locations using original hardware 6 Reconnect tour box connectors to motorcycle harness 7 Plug in all electrical connectors from trike har ness to motorcycle harness 8 Connect battery and check lights for proper operation 9 Tighten all tour box mounting hardware 10 See Fig 2 Route safety cable to front of tour box Install cable clamp and make small loop Crimp cable clamp and secure to front of tour box e 1 Cable Clamp CC1900 11 Install seat and grab handles using original hardware 12 Install passenger footboards using original hardware 13 Verify all side covers are reinstalled 14 Install wheels and torque lug nuts to 85 ft Ibs Install center caps if applicable 15 See Fig 3 Install badges on trunk door Place Lehman badge on LH side and Monarch II badge on RH side e 1 Lehman Badge GB1320 e 1 Monarch Il Badge GB
8. con tinues to junction block located on steering head Disconnect lower hard line from block Remove block from frame and remove entire line from motorcycle 3 See Fig 3 Install new brake line between anti dive valve and master cylinder using OEM banjo bolts and the following hardware Torque banjo bolts to 18 ft lbs e 1 Front brake line 5002066 e 4 Copper Banjo Washers GC6002 Anti dive valve Remove lower line from block SWINGARM INSTALLATION Swingarm Installation 1 See Fig 1 Place Lehman swingarm into motorcycle frame Make sure factory Honda shock is through center of swingarm during installation Shock will be mounted into place later Fig 1 ITEM PART QTY DESCRIPTION 0 5 LS6300 1 SWINGARM LP6000 1 PIN SWINGARM RH LP6001 1 PIN SWINGARM LH 1 2 3 17 2 Apply anti seize compound to threads and ends of swingarm pins that go into swingarm bearings 3 See Fig 2 Start Lehman swingarm pins into motorcycle frame CAUTION Do not over tighten left swingarm pin Tighten pin enough to seat in bearing and adjust to eliminate side play 4 Install Lehman swingarm and use a Snap On A26 drag link socket or similar tool to tighten pins Torque right swingarm pin to 80 ft Ibs 5 Move swingarm up and down several times to ensure free movement Check clearance to sides and torque left swingarm pin to 25 ft Ibs This is ensures no later
9. the state of this product at the time of its publication and may not reflect the product in the future Leh man Trikes is a registered trademark All other brands and product names are trademarks or registered trademarks of their respective hold ers Printed in the United States of America SAFETYINFORMATION 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 N 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 Disassembly NOTE Refer to Honda service manual for de tailed instructions on removal of OEM parts 1 Load motorcycle on lift and secure
10. 1321 16 Remove motorcycle center stand NOTE RH center stand bolt has LH threads 44 Tire Pressure Monitoring System TPMS Dis able If applicable 09 models NOTE Refer to Honda service manual for de tailed information 1 2 See Fig 1 Carefully remove RH trim See Fig 2 Remove the RH fairing storage compartment See Fig 3 Disconnect wire harness Remove mounting bolts and remove module from bike 45 y Disconnect harness from control module 2 TPMSDISABLE 5 See Fig 4 Splice white wire with yellow stripe and black wire with white stripe to solid green wire NOTE Splice wiring from connector side 6 Cover all exposed wires with heat shrink 7 Reconnect module Turn on ignition and verify TPMS light is not illuminated 8 Reinstall module storage compartment and fairing trim 9 Place TPMS disabled sticker inside tour box lid Fig 4 TPMS Module Splice White Yellow wire and Black White wire to solid Green wire Green Black vy ite White J yellow Brown Ju hte Module Plug Wihte Black Gray Yellow Green Black 46 M ABSDISALE __ ABS Disable If applicable 1 Disconnect battery and verify ignition is in the OFF position NOTE ABS control module location will vary depending on model year Refer to the Honda service manual for access to module 1 Remove all ABS related fuses fr
11. 19mm socket Dis card wheel nuts 29 Remove battery and battery box to access re verse module Remove and save reverse module Remove mounting bracket from re verse module Temporarily leave battery out and box loose for easier access to upper shock mounting hardware Disassembly 30 See Fig 10 Remove side stand switch as sembly Disconnect sensor from side stand while stand is in the up position 31 See Fig 11 Secure sensor from turning using the following hardware e 1 Original Upper Amp Mounting Bolt e 1 Original Upper Saddlebag Washer e 1 M6 Flange Lock Nut CN1902 Tour Box Frame Modification ALL MODELS 1 SeeFig 1 Mark and cut tour box frame as shown with reciprocating saw or equivalent 2 Remove tour box frame from motorcycle frame And discard mounting hardware Use touchup paint on bottom of tour box frame where cuts were made i Remove side stand vd LEN Fender Modification TRIMMING FENDER 2001 05 MODELS CAUTION Do not cut electrical components 1 See Fig 1 Mark and trim fender as shown 2 See Fig 2 Fender should look as shown when completed Cut here Fig 2 Modified fender Fender Modification TRIMMING FENDER 2006 MODELS CAUTION Do not cut electrical components 3 See Fig 3 Mark and Cut amplifier box 1 in front of rubber cover 4 See Fig 4 Mark and cut front half of fender 5 1 2 from rear
12. LEHMAN Urn ones Monarch iT 2001 2010 Honda GL1800 Models Solid Axle Installation Instructions Oct 2014 125 Industrial Drive Spearfish SD 57783 Toll Free 888 3WHEELS SAFETYINFORMATION WARNING 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 2008 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
13. S Flat Washers CW2006 e 2 10 24 x 1 2 Phillips Screws CB1009 Rear Harness Modification 5 SeeFig 3 Remove rubber grommet from center of LH RH saddle bag wiring harness NOTE Do not remove rear grommet from taillight pocket wiring 6 Remove excess electrical tape and reposition latch sensor connector toward front of harness Cover exposed wires with electrical tape 33 BODY Body Preparation 1 See Fig 1 Install side cover brackets to body using the following hardware 1 LH Side Cover Bracket LF6305 BL 1 RH Side Cover Bracket LF6305 BR 4 M6 x 25 Button Head Bolts CB191 1 4 M6 Fender Washers CW2107 e 4 M6 Lock Nuts CN1902 2 SeeFig 1 Install grommets from OEM sad dlebags into side cover brackets 3 Install trike wiring harness to plastic clips on body 4 Install side cover extensions to OEM side cov ers using original hardware Install trim seal along back edge of extension Fig 2 e 2 Trim Seal CW2505 5 Install modified wiring harnesses to body Use harness with main red connectors on LH side and blue connectors on RH side NOTE Turn signal connectors are different be tween 2001 06 and 2007 10 models 6 SeeFig 2 Install harness grommets through taillight pockets on each side 7 See Fig 3 Connect taillights to harness and carefully install into body using the following hardware e 6 1 4 Stainless Flat Washers CW2008 e 6 OEM Taillight Mounting Nuts 8 S
14. al play in bear ings Back off left pin and tighten until resis tance is felt 6 Install LH lock nut using Loctite 242 Torque pivot nut to 80 ft Ibs using Honda pivot lock nut wrench 07ZMA MCA100 As torque on this wrench is multiplied set wrench to 72 ft Ibs 7 Remove RH front chrome cover and attach rubber boot to transmission housing Reinstall swingarm pn covers with original hardware 8 SeeFig 3 Install left and right swingarm stop blocks to motorcycle frame Apply Loctite 262 to left and right bump stop studs and thread studs completely into bump stop blocks e 1 RH Stop Block 5001100 1 LH Stop Block 5001102 e 2 Rubber Bump Stop 5001154 2 M8 x 30 Flange Bolt CB1921 9 SeeFig 4 Guide Honda shock into place Check position of oil line to shock before in stalling upper shock bolt Ensure oil fitting is Install swingarm stop blocks on left hand side and oil line is on right hand E TO B side Torque top shock bolt to 31 ft Ibs ATTACH THE SS 18 10 See Fig 5 Install OEM Honda shock link to Lehman swingarm with original hardware and M12 washer under nut and torque bolt to 47 ft Ibs e 1 M12 Washer CW2150 11 See Fig 6 Install lower shock linkage with original hardware and torque lower shock bolt to 31 ft Ibs and linkage bolts to 47 ft Ibs 12 Reinstall shock compressor to original location on frame 13 Install urethane and steel bushings to ends of swingarm e 4 Uretha
15. e bolts e 2 M8 x 1 25 x 25 Flange Bolts CB1920 6 Drill out lower frame holes on tour pack frame to 11 32 7 See Fig 5 Install upper tour pack frame bolts and tour pack frame top holes use M8 x 50mm flange bolts and original M8 flanged nuts bot tom holes use original top tour pack M8 x 40 bolts Torque bolts to 18 ft Ibs e 2 M8 x 50 Flange Bolt CB1923 e 2 M8 Flange Nuts OEM e 2 M8 x 40 Flange Bolts OEM 8 See Fig 4 Torque front frame mounting hard ware to 22 ft Ibs Once front trike frame hard ware is secure remove upper tour pack frame hardware and remove tour pack frame from trike until after the body is installed 9 See Fig 6 Attach reverse resistor to frame on left side side using the original mounting hard ware 10 Connect electrical connectors and battery feed bo s y 28 11 See Fig 7 Original frame covers require modi fication before reinstalling 12 See Fig 8 Trim rear cover as needed for proper clearance around trike frame Reinstall frame covers with original hardware in front and cable tie in rear 29 Amplifier Installation 2006 Models 1 Remove metal inserts from amplifier mounting holes 2 See Fig 1 Install amplifier mounting brackets to motorcycle frame using the following hard ware e 2 Amplifier Mounting Brackets LB6325 e 2 Bolts From OEM Inner Fender e 2 Nuts From OEM License Plate Bracket NOTE LH bracket is mounted on
16. e following hardware Part GB1099M LB1294 CC3106 CC4017 LB6322 EN Attach bracket e 1 Clevis Pin CC3106 to swingarm e 1 Cotter Pin CC4017 Description Park Brake Lever Cable Pulling Bracket Clevis Pin Cotter Pin Park Brake Bracket Torque bolts to 36 ft Ibs dh e 2 M10 x 25 Flange Bolts CB1928 e 2 M10 Flange Nuts CN1910 7 See Fig 2 Route cables through holes in park brake bracket Secure to bracket with nuts and washers supplied with cables 8 See Fig 2 Install cables through cable pulling bracket with jam nut on each side of bracket e 4 5 16 NF Nuts CN3009 9 Adjust park brake at lever assembly Park brake should fully engage at 3 4 clicks on lever 26 am A to brackets a Frame Installation 1 See Fig 1 Position Lehman frame above dif ferential See Fig 2 Install left and right upper mount ing bolts to secure frame using M8 Flange Bolts e 2 M8 x 1 25 x 25 Flange Bolts CB1920 See Fig 3 Install aux shock into upper shock mount While aligning holes insert upper aux shock bushing into shock mount and aux shock e 1 Upper Shock Bushing LB6313 Apply red Loctite 262 to upper shock bolt with flange nut Torque bolt to 36 ft Ibs e 1 M10 x 1 5 x 45 Flange Bolt CB1935 e 1 M10 Flange Nut CN1910 27 5 See Fig 4 Install left and right lower mount y ME ing bolts to secure frame using 2 M8x1 25x30 GR 8 8 hex flang
17. ee Fig 2 Install large OEM rubber grommets over turn signal connectors large holes in body 9 See Fig 3 Plug extra taillight mounting holes locations vary by model year with silicone Lam ME co M ca A Fig 3 AL zm REM 2 Silicone extra holes d E A 7 Ki dE vw Le Door Switch Wiring 10 11 12 13 14 see Fig 4 Place rubber grommet in access hole as shown and route door switch through hole e 1 Rubber Grommet GGO001 1 Install trunk switch harness through grommet Apply silicone around harness from inside trunk e 1 Latch Wiring Harness GH0026 Install plastic connector onto terminals inside trunk Plug harness into latch assembly Apply silicone around harness and grommet from inside trunk 35 Door latch wiring Door Installation NOTE Remove any residue from seal mounting surface on door before installing seal 1 See Fig 1 Install trunk door seal starting at the bottom center of trunk opening Solid lip on seal will face trunk edge See Fig 2 Install original strikers and hard ware from LH saddlebag to top of trunk door Verify hinges are in the middle of adjustment slots in trunk See Fig 3 Before installing door check spac ing of door hinges for consistency from side to side If hinges are not equal loosen hardware on crossbar between hinges Twist bar until hinges are equal and tighten hardware Start seal here
18. erential using the following hardware Torque to 78 ft lbs e 1 1 2 x 2 1 4 Bolt CB1410 e 2 1 2 Flat Washers CW2025 e 1 1 2 Lock Nut CN3060 See Fig 8 Attach stabilizer to lower shock mount using the following hardware Install with head of bolt against rod end Use flat washer on nut side only Torque to 78 ft Ibs e 1 1 2 x 3 Bolt CB1425 e 1 1 2 Flat Washers CW2025 e 1 1 2 Lock Nut CN3060 See Fig 5 Center driveshaft in swingarm tunnel by rotating stabilizer bar left or right as needed Tighten front and rear jam nuts once driveshaft is centered Tighten differential mounting hardware Torque to 85 ft Ibs 23 Stabilizer assembly LH thread rod end Attach stabilizer Brake Installation 1 re See Fig 1 Install single brake line line with straight tab to residual valve using the follow ing hardware Torque banjo bolt to 16 ft lbs e 1 Residual Valve 5002037 e 1 M10 Banjo Bolt CB6001 e 2 Copper Banjo Washers GC6002 Remove rear brake reservoir cap Bleed rear brake system at rear calipers with brake bleeder or hand operated vacuum pump Bleed front brake system with rear pedal in the following order Refer to Honda service manual for further information e Fig 2 LH front upper bleeder e Fig RH front lower bleeder e Fig 4 LH front anti dive valve Repeat bleeding on front and rear until all air is eliminated from brake system
19. from motorcycle See Fig 4 Remove and save the following from LH and RH saddlebags e Taillights and mounting nuts e Large rubber plugs e Upper front saddlebag mounting washers See Fig 5 Remove and save the following from the LH saddlebag only e atch assembly and mounting screws e Door strikers and mounting screws e Latch cable Hemove and save LH RH passenger foot boards and mounting hardware See Fig 6 Remove and save rear frame covers Save front mounting bolts 2 only See Fig 6 Remove and save swingarm pin covers and hardware Hemove and discard rear crash guards and hardware Fig 5 Pin cover Discard rear bolt Disassembly 23 See Fig 7 Loosen muffler clamps Remove Save rubber and save muffler mounting bolts and remove inserts mufflers Remove and save rubber inserts from heat shields 24 See Fig 7 Remove and save metal inserts and rubber bushings from saddlebag supports 25 Remove and save 4 nuts from heat shield on RH muffler Discard heat shield 26 See Fig 8 2006 MODELS Remove and Save mounting save 4 amplifier box mounting bolts Remove hardware amplifier from rear fender NOTE Long bolts upper will be reused for brake line clamp installation and side stand switch disabling Short bolts lower will be used for amplifier installation on trike 27 See Fig 9 2006 MODELS Remove and save rear inner plastic fender mounting bolts 28 Remove rear wheel with
20. front wheel 2 Place motorcycle on center stand 3 Remove seat with 6mm Allen socket Save grab handles and hardware 4 SeeFig 1 Remove LH and RH side covers Remove and save short screws from exten sions Side cover extensions will not be reused 5 SeeFig 2 Remove and save side cover grom mets from front of saddlebags 6 Disconnect battery by removing negative cable first 7 Disassemble tour box Remove side and cen ter trim molding Remove lower cover and in ner latch cover Save all hardware as tour box will be reinstalled on trike 8 Disconnect saddle bag latch cables from re lease levers inside tour box 9 Remove lights from tour box with an 8mm Socket 10 Remove cable ties holding tour box harness to frame Remove connector holding harness to rear tab on tour box 11 Disconnect all wiring for tour box located under seat Make note of wiring locations as harness will need to be installed in same location during reassembly 12 Remove tour box mounting hardware with 8mm Socket Save all hardware Carefully remove tour box from motorcycle Store all tour pack hardware and trim in tour box as it will be re used 13 Remove helmet holders from tour pack frame and discard 14 Raise trike on lift 15 See Fig 3 Remove rear fender cover Save 2 upper mounting screws only Remove li cense plate bracket and save nuts Disassembly 16 17 18 19 20 21 22 Remove saddlebags
21. ined on both front and rear braking The diagrams below outline the difference between the original Honda GL1800 brake system and the modified Trikes brake system Fig 1 Fig 2 14 Brake System Modification Rear NOTE For ABS Disable see pg 47 1 See Fig 1 Disconnect inner rear brake line upper line on caliper 2 Disconnect upper line at caliper and discard brake line NOTE Allow brake line to drain before blocking off 3 Block off inner brake line using the following hardware e 1 M10 Banjo Bolt CB6001 e 2 Copper Banjo Washers GC6002 e 1 1 2 Spacer S001067 Block off line 4 See Fig 2 Using cable ties secure discon nected brake line to top of crossbar on frame 5 Disconnect lower brake line from caliper 6 See Fig 3 Route brake line above plastic panel on RH side below shock compressor location 7 Drill 1 4 hole in plastic and mount brake line using the following hardware that was saved from disassembly e 1 Original Front Brake Line Clamp e 1 Original Upper Amplifier Mounting Bolt e 1 Original Saddlebag Washer e 1 M6 Lock Nut CN1902 Secure line above crossbar NS Te Mount to plastic with original clamp 15 Fig 1 Brake System Modification Front 1 Remove front fenders and wheel covers 2 See Fig s 1 amp 2 Remove OEM line from anti dive valve and front master cylinder Line
22. inside of frame tab RH bracket is mounted on outside of frame tab See Fig 1 Mount amplifier box using the fol lowing hardware e 2 Bolts From OEM Rear Fender Cover e 2 5 16 Flat Washers CW2010 e 2 Nuts From OEM Heat Shield 4 See Fig 2 Drill 1 4 holes where plastic fender and amplifier box overlap Install with the fol lowing hardware e 2 Bolts From OEM Amplifier Box Mount ing e 2 Nuts From OEM Heat Shield 5 See Fig 3 Amplifier box should look as shown when complete 30 Latch Modification 1 See Fig 1 Remove release cable and plastic clip from LH latch assembly 2 See Fig 1 Bend cable tab straight See Fig 1 Remove original release lever 4 See Fig 2 Install cable extension using the following hardware NOTE Tighten screw just enough to engage lock nut Over tightening will cause extension bracket to bind up e 1 Cable Extension LB6319 e 1 10 32 x 1 2 Machine Screw CS4066 e 1 10 32 Lock Nut CN3068 5 SeeFig 2 Install latch assembly and cable bracket to latch bracket using the following hardware e 1 Latch Mount Bracket LB6302 e 1 Cable Bracket LB6320 e 4 OEM Phillips Screws From Saddle bag 6 SeeFig 2 Install cable clip and cable to new extension 7 Test latches to verify they release at the same time Adjust rod length as needed SS Door may not release properly if latches do not release together 8 See Fig 2 Instal
23. l cable clamp to safety re lease cable Loop cable through small hole in cable extension bracket and crimp cable clamp e 1 Cable Clamp CC1900 e 48 Safety Cable 9 See Fig 3 Complete latch assembly should look as shown 31 Remove release lever Fig 2 Cable bracket Remove ER nd ci cable L atch bracket Latch Installation See Fig 1 Install latch assembly into trunk using the following hardware Leave latch loose to move in slots e 4 M6 x 16 Button Head Bolts CB1904 e 4 M6 Fender Washers CW2107 See Fig 2 Route latch cable through large hole in front trunk wall Secure grommet in hole See Fig 2 Route safety release cable through small hole in front trunk wall Apply silicone around safety release cable from inside trunk 32 Taillight Modification 2006 Models 1 One taillight mounting stud and part of plastic landing needs to be removed This stud is the Cut plastic stud short stud closest to pointed corner of red lens 3 16 above opening closest to centerline of motorcycle when mounted 2 SeeFig 1 Cut plastic and stud approximately 3 16 above tiny slot in bottom of landing This will leave a flat base about 3 16 thick 3 Drill a 3 16 hole in center of new flat landing for a screw to retain metal adapter 4 SeeFig 2 Insert short side of taillight adapter to each light using the following hardware e 2 Taillight Adapter LP6301 e 2 1 4 S
24. ll original tour pack frame to trike frame Torque hardware to 18 ft Ibs 3 Position body on frame Use rubber spacers as needed on front and rear mounting holes 4 SeeFig 1 Install side covers and adjust body to achieve a consistent 1 8 gap between the front of body and side cover 5 SeeFig s 2 amp 3 Align body to trike Center body by checking side to side wheel opening and front to back front of fender measure ments 6 Determine body height by measuring from in ner fender down to center of axle Ensure gaps at side covers are tight and equal on both sides NOTE Adjust body height by adding or remov ing shims as needed 38 8 10 11 See Fig 4 From below trike drill 1 4 holes in center of body mount tabs on Lehman frame Install the body to the frame using the following hardware Tighten hardware down evenly e 4 M6 x 35 Socket Head Bolts CB1934 e 4 1 4 x 1 25 Fender Washers CW2108 e 4 M6 Fender Washer CW2107 e 4 M6 Flange Nut CN1902 See Fig 5 Install fender braces to middle pre drilled hole in front of body Attach to body using the following hardware Apply Loctite 242 and tighten hardware e 1 LH Fender Brace LB6323 e 1 RH Fender Brace LB6324 e 2 M8 x 20 Flange Bolt CB1919 e 2 M8 Flange Nut CN1905 See Fig 5 Clamp other end of brace to Leh man frame and drill second mount hole in trike frame using an 11 32 drill bit Attach to trike f
25. nd cut excess wire 8 See Fig 3 Install 2 female terminal pins and 1 male connector to wiring from light 9 See Fig 3 Install black clip BT3001 to secure wiring to plate Cut plug from original license plate light and add 34 of wire Cover with heat shrink NOTE Connect license plate wiring as follows Black wire on light to green on harness Red wire on light to brown wire on harness 10 Run wire through body grommet from back side and install 2 male terminal pins and 1 female connector 11 See Fig 4 Connect wiring and install light as sembly to bracket using the following hard ware e 2 M6 x 16 Button Head Bolts CB1904 e 2 M6 Flange Lock Nuts CN1902 41 Exhaust Installation 1 See Fig s 1 amp 2 Assemble exhaust components as shown ITEM PART QTY 1a LB6011 1b LB6012 2 2014 3 LP6300 4 GC1013 5 GGDO000 6 CB1905 7 1902 8 LH6305 1 1 1 Fig 1 DESCRIPTION Honda Parts LH Exhaust Cover Bracket RH Exhaust Cover Bracket Hose Clamp 24 Exhaust Pipe Extension Exhaust Clamp Exhaust Gasket Fig 2 Flange Bolt M6 x 1 x 20 Flange Lock Nut M6 x 1 Muffler Hanger See Fig 3 Attach mufflers to mounting brack ets using the original hardware Adjust fit relative to body side to side About 1 of muffler should extend past rear of body See Fig 4 Center exhaust tips in body cut outs Adjust to equal height Tighten exhaust
26. ne Bushing LB6301 e 4 Steel Bushing LB6303 G Ki Ai i en pP um be o A M i TUER P oce soy Zo oi GC F te n US ee C M n hl C ies FS Metts D 1 Rx x 4 1 E y um ou USE OEM FASTENERS TO ATTACH SHOCK Be A h r EN Ss E Pa _ RC a Ai dy vr ET oT A WW V a ad d Bra m a pi SPACER CW2150 PLACE TE WASHER UNDER NUT Ire F a is Dy AD d a vi p ram zx ut a ta Ki ZA Kos Qm i ty a i d po v 7 USE STOCK FASTENERS TO ATTACH SHOCK LINKAGE 19 Auxiliary Shock 1 See Fig s 7 amp 8 Install lower end of auxiliary shock with shim and flange bushing as shown Apply a small amount of lube to bushing e 1 5 8 Shim CS4030 e 1 Flanged Bushing LB6314 20 Bushing Flange on RH side DIFFERENTIAL INSTALLATION Differential Installation NOTE The OEM transmission output shaft boot is not reused 1 Shift transmission into NEUTRAL 2 See Fig 1 Install U joint to driveshaft yoke Grease fitting should face yoke e 1 Driveshaft Yoke LY1002 e 1 U Joint S002086 3 See Fig 2 Apply Loctite retaining compound Green to yoke splines and Install the stub shaft into yoke End of shaft should be flush with yoke surface Install set screw and torque to 19 ft lbs e 1 Stub Shaft
27. om fuse panel Location will vary by year See Fig 1 Unplug ABS control module Posi tion black 5 pin connector so the unplugged end is facing you with 3 pin slots on the bottom See Fig 1 Remove a small amount of plastic between bottom center and bottom right pin slots Remove only enough material to install a mini fuse Install 5 amp mini fuse from fuse panel into bottom center and bottom right slots Verify that fuse connects yellow blue wire ABS light to larger green wire ground Use electrical tape to cover plug and secure fuse into place Reconnect battery and verify ABS light re mains off 47 DETAIL A cut here for fuse Y E clearance X N eg rewon _ DEMLTTITTITOT CAN RN CNN e posmo oo o isd DREES ove s eme Femmes ed S e wema EES Tank soor seats ana operetes snooty fe oo o _ m poama o peamees ooo ooo M menaren enman sasons fe eener _ 17 arany onnes merane ie 48 GB6300 BOLT BAG DRIVETRAIN Hardware quantities vary by model year p ees sonra monsxes ___ comer emosxuww ccs PIN CLEVIS 5 16 X 19 32 50 BX p ew oneone s oem Wan corpenamwowe 49 GB6301 BOLT BAG DRIVETRAIN Hardware quantities vary by model year p pens wee
28. rame using the following hardware Use 1 M8 x 1 25 x 20mm flange bolt and 1 M8x1 25 flange nut to attach brace to frame Apply Loctite 242 and tighten hardware e 2 M8 x 20 Flange Bolt CB1919 e 2 M8 Flange Nut CN1905 39 d i License Plate Installation Use stock license plate bracket and a license plate to mark location of license plate bracket in middle of body on raised surface Cover area to be drilled with masking tape center and level bracket and mark holes NOTE Make sure license plate has proper clearance between door and hitch if applicable 3 See Fig 1 Drill 2 1 4 holes 1 1 2 from bot tom of trunk opening and mount bracket into place See Fig 1 Drill 1 7 16 hole for license light wires centered between license plate bracket bolts and 3 from bottom of trunk opening Drill hole so it is toward top of bracket so it is un seen when plate is on Install grommet in body e 1 Rubber Grommet GGO001 1 Attach license plate bracket to body using the following hardware e 2 M6 x 25 Button Head Bolts CB191 1 e 2 1 4 Flat Washers CW2006 e 2 M6 Flange Lock Nuts CN1902 See Fig 2 Bolt license plate light using the following hardware 1 License Plate Light S001469 e 1 Support Plate 5001601 e 2 M6 x 16 Button Head Bolts CB1904 2 M6 Washers CW2154 2 M6 Lock Nut CN1903 1 1 40 7 See Fig 3 Measure 5 of wiring from back side of light a
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