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2002-2008 FLH Renegade Installation Instructions

1. LEHINAN LT HIKES Leader of the Three World Henegade 2002 2008 H D TOURING MODELS INSTALLATION INSTRUCTIONS FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE December 2013 2002 2008 FLH Renegade Rev 8 Table of Contents SECTION Introduction Unpacking Kit Preparing Motorcycle Installing Lehman Swingarm i x 02 06 MODELS INCLUDE Top Motor Mount Link Installing Differential 02 08 BASE KIT Belt Tensioning and Tracking CARRIER PULLEY ASSEMBLY 70 TOOTH Brake Systems BE Installing Lehman Frame and Suspension 07 08 MODELS INCLUDE Installing Exhaust 02 08 BASE KIT g CARRIER PULLEY ASSEMBLY 66 TOOTH oay ABS DISABLE KIT 1 Neck Race Preload pe 5001068 Motor Mounts General Information Replacement Parts Renegade Torque Specifications Final Trike Inspection Notes before starting conversion For 2002 03 models the standard Lehman Renegade conversion will not accommodate the original 1 1 2 final drive belt The following belt replacement is required to properly complete the Renegade installation Model Required H D part number FLH 2002 03 1 1 8 width 139 tooth 40024 04 For FLHX Street Glide and FLTR Road Glide installations the following parts will need to be or dered from H D for antenna and turn signal installation HD P N Description Qty 16252 86 Base antenna 1 76253 86 Reinforcement plate 1 76255 86 Gasket base 1 11486 Grommet 1 68713 9
2. 1 Center differential to motorcycle frame this is critical for proper belt tensioning Make sure distance is within 1 16 from side to side 2 SeeFig 1 Level swingarm to motorcycle frame This will help achieve proper ride height With standard shocks measure 12 from inner boss against center section to center of upper motor cycle frame 3 SeeFig 2 Using adjusters push differential assembly back until belt has about 3 8 slack with 10 Ibs pressure at midpoint of bottom run Measure between adapter plates and pinch blocks to ensure that distances are equal 4 Rotate pulleys forward for at least 3 revolutions of rear pulley by pulling backwards on bottom run of belt Pull belt straight back to get an accu rate reading Check that belt is running about 0 030 from flange on rear pulley Tap differen tial 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 Ibs force at midpoint of lower strand of belt Correct deflection is 5 16 3 8 7 ncrease 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
3. e 2 1 4 Fender Washers CW2108 2 OEM Flange Nuts 24 2002 2008 FLH Renegade Rev 8 Installing Exhaust 2002 2008 models See Fig 4 Install mufflers to Lehman frame using original mounting hardware Make sure mufflers 1 are level before making final cuts to exhaust pipes Note Some adjustment may be required to get pipes even and level DO NOT CUT TOO MUCH MATERIAL FROM EXHAUST PIPES INITIALLY 2 See Fig 3 For RH exhaust cut 2 1 2 from end of head pipe See Fig 1 For LH exhaust cut 6 1 8 up on outside radius of head pipe This pipe may need to be tilted downward to achieve proper angle with muffler See Fig 2 Cut 1 3 4 off back of Lehman supplied LH drop pipe LP1350 See Fig 2 Cut 5 1 2 off back of Lehman supplied RH drop pipe LP1351 Trim heat shields as needed for proper fitment Fasten exhaust clamps to joint using 5 16 X 1 1 4 NF Gr 8 bolt and 5 16 NF Gr 8 nut Position clamp so they do not squeeze a slit open on sides and clamp opening does not line up with slits in pipe Note Pipe length may need to be adjusted accord ing to the following With or without light bar Rare occurrences of body alignment 25 Fig 2 2002 2008 FLH Renegade Rev 8 Item MG A O gt Part GC1001 CB1164 CN3009 Qty N N N a da Fig 4 Desc Oem Part Right Exhaust Pipe Left Exhaust Pipe Exhaust Clamp 5 16 x 1 1 4 NF Gr 8 Bolt 5 16 NF Gr 8 Bolt
4. 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 33 2002 2008 FLH Renegade Rev 8 Door Adjustment Procedures Fig 6 1 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 E ge Pod y TU e Latch Bracket Tun 34 2002 2008 FLH Renegade Rev 8 POS Make sure cable biocket is __ 7 E nof foo for forward I the kov lock will not work 2 H bracket Is foo far back the a Latch wil not close to two clicks Bag Moke sure stiker pin ls In line with l The latch or door will not close property iker Pin ee m m Lea E EE mum a nali lo make sure you have a good door seal use a piece of paper Put paper between door and weciher seal Close door and Then tug on The paper If the paper does not come out with ease you have good seal and if it does adjust your door and Ty again Jado Iech Paper 2 Paper Paper am Lehman 35 2002 2008 FLH Renegade Rev 8 TOUR PACK MOUNTING IS DIFFERENT BETWEEN 2002 05 and 2006 08 MODELS PLEASE FOL LOW INSTRUCTIONS THAT MATCH YEAR OF MOTORCYCLE YOU ARE WORKING ON 2002 2005 FLH TOUR PACK MOUNTING 1 Bottom of tour pack h
5. in following order e Lower pin then upper pin into side cover mount e Upper forward pin into motorcycle frame 4 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 5 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 6 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 4 1 4 x 1 1 4 Fender Washers CW2108 4 Foam Sealing Washers FG1002 4 1 4 Flat Washers CW2007 4 1 4 Lock Nuts CN3041 OL A 7 See Fig 5 Install upper body braces LB1235 by at taching slotted side on top of Lehman frame using the following hardware Leave hardware loose e 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 8 Slide bracket against trunk mark and drill 1 4 hole 9 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 10 Tighten 5 16 hardware into place on trike frame 11 Verify all body mounting hardware is tight 2 2 31 Fig 1 UT LH Side cover bracket 1 Ec E pad Side co
6. 13 See Fig 4 Lower portion of frame braces will at tach to welded tabs on motorcycle frame above swingarm Braces are bolted to outside of motor cycle frame Top end of frame braces are not factory drilled Braces should line up with hole in frame ahead of top square tube Clamp top of frame braces to outside of Lehman frame and drill through braces using a 3 8 drill bit Bolt together with 3 8 x 1 1 4 bolts flat washers and lock nut Use new air line to connect shocks to valve See Fig 5 Air valve plate for front and rear shocks must be relocated Recommended loca tion is on right side of trike behind top bolt on electronic control module Re route air lines to fit Charge system with air 20 psi and check for leaks with soapy water A plastic imitation fender is used to mount seat and grab handle LH1026 Imitation fender will use original motorcycle fender mounting hard ware Front of imitation fender mounts in same location as original fender Rear of imitation fender mounts to rear holes on motorcycle frame using 5 16 x 1 1 2 bolts Note To meet DOT and MOT requirements one of the following must be installed stock grab handles stock grab strap or Lehman supplied grab handles For 2002 05 models the OEM grab handle can be reused 14 Attach grab handle to imitation fender using 1 4 X 1 bolts 1 4 fender washers and original flanged nuts e 1 Grab Handle LH1026 e 2 1 4 x 1 Bolts CB1085
7. 3 Install frame plates to H D frame with 2 5 16 X 1 1 2 bolts flat washers if necessary between frame plate and motorcycle frame and lock nuts for front hole only Rear bolt will be used with imitation fender Do not tighten bolts oet frame in place and install 2 1 2 X 1 1 2 bolts flat washers and lock washers through front holes of trike frame and into original shock mount on H D frame See Fig 2 and 3 Attach frame plates LB1220 to Leh man frame plate using 5 16 X 1 bolts flat washers and a lock nuts See Fig 2 Level Lehman frame to H D frame Frames should be parallel with each other Tighten all bolts when level Torque front 1 2 bolts to 78 ft lbs Torque all frame plate bolts to 19 ft Ibs See Fig 3 Lower differential and install 1 2 X 2 1 4 bottom shock bolt through lower shock eye and thread it into shock plate Use 1 washer under head of bolt Torque bolt to 40 ft lbs and secure bolt with lock nut Fig 2 See Fig 3 Raise differential and install top of shock 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 Fig 3 E Use 5 10 X T polte flat washers and lock nute In the rear aote of Use 5 16 X 1 1 2 bolte flat washers and lock pute Inthe 7 Use 516 X 11 2 botte and Tat washere in the rear 2002 2008 FLH Renegade Rev 8 10 11 12
8. 41609 See Fig 5 Inspect crimps before installing into connector Distortion should be minimal Fig 4 Fig 5 Insulation crimp Male terminal UA Ug Wire core crimp Female terminal 29 2002 2008 FLH Renegade Rev 8 Fig 5 6 position connector for trailer GH0023 2 Erro ke 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 se 6 Position Connector for Trailer 2 12 Volt Switched 8 Position Connector Under Seat Tracer x 5 2 Ground Taillight am gp SET 7 2 Running Light Red White ee m Tracer Brown Purple ac p s x Orange White Tracer Left Turn Signal Right Turn Signal fi Left STOP E MEME Right Lg de Black 2002 2008 FLH Renegade Rev 8 30 Body Installation 1 See Fig 1 Bolt side cover bracket to body using 1 4 X 1 button head bolts and 1 4 flat washers on outside of body Use 1 4 fender washers and 1 4 lock nuts on inside of fender 2 Route emergency trunk release cable along H D frame and secure behind LH side cover 3 Set body roughly in place on trike frame 4 SeeFig 2 Attach side covers to frame and body
9. ABS unit MR and tighten 3 SeeFig 1 Disconnect OEM rear brake line silver from ABS unit R and discard brake line was disconnected from rear caliper during motor cycle disassembly 4 SeeFig 2 Re install banjo bolt with spacer 5001067 in ABS unit and tighten 5 SeeFig 3 Locate ABS front wheel sensor plug under left side of fairing and disconnect Secure longer sensor plug to fairing wire bundle with cable tie CT1026 6 SeeFig 4 Locate ABS rear wheel sensor plug left side of ABS unit Disconnect plug remove sensor from right side axle and discard 21 2002 2008 FLH Renegade Rev 8 ABS Systems Continued Note Items 7 11 can be performed during Neck Race Preload check on page 38 7 Remove outer fairing refer to HD service man ual Caution Disabling ABS light will also disable cruise control light 8 See Fig 5 Disable ABS warning light by cut ting orange wire with white stripe 9 SeeFig 6 Install 2 heat shrink to each end of cut wire 10 Re install fairing 11 See Fig 7 Place ABS warning label above warning light indicators on fairing ABS Disabled sticker here 22 2002 2008 FLH Renegade Rev 8 Installing Lehman Frame and 1 Note See Fig 1 Front bolt on each side will install from inside with head of bolt toward middle of trike This provides clearance between fender and bolt 2 Note Do not install flat washer under lock nut 6 See Figs 1
10. Before loosening lock nuts from OEM motor mount link measure length from center to center of holes 3 Remove OEM motor mount link save washer on RH side Fig 2 Lehman Motor Mount Link Installation 4 Adjust Lehman motor mount link to same distance from center of hole to center of hole as OEM motor mount link e 1 Upper Engine Stabilizer Link GMO142 Note Locate position of eyelet holes and alignment of OEM link Lehman link must be adjusted same as OEM link 5 Install Lehman link Fig 3 using existing OEM bolts washer on RH side blue Loctite 242 and supplied motor mount link shims Note Be sure to shim both sides of link ends 6 Torque OEM bolts to 22 ft Ibs 12 2002 2008 FLH Renegade Rev 8 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
11. bracket and save Disconnect airlines from shocks and remove shocks Stand shocks upright to prevent oil leaks Save air valve plate and discard original shock mounting bolts Remove rear fender Save two front mounting bolts Save turn signal lights and fender mounting hardware including stud plate for grab rail These parts will be re used Remove brake line from caliper and remove caliper Remove clip from rear axle and remove axle nut with 36mm socket Axle can now be removed Remove rear wheel assembly Support bottom side of transmission housing with floor jack and padded block Remove pivot shaft nut from LH side of bike Remove LH RH swingarm brackets Tap shaft out of swingarm and remove from RH side Swingarm may now be removed For 2002 07 models fuel tank must be removed Refer to HD service manual for proper procedure 2002 2008 FLH Renegade Rev 8 Installing Lehman Swingarm Note If all original components from H D swingarm are in good working order they may be re used 1 Press bearing assemblies out of 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 following HD service manual procedure Bearings should bottom out on stop in Lehman swingarm collar Note Refer to H D service manual for swingarm installation procedures a
12. 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 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 16 2002 2008 FLH Renegade Rev 8 12 See Fig 10 Remove RH front plate hardware and install tapered washers 8001784 into holes on RH side before installing brace 13 Bolt rear half of differential brace to housing us ing bolts CB1939 14 See Fig 11 Bolt front half of differential brace to top of swingarm gusset with a 3 8 x 1 bolt flat washers and lock nut P f Note Do not bolt down brace until belt tension ing is completed 15 Tighten bolts in following order a Front half of brace to swingarm gusset Torque bolts to 35 ft Ibs b Rear half of brace to differential housing Torque bolt to 17 ft Ibs c Torque LH fro
13. nuts 3 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 38 2002 2008 FLH Renegade Rev 8 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 Adjusting Motor Mounts The front and top motor mounts may need to be adjusted to achieve correct vertical alignment and to center differential housing to frame To do this trike must be sitting on a level surface Refer to H D service manual for correct procedure on adjusting motor mount assemblies 39 2002 2008 FLH Renegade Rev 8 Renegade Torque Specifications owingarm pivot shaft H D owingarm plates H D Axle flange bolts Park brake bracket to swingarm Differential brace to swingarm Differential brace to housing Pinch block bolts Adapter plate to swingarm Banjo bolts Torque link to frame Torque link to engine Lehman frame to H D frame Frame plate bolts Frame brace Shock bolts Wheels aluminum Wheels wire Caliper to bracket
14. outline around it Note For 2006 2007 models a small notch must be cut from plastic HD frame cover to accommodate Lehman mo tor mount bracket LB1277 Move any wiring before cutting 5 Sand or grind frame to bare metal finish inside outline where bracket will fit A slightly rough surface is desirable Note Use a generous amount of glue Loctite 330 to fill between bracket and frame Apply glue to plate and spray activator onto glue rather than frame 6 Gei See Fig 2 Install 3 8 x 1 1 2 bolt lock washer and flat washer through bracket and into frame Use 2 3 C clamps to hold bracket to frame Allow adhesive to cure for 24 hours Installation may proceed while glue cures Attach link assembly to upper mounting bracket Fig 2 ITEM QTY DESCRIPTION PARTM o au 131 _ 1 1 BOLT ae 186x112GR8 Cae 2002 2008 FLH Renegade Rev 8 10 Link should run horizontal to motorcycle Be sure to shim both sides of link end with supplied shims and use OEM spacer Fig s 2 amp 3 11 Tighten all bolts to factory torque specs frame 22 ft Ibs engine 33 ft Ibs 12 Check for any interference of motorcycle parts wire harnesses air hoses etc 13 Reroute any wire harnesses around or behind bracket The coil wire on a fuel injected model will run over top edge of bracket Note Make sure harnesses are not pinched when fuel tank is reinstalled Fig 3 10 2002 20
15. 08 FLH Renegade Rev 8 Head Bolts and Front Motor Mount Reminder Applies only to 2002 2007 Models FLH Head Bolts 1 Remove existing 3 8 bolt lock washer and flat washer that holds engine stabilizer bracket to en gine Apply blue Loctite 242 to threads of 3 8 x 1 1 4 hex flange locking bolt Assemble bolt spacer LS1189 and external tooth lock washer in appropriate order Torque bolt to 42 ft Ibs Reinstall gas tank according to H D service manual once top motor mount glue is fully cured FLH Lower Engine Mount Bolt Remove 3 8 bolt lock washer and flat washer that holds engine stabilizer to engine Apply blue Loctite 242 to threads of 3 8 x 1 1 2 hex flange locking bolt Install 3 8 x 1 1 2 flanged bolt and original washer Torque bolt to 42 ft Ibs On same bolt install 3 8 supplied locknut and torque to 38 ft Ibs Remove bolt lock washer and flat washers that hold stabilizer to frame Apply Loctite to supplied 3 8 x 1 1 2 flanged head bolt Install supplied bolt with original flat wash ers to frame Torque bolt to 42 ft Ibs 7 Remove front engine mount apply Loctite to threads and re install nut Torque bolt to 45 54 ft Ibs o am Ee 11 2002 2008 FLH Renegade Rev 8 Reminder For 2008 models do not disturb OEM head bolts or lower engine mount bolt Top Motor Mount Link Removal 2008 Models 1 OEM top motor mount link will be replaced with Leh man Motor Mount Link Fig 1 2
16. 26 2002 2008 FLH Renegade Rev 8 Lights and Wiring Caution Use care with painted surfaces 1 SeeFig 1 Drill 15 16 hole for turn 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 BGO200 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 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 8 4 Inspect crimps before installing into connector Distortion should be minimal Fig 3 Female Terminal Insulation crimp Wire core crimp Fig 4 27 2002 2008 FLH Renegade Rev 8 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 C
17. 4A Lamp rear signal 2 Dakota Digital offers a hidden antenna kit as an alternative Part ANT 2000 ABS Models Disabling the ABS light will also disable the cruise control light 2002 2008 FLH Renegade Rev 8 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 si
18. W2005 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 using 2 1 4 x 1 bolts See Fig 5 Run wiring through lower hole in door e 1 License 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 hard ware 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 har ness 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 28 2002 2008 FLH Renegade Rev 8 Renegade Wiring Harness 1 See Fig s 1 2 Attach wiring harness to body clips on underside of body Connect 8 position connector on wiring harness Fig 3 to OEM harness located under rider Light bar seat at rear of OEM frame connector side l See Fig s 4 5 Before connecting license plate and light bar optional to harness terminals 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
19. as ribs that match up with ribs on Renegade body 2 Take flat weather seal 1 16 X 1 1 2 X 24 and cut two pieces 10 1 2 long Place foam seals on three center ribs with short left over piece on middle rib Note If tour pack is too far forward this may cause interference with front trunk wall when drill ing mounting holes into body 3 Settour pack into place where it will be comfortable for passengers Seat may be set in place to help locate tour pack Make sure side to side and front to back measurements are equal before drill ing Carefully open tour pack and locate 8 holes in metal plate in floor Drill forward 4 mounting holes in tour pack plate and body to 21 64 4 Attach tour pack using 4 5 16 X 2 bolts lock washers flat washers and tour pack supports LS1028 inside trunk Now that tour pack is installed on fiberglass instead of steel a new ground wire must be added Run an appropriate ground wire from tour pack plate to motorcycle chassis o Install tour pack liner inside tour pack 36 2002 2008 FLH Renegade Rev 8 2006 2008 FLH TOUR PACK MOUNTING 1 2 9 10 11 13 14 Use original H D chrome tour pack frame See Fig 1 Cut both sides of frame 3 4 ahead of leading edge of forward hole Drill out LH 2 and RH 2 chrome frame holes to 21 64 Insert supplied chrome plugs GP0106 into cut end of tour pack frame Drill out 4 aluminum H D tour pack spacers to 21 64 See Fig 2 D
20. bolts Caliper bracket to axle flange bolts Differential housing plate bolts Axle tube bolts 45 ft Ibs 42 ft Ibs 38 ft Ibs 35 ft Ibs 35 ft Ibs 17 ft Ibs 25 ft Ibs 35 ft Ibs 16 ft Ibs 22 ft Ibs 33 ft Ibs 78 ft Ibs 19 ft Ibs 35 ft Ibs 40 ft Ibs 85 ft Ibs 75 ft Ibs 38 ft Ibs 38ft Ibs 17ft Ibs 38ft Ibs 40 2002 2008 FLH Renegade Rev 8 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 O N O BR C N Trunk clean and dry O Trunk door seals and operates smoothly Shocks set mid setting NO Heat shields side covers C2 Renegade Lehman badge installed A Accessories if applicable C No paint defects en Warranty owner s manual included 41 Good Rework L O L L O L L L E L L L L L L L L L L L L L L O O O L L L L L O 2002 2008 FLH Renegade Rev 8
21. entered Support 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 4 Remove seat and save mounting screw 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 6 f 8 9 10 Remove saddlebags if equipped 12 11 17 19 20 21 22 23 Remove tour pack For 2006 08 models save mounting bar spacers and hardware for rear hole Raise motorcycle lift to working height Remove side stand mounting bolt and separate side stand from bracket Remove passenger footboards Save boards and hardware for re installation Remove side covers Remove rear side cover grommets from motorcycle for use with Lehman side cover mounts Remove mufflers and saddlebag mounts Keep all muffler mounting hardware including rubber iso lators located in saddlebag mounts These parts will be re used Remove rear heat shields from exhaust pipes and loosen head pipe bolts Save all exhaust hard Ware Remove carriage bolt from lower RH exhaust
22. evis Pin CC3106 e 1 Cotter Pin CCA017 5 SeeFig 6 Route left park brake cable above differential and under motorcycle frame at taching cable ties to cable and frame and in stall in left hole in handle mount 6 SeeFig 7 Route right park brake cable up around axle and forward to right hole in handle mount 7 See Fig 7 Secure both cables to upper rear pinch block with clamp GC0108 8 SeeFig 8 Secure cable retaining nuts to handle mount with 7 8 wrench 9 Check for tire clearance 10 See Fig 8 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 11 Adjust park brake cables at handle to engage at 3 4 clicks Note Take up slack in cables before tighten ing ends to ensure good adjustment range with threaded end of brake cables 20 1 GB1098 Park Brake Lever 2 LB1294 Cable Pulling Bracket 3 CC3106 Clevis Pin d 4017 Cotter Pin 5 LB1292 Park Brake Bracket Left park brake cable h v pu 66 2 E Fig 7 er Be a e 2002 2008 FLH Renegade Rev 8 ABS Systems 1 SeeFig 1 Disconnect OEM rear brake line black from ABS unit MR Route brake line From Master along lower frame tube and above swingarm Cylinder to This line will be used for the rear brake system ABS black 2 SeeFig 2 Re install banjo bolt with spacer 5001067 in
23. ional DOT USA MOT Canada State Provincial and local vehicle is standards is the responsibility of the installer Installation of the parking brake and grab handles is necessary to achieve compliance with DOT MOT ARB Label Confirmation California Kits Fig 1 1 See Fig 1 California Air Resource Board ARB certification label must be affixed on all swingarms for kits sold into Califor nia Label should be placed on left side of swingarm 1 2 from rear weld Make sure label correlates with correct model year 2002 2008 FLH Renegade Rev 8 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 pe si T L XX NL RN od LB1295 2002 06 SWINGARM BUSHING 2002 2008 FLH Renegade Rev 8 LB1301 LB1302 2007 08 SWINGARM BUSHINGS 2002 2008 FLH Renegade Rev 8 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 Make sure motorcycle is standing straight up and handlebars are c
24. lat 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 32 2002 2008 FLH Renegade Rev 8 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 lock Install Renegade badge to bottom right side of 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 washers and 1 4 bolts e 2 1 4 x 1 2 Bolts CB1075 e 2 1 4 Lock Washers CW2040 otriker pin and bracket 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 Strip and solder ends of license plate wires from the body and door together Slide shrink tubing over soldered connections and heat Solder and heat shrink light wiring to trunk wiring
25. nd torque specifica tions for specific model of motorcycle 3 Install Lehman swingarm with word TOP stamped into swingarm collar facing upward Use Loctite 242 on threads Torque rear swingarm fork pivot shaft to 45 ft Ibs 4 Install steel bushings into swingarm with shoul der toward inside of swingarm 2002 2006 Models 5 SeeFig 1 Install orange urethane bushings and steel bushings into swingarm rubber mounts on both sides of trike e 2 Orange Urethane Bushings LB1295 e 2 Steel Bushings LB1296 2007 2008 Models 6 SeeFig 2 Urethane bushings are black for 2007 08 models Each bushing is marked L and has a unique ridge to fit properly into fork brackets on 2007 08 kits Install with steel bushings e 1 LH Urethane Bushing LB1301 e 1 RH Urethane Bushing LB 1302 e 2 Steel Bushings LB1296 7 Re install rear swingarm fork brackets Apply Loctite 242 and torque bolts to 42 ft Ibs 8 Be sure swingarm moves freely up and down with no side to side movement Light resistance is normal Fig 2 2002 2008 FLH Renegade Rev 8 Top Motor Mount Link 2002 2007 Models Only Fig 1 2008 Models See pg 12 Before loosening lock nuts for original top motor mount link measure length from center to center of bolt holes Remove OEM top motor mount link Adjust Lehman stabilizer link Fig 1 to achieve same length as OEM motor mount link Position top motor mount bracket LB1277 against frame and
26. nt plate bolts to 17 ft Ibs 17 2002 2008 FLH Renegade Rev 8 Disc Brakes 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 Brake pads will need to be seated in during initial test ride Note FOR ABS DISABLE SEE PAGE 21 Brake System 1 SeeFig 1 Attach brass tee to differential brace using the following hardware e 1 Brass Tee CF5105 e 1 Spacer S001530 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 2 SeeFig 1 Install original brake line from master cyclinder and rear braided lines to brass tee using the following hardware Torque 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 18 2002 2008 FLH Renegade Rev 8 Note Be sure you have correct model year res Fig 3 ervoir extension pack before proceeding Reminder packs are labeled 1997 2007 and 2008 5 See Fig 3 Remove original master cylinder reservoir cap screws and discard Install ex tension t
27. o master cylinder with new extension screws Do not over tighten extension screws Note Verify all brake lines and hardware are tight before bleeding system 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 over bleeder valve on caliper D 8 Pump brake pedal to build pressure Ee 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 11 Install master cylinder reservoir cap with new screws Do not over tighten cap screws Park Brake Assembly 1 See Fig 4 Install park brake cable to caliper brackets Secure cable to bracket with cir clip provided on cables p 19 2002 2008 FLH Renegade Rev 8 2 SeeFig 5 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 SeeFig 5 Place park brake lever within park brake bracket ensuring ratchet is secure on cross brace Attach with large clevis pin 4 SeeFig 5 Attach park brake cable pulling bracket to brake lever using small clevis pin and cotter pin e 1 Cable Pulling Bracket LB1294 e 1 Cl
28. rill forward 4 mounting holes in tour pack plate to 21 64 Use 2 5 16 bolts in rear holes to line up chrome Fig 2 rail to bottom of tour pack and place it on body such that rear of chrome rail is just behind center body rib Set tour pack into place where it will be comfortable for passengers Seat may be set in place to help locate tour pack Make sure side to side and front to back measurements are equal before drilling go Drill holes to Note If tour pack is too far forward this may cause UN 21 64 interference with front trunk wall when drilling mounting holes into body Drill 2 front mounting holes Center rear hole is not used Remove short 5 16 bolts from rear holes and place them in front Drill rear holes Place aluminum HD spacers onto body Place modified frame onto spacers Place tour pack on top and install with 4 5 16 X 2 bolts lock washers flat washers and tour pack supports Mount liner back into tour pack Note There will be left over fasteners as bolt bag is universal and fits various model years 37 2002 2008 FLH Renegade Rev 8 Final Assembly 1 Install seat to fender using original H D mounting hardware Note Make sure insert in fender is free of paint before installing screw 2 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
29. tting 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 seated 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 2002 2008 FLH Renegade Rev 8 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 NOTE Compliance with nat
30. ver installed 8 z s Body brace attached to frame 2002 2008 FLH Renegade Rev 8 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 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 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 2 Door Lanyard S001686 7 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 to door using shoulder screws f Washer under with M6 f
31. 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 CO loch Ch Ex o hI wh 13 2002 2008 FLH Renegade Rev 8 4 See Fig 3 and 4 Loosely install hardware to pinch blocks before installing differential to swingarm 14 Part z CB1276 CB1286 CH3016 CwW 015 Cwv70450 LP1032 Part CB1276 CB1286 CN3016 Cw 015 CWw 050 LP1037 Desc 3 0 X 3 NF GR 8 BOLT 30 X 312 GR 8 BOLT 3 8 HF GR 8 HUT 3 8 GR 8 FLAT WASHER 3 8 LOCK WASHER SHOCK MOUNT PLATE 78 X 3 NF GR 8 BOLT F8 X 31 7 GR 8 BOLT 3 6 NF GR 8 NUT 78 GR 8 FLAT WASHER 3 6 LOCK WASHER SHOCK MOUNT PLATE 2002 2008 FLH Renegade Rev 8 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 15 2002 2008 FLH Renegade Rev 8 Belt Tensioning and Tracking

2002-2008 FLH Renegade Installation Instructions

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