Part Number - Lehman Trikes

Transcription

2008
Parts Supplem ent
Supplement to Victory®
Kingpin™ Parts Manual
S001016
NOTE:
Throughout this manual, a vendor reference of “various” refers to your
local parts supply store or warehouse. Be sure to follow all DOT and grade
specifications listed in this manual when buying parts.
PB0208V2GR
© 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 the state of this product at the time of its publication, and may not reflect the product in
the future. Lehman Trikes® is a registered trademark. All other brands and product names are trademarks or registered trademarks of
their respective holders. Printed in the United States of America.
Reader’s Comments
Lehman Trikes continuously strives to improve the quality and
usefulness of its publications. To do this effectively we need user
feedback—your critical evaluation of this manual.
Please comment on this manual’s completeness, accuracy,
organization, usability and readability.
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City __________________ State __________________ Zip __________
2008 PIT BOSS
Clip out and mail or fax to:
Lehman Trikes USA, Inc.
Technical Communications
125 Industrial Drive
Spearfish, SD 57783
Fax- 605-642-1182
PIT BOSS POWERED BY VICTORY®
PARTS DESCRIPTION INDEX
CYLINDER, MASTER ...................................... 13
A
ACTUATOR, TRUNK RELEASE .....................
ASSEMBLY, AXLE, LEFT................................
ASSEMBLY, AXLE, RIGHT .............................
ASSEMBLY, CARRIER ...................................
ASSEMBLY, DIFFERENTIAL ..........................
ASSEMBLY, PULLEY, REAR ..........................
ASSEMBLY, TRUNK LATCH...........................
ASSEMBLY., PARK BRAKE............................
D
21
19
19
19
19
19
21
15
DOOR, TRUNK ................................................ 21
F
FITTING, BRASS, DIFF. .................................. 19
FOOTPAD, LH ................................................. 21
FOOTPAD, RH................................................. 21
FRAME, LICENSE PLATE............................... 23
B
G
BADGE, VICTORY .......................................... 23
BAR, STABILIZER ........................................... 11
BEARING, AXLE.............................................. 19
BEARING, SWINGARM..................................... 9
BELT, DRIVE ................................................... 19
BODY............................................................... 21
BOLT, BANJO.................................................. 13
BRACE, BODY MOUNT, LH............................ 13
BRACE, BODY MOUNT, RH ........................... 13
BRACE, FRAME, BOTTOM............................. 11
BRACE, FRAME, LH ....................................... 11
BRACE, FRAME, RH....................................... 11
BRACE, SHOCK, LH ......................................... 9
BRACE, SHOCK, RH......................................... 9
BRACKET, AUTO CANCEL MODULE ............ 23
BRACKET, CABLE PULLING .......................... 15
BRACKET, DRIVER SEAT, BACKREST ......... 23
BRACKET, FRONT BODY MOUNT, LH .......... 13
BRACKET, FRONT BODY MOUNT, RH ......... 13
BRACKET, LATCH, MOUNT ........................... 21
BRACKET, LATCH/ACTUATOR MOUNT........ 21
BRACKET, LICENSE PLATE .......................... 23
BRACKET, LOWER SHOCK MOUNT ............... 9
BRACKET, PARK BRAKE ............................... 15
BRACKET, PIN, STRIKER............................... 21
BRACKET, REAR, LH, EXHAUST MOUNT..... 17
BRACKET, REAR, RH, EXHAUST MOUNT .... 17
BRACKET, STABILIZER BAR ......................... 11
BRACKET, TAILLIGHT MOUNT...................... 23
BRACKET, UPPER AUX. SHOCK..................... 9
BUSHING, POLY-URETHANE .......................... 9
BUSHING, SHOCK............................................ 9
GASKET, BODY, FRONT ................................ 21
GASKET, BODY, REAR ...................................21
GASKET, HANDLE, GRAB.............................. 21
GASKET, RESERVOIR COVER...................... 13
H
HANDLE, GRAB, LH/RH.................................. 21
HANDLE, PARK BRAKE.................................. 15
HARNESS, TRUNK ACTUATOR..................... 23
HARNESS, WIRING ........................................ 23
HINGE, TRUNK ............................................... 21
HOSE, BRAKE................................................. 13
K
KIT, BRAKE LINE, BRAIDED........................... 13
KIT, DISC BRAKE (INCLUDES PARK BRAKE
ASSM.)........................................................ 13
KIT, WHEEL..................................................... 23
L
LAMP, TAIL...................................................... 23
LATCH, STRIKER PIN..................................... 21
LATCH, TRUNK ............................................... 21
LINER, TRUNK ................................................ 23
C
CABLE, PARK BRAKE, LONG ........................
CABLE, PARK BRAKE, SHORT......................
CABLE, TRUNK, SAFETY RELEASE .............
CALIPER, BRAKE ...........................................
CLAMP, EXHAUST..........................................
CONNECTOR, VALVE, RESIDUAL ................
COVER, RESERVOIR .....................................
M
15
15
21
13
17
13
13
MANUAL, OWNER’S ....................................... 23
4
SHIELD, DEBRIS, DIFFERENTIAL ................. 19
SHOCK, REAR ................................................. 9
SPACER, DISC BRAKE................................... 13
SPACER, FRAME, REAR................................ 11
SPACER, LICENSE PLATE MOUNT............... 23
SPACER, STAB. BAR...................................... 11
STUD, AXLE .................................................... 23
SWINGARM ...................................................... 9
N
NIPPLE, GREASE ZERK, DIFF....................... 19
P
PADS, CALIPER.............................................. 13
PIN, SHOCK ...................................................... 9
PIPE, EXHAUST, FRONT, LH ......................... 17
PIPE, EXHAUST, REAR, LH ........................... 17
PIPE, EXHAUST, REAR, RH........................... 17
PLATE, MOUNT, DIFFERENTIAL ................... 19
T
TIE, CABLE...................................................... 23
TIRE, REAR ..................................................... 23
R
RAIL, FRAME, LH............................................
RAIL, FRAME, RH ...........................................
REFLECTOR, RED, ASSEMBLY ....................
RESERVOIR, MASTER CYLINDER................
ROD, END, LH.................................................
ROD, END, RH ................................................
ROTOR, DISC, BRAKE ...................................
V
11
11
23
13
11
11
13
VALVE, RESIDUAL, PRESSURE .................... 13
W
WHEEL, CHROME PLATED ........................... 23
WRENCH, HEX, REMOVAL ............................ 23
WRENCH, SPANNER, SHOCK ........................ 9
S
SEAL, NEEDLE BEARING ................................ 9
5
PART NUMBER INDEX
LB6605............................................................. 13
LB6606............................................................. 13
LB6609.............................................................. 9
LB6610.............................................................. 9
LB6611.............................................................. 9
LB6616............................................................. 15
LB6627............................................................. 11
LC6201 ............................................................ 13
LCK5100 .......................................................... 13
LCK5100-1 ....................................................... 13
LCK5100-2 ....................................................... 13
LCK5100-3 ....................................................... 13
LCK5100-4 ....................................................... 13
LCK5100-5 ....................................................... 13
LCK5100-6 ....................................................... 15
LD1103 ............................................................ 19
LD6600 ............................................................ 19
LF6602............................................................. 11
LG6601 ............................................................ 21
LG6602 ............................................................ 21
LP2010..............................................................19
LP6400............................................................. 19
LP6601............................................................. 17
LP6602............................................................. 17
LP6603............................................................. 17
LP6605.............................................................. 9
LS0600.............................................................. 9
LS0601.............................................................. 9
LS1018............................................................. 19
LS6408............................................................. 11
LS6600.............................................................. 9
LS6601............................................................. 11
LT6601............................................................. 23
1
1910620 ........................................................... 13
3
3211102 ........................................................... 19
3610096 ............................................................. 9
C
CB1697 ............................................................
CC2017............................................................
CF5112 ............................................................
CH1008............................................................
CN1100............................................................
CR1810............................................................
CR1811............................................................
CS1001 ............................................................
CT1015 ............................................................
CT1026 ............................................................
13
17
19
13
19
11
11
23
23
23
G
GB0320.............................................................. 9
GB1001............................................................ 19
GB1024.............................................................. 9
GB1032.............................................................. 9
GB1099M......................................................... 15
GB1139............................................................ 13
GB1146............................................................ 13
GB1154............................................................ 13
GB1180............................................................ 15
GB1181............................................................ 15
GB1326............................................................ 23
GB6211............................................................ 13
GB6213............................................................ 13
GC1015 ........................................................... 17
M
MA2012............................................................ 19
MA2013............................................................ 19
S
S001000............................................................ 9
S001001........................................................... 17
S001002........................................................... 17
S001003........................................................... 11
S001004........................................................... 23
S001007........................................................... 23
S001013........................................................... 23
S001015........................................................... 23
S001021........................................................... 13
S001022........................................................... 13
S001023........................................................... 21
S001025........................................................... 23
S001026........................................................... 21
S001027........................................................... 21
S001028........................................................... 23
S001029........................................................... 21
S001030........................................................... 21
H
HW0050 ........................................................... 23
L
LB1294 ............................................................ 15
LB1298 .............................................................. 9
LB6419 ............................................................ 11
LB6600 ............................................................ 11
LB6601 ............................................................ 11
LB6602 ............................................................ 11
6
S001033 ..........................................................
S001034 ..........................................................
S001035 ..........................................................
S001037 ..........................................................
S001038 ..........................................................
S001039 ..........................................................
S001040 ..........................................................
S001043 ..........................................................
S001044 ..........................................................
S001053 ..........................................................
23
23
21
23
21
23
23
21
21
21
S001054........................................................... 21
S001055........................................................... 21
S001056........................................................... 21
S001058........................................................... 21
W
WK0029 ........................................................... 23
7
#1
#2
#3
#4
#5
#6
#7
#8
8
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
6
7
8
Part No.
LB1298
LB6609
LB6610
LB6611
LP6605
LS0600
LS6600
S001000
Qty.
4
1
1
1
1
1
1
1
Part Description
BUSHING, POLY-URETHANE
BRACE, SHOCK, LH
BRACE, SHOCK, RH
BRACKET, LOWER SHOCK MOUNT
PIN, SHOCK
SHOCK, REAR, C/W, SPRING
SWINGARM
BRACKET, UPPER AUX. SHOCK/RESERVOIR MOUNT
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
SUPPORTING HARDWARE/EQUIPMENT
(VARIOUS INDICATES A LOCAL SUPPLY STORE, ETC.)
Part No.
CB1380
Qty.
1
Part Description
BOLT, ½“ X ¾“ NC PLTD.
Location
CB1406
2
BOLT, ½“ X 2“ NC GR. 8
CB1970
1
M10 X 1.5 X 120 PLTD.
CN3062
1
NUT, LOCK ½“ NC GR. 8
CW2025
2
WASHER, FLAT, ½“ GR. 8
CW2061
2
WASHER, LOCK, ½“ GR. 8
CB1924
GB0320
4
2
GB1024
2
GB1032
1
LS0601
1
3610096
2
BOLT, M8X35 BTN HD SKT CAP
BUSHING, SHOCK
BEARING, SWINGARM, (VENDOR
PART # 6004)
BEARING, SWINGARM (VICTORY
PART # 3514413)
WRENCH, SPANNER, SHOCK
SEAL, NEEDLE BEARING,
SWINGARM
9
SHOCK PIN
UPPER/LOWER SHOCK MT.
HOLES
UPPER SHOCK MT. HOLES
UPPER SHOCK MT. HOLE,
SHOCK PIN
LOWER SHOCK MT. HOLE,
SHOCK PIN
LOWER SHOCK MT. HOLE,
SHOCK PIN
UPPER SHOCK MT. BRACKET
SHOCK, REAR, CW, SPRING
Vendor
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
LEHMAN
SWINGARM, LH
VARIOUS
SWINGARM, RH
VICTORY
SHOCK ADJUSTMENT
LEHMAN
SWINGARM, RH
VICTORY
#1
#2
#3
#4
#5
#6
#7
#8
10
ILLUSTRATED PARTS
Ref.
1
1
2
3
4
5
6
7
8
Part No.
CR1810
CR1811
LB6419
LB6600
LB6601
LB6602
LB6627
S001003
LF6602
Qty.
1
1
1
1
1
1
1
1
1
Part Description
ROD, END, RH, ½” -20 , MALE
ROD, END, LH, ½” -20, MALE
BRACKET, STABILIZER BAR
BRACE, FRAME, BOTTOM
BRACE, FRAME, LH
BRACE, FRAME, RH
BAR, STABILIZER
RAIL, FRAME, LH
RAIL, FRAME, RH
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
Qty.
Part Description
CB1234
2
BOLT, 3/8” X 1” NC GR. 8
CB1242
2
BOLT, 3/8” X 1 ¼” NC GR. 8
CB1268
3
BOLT, 3/8” X 2 ½” NC GR. 8
CB1299
1
BOLT, 3/8” X 6 NC GR. 8 HEX HD.
CB1406
CN3026
1
2
BOLT, ½” X 2 NC GR. 8
NUT, ½” NF PLTD., GR. 8
CN3062
3
NUT, ½” NC GR. 8 NYLOCK
CW2025
1
WASHER, FLAT, ½” GR. 8
CW2049
LS6408
LS6601
1
1
1
WASHER, LOCK, 3/8” GR. 8
SPACER, STAB. BAR
SPACER, FRAME, REAR
11
Location
FRAME RAIL-SHOCK MT.
BRACKET
STABILIZER BAR-DIFF.
HOUSING
FRAME RAIL-MUFFLER MT.
BRACKET
FRAME RAIL-MUFFLER MT.
BRACKET
STAB. BAR-SWINGARM
STAB. BAR-SWINGARM
STAB. BAR-STAB. BAR
BRACKET
STAB. BAR-STAB. BAR
BRACKET
STAB. BAR-DIFF. HOUSING
STAB. BAR BRACKET
FRAME RAIL
Vendor
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
LEHMAN
LEHMAN
#1
#2
#3
#4
12
ILLUSTRATED PARTS
Ref.
1
2
3
4
Part No.
S001021
S001022
LB6605
LB6606
Qty.
1
1
1
1
Part Description
BRACKET, FRONT BODY MOUNT, LH
BRACKET, FRONT BODY MOUNT, RH
BRACE, BODY MOUNT, LH
BRACE, BODY MOUNT, RH
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
Qty.
2
Part Description
BOLT, 5/16” X 1” Z FL SER.
CB1950
CB1936
GB1139
1910620
GB6211
GB6213
LC6201
2
2
1
1
1
1
1
LCK5100
1
BOLT, M10 X 1.5 X 60 PLTD. FLG HX
BOLT, M10 X 1 X 60 SHCS Z 12.9
KIT, BRAKE LINE, BRAIDED
CYLINDER, MASTER
RESERVOIR, MASTER CYLINDER
GASKET, RESERVOIR COVER
COVER, RESERVOIR
KIT, DISC BRAKE (INCLUDES PARK BRAKE
ASSM.)
CB1162
LCK51001
LCK51002
LCK51003
LCK51004
LCK51005
CB1095
CC2013
CW2005
CB1697
CH1008
CN3042
CS4065
CB1903
GB1146
GB1154
GC6002
S001099
S001103
Location
BODY MOUNT
BRACKETS
SHOCK MT. BRACE
BODY BRACES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
Vendor
VARIOUS
ASSM., BRAKES
LEHMAN
VARIOUS
VARIOUS
LEHMAN
VICTORY
LEHMAN
LEHMAN
LEHMAN
2
CALIPER, BRAKE, 1.38”
ASSM., BRAKES
LEHMAN
2
ROTOR, DISC, BRAKE, .188” X 11.59”
ASSM., BRAKES
LEHMAN
1
PADS, CALIPER, DISC BRAKE (SET)
ASSM., BRAKES
LEHMAN
2
SPACER, DISC BRAKE, .630”
ASSM., BRAKES
LEHMAN
2
SPACER, DISC BRAKE, 1.03”
ASSM., BRAKES
LEHMAN
1
3
2
1
1
3
2
2
1
1
2
1
1
BOLT, .25-20NC X 1.5 LG HHCS
CLAMP, HOSE, BRAKE, ¾” X 1 ¾”
WASHER, FLAT, ¼” GR. 8
BOLT, BANJO
HOSE, BRAKE, 5/16”, D.O.T. COMP. (13.5”)
NUT, LOCK, ¼” NC GR. 8
SCREW, MACH., 10-32 X ½” PHLPS HD.
BOLT, 10-32 X 3/4 SHCS Z
VALVE, RESIDUAL, PRESSURE
CONNECTOR, VALVE, RESIDUAL
WASHER, COPPER, BANJO SEALING
FITTING, -3AN FEM TO M10-1.25 FEM
SPACER, ALU., 1/2"OD X 1/4 ID-1/4" LON
ASSM., RES. VALVE
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., BRAKES
ASSM., RES. VALVE
ASSM., RES. VALVE
ASSM., BRAKES
ASSM., RES. VALVE
ASSM., RES. VALVE
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
LEHMAN
LEHMAN
VARIOUS
LEHMAN
VARIOUS
13
#1
#2
#3
#4
#5
14
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
Part No.
GB1099M
GB1180
GB1181
LB1294
LB6616
Qty.
1
1
1
1
1
Part Description
HANDLE, PARK BRAKE
CABLE, PARK BRAKE, SHORT (42.5”)
CABLE, PARK BRAKE, LONG (64”)
BRACKET, CABLE PULLING
BRACKET, PARK BRAKE
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
CB1156
Qty.
2
Part Description
BOLT, 5/16” X ¾” NC BTN. HD SS
CC2023
1
CC3106
1
BRAKE LINE SPLICE (VENDOR PART # 90554)
PIN CLEVIS, 5/16” X 19/32” 50/BX
CC4017
1
PIN, COTTER, 3/32” X ½”
CN3009
4
NUT, 5/16” NF GR. 8
CW2010
2
WASHER, FLAT, 5/16”
CW2049
2
LCK51006
1
ASSM., PARK BRAKE, LH/RH
15
Location
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
ASSM., PARK
BRAKE
Vendor
VARIOUS
VARIOUS
LEHMAN
LEHMAN
VARIOUS
VARIOUS
VARIOUS
LEHMAN
#1
#2
#3
#4
#5
16
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
Part No.
LP6601
LP6602
LP6603
S001001
S001002
Qty.
1
1
1
1
1
Part Description
PIPE, EXHAUST, FRONT, LH
PIPE, EXHAUST, REAR, LH
PIPE, EXHAUST, REAR, RH
BRACKET, REAR, RH, EXHAUST MOUNT
BRACKET, REAR, LH, EXHAUST MOUNT
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
CC2017
GC1015
Qty.
1
3
Part Description
CLAMP, EXHAUST, SIZE 32
CLAMP, EXHAUST, 47-51MM
17
Location
EXHAUST ASSM.
EXHAUST ASSM.
Vendor
VARIOUS
VARIOUS
#1
#2
#3
#4
#5
#6
#7
18
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
6
7
Part No.
LD1103
LD6600
LP2010
LP6400
LS1018
MA2012
MA2013
Qty.
1
1
1
4
1
1
1
Part Description
ASSEMBLY, CARRIER, DIFFERENTIAL
ASSEMBLY, DIFFERENTIAL
ASSEMBLY, PULLEY, REAR
PLATE, MOUNT, DIFFERENTIAL
SHIELD, DEBRIS, DIFFERENTIAL
ASSEMBLY, AXLE, LEFT
ASSEMBLY, AXLE, RIGHT
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
3211102
CF5112
CN1100
GB1001
CB1242
CB1392
CB1567
CN3014
CN3062
CW2025
CW2049
CW2061
Qty.
1
1
1
2
10
8
4
4
4
16
8
8
Part Description
BELT, DRIVE
FITTING, BRASS, DIFF., 3/16” X 1/8”
NIPPLE, GREASE ZERK, DIFF.,
BEARING, AXLE, DIFFERENTIAL (RW207)
BOLT, 3/8” X 1 ¼” NC GR. 8
BOLT ½” X 1 ¼” NC Z FL SER GR.8
BOLT, ½” X 4 ½” NC PLTD. GR. 8
NUT, 3/8” NC GR. 8
NUT, ½“ NC GR. 8
WASHER, FLAT, ½” GR. 8
WASHER, LOCK, ½” GR. 8
19
Location
DIFF./DRIVE
DIFF./DRIVE
DIFF./DRIVE
DIFF./ DRIVE
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
DIFF./VARIOUS
Vendor
VICTORY
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
#1
#2
#3
#4
#5
#6
20
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
6
Part No.
S001026
S001027
S001035
S001038
S001044
S001053
Qty.
1
1
2
1
1
1
Part Description
BODY, COMPLETE
DOOR, TRUNK
HANDLE, GRAB, LH/RH
HINGE, TRUNK
BRACKET, PIN, STRIKER
ASSEMBLY, TRUNK LATCH
Vendor
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
Part No.
CB1084
CB1153
CB1159
CB1161
CB1162
Qty.
8
1
2
2
4
Part Description
BOLT, ¼” X ¾” BUTTON SOC CAP SS
BOLT, 5/16” X ½” NC PLTD. (HINGE STOP BOLT)
BOLT 5/16” X 1” NC BUTTON HD SS
BOLT, 5/16” X 1” NC GR. 8
BOLT 5/16”-18 X 1 Z FL HX SERR
CC1901
1
CN3042
CN3048
CS4066
CW2005
CW2010
CW2041
CW2109
LG6601
LG6602
S001023
S001029
S001030
S001043
S001054
S001055
S001056
S001058
S001061
4
2
1
8
4
8
6
2
2
1
1
1
1
1
1
1
4
1
CLAMP, CABLE, TRUNK (FASTENAL PART #
C0L1Z0921)
NUT, LOCK ¼” GR. 8
NUT, LOCK 5/16” NC GR.8
SCREW MACH. 10-32” X ½” RD. HD
WASHER, FLAT, ¼” GR. 8
WASHER, FLAT 5/16” GR. 8
WASHER, LOCK ¼” SS
WASHER, FENDER, 5/16” X 1 1/2”
GASKET, BODY, REAR
GASKET, BODY, FRONT
BRACKET, LATCH/ACTUATOR MOUNT
LATCH, TRUNK
LATCH, STRIKER PIN
ACTUATOR, TRUNK RELEASE
BRACKET, LATCH, MOUNT
FOOTPAD, LH
FOOTPAD, RH
GASKET, HANDLE, GRAB
CABLE, TRUNK, SAFETY RELEASE
21
Location
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
GRAB
HANDLES
ASSM., TRUNK
Vendor
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
ASSM., TRUNK
ASSM., BODY
ASSM., BODY
ASSM., TRUNK
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., TRUNK
ASSM., TRUNK
ASSM., TRUNK
ASSM., TRUNK
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., TRUNK
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
VARIOUS
#1
#2
#3
#4
#5
22
ILLUSTRATED PARTS
Ref.
1
2
3
4
5
Part No.
LT6601
S001004
S001040
S001025
S001037
Qty.
1
1
1
2
1
Part Description
WRENCH, HEX, REMOVAL TOOL
BRACKET, DRIVER SEAT, BACKREST
FRAME, LICENSE PLATE (VENDOR PART # 8201-52)
LAMP, TAIL
BRACKET, TAILLIGHT MOUNT
Vendor
LEHMAN
LEHMAN
BIG BIKE PARTS
LEHMAN
LEHMAN
Part No.
CB1080
CN3132
CS1001
CT1015
Qty.
6
8
8
2
Part Description
BOLT, ¼” X ¾” NC PLTD. GR. 8
NUT, LUG, ½” OPEN, ACORN (558-016)
STUD, AXLE, ½” X 1 7/8”
TIE, CABLE (BLACK, NYLON-7.31”)
CT1026
5
TIE, CABLE, COLORED (MIN.,-100 LBS./250°)
CW2005
CW2040
CW2536
FG1002
GB1326
GG0010
4
4
6
4
1
8”
HW0050
S001007
S001013
S001015
S001028
S001033
2
1
1
1
1
1
WASHER, FLAT ¼” GR. 8
WASHER, LOCK ¼” PLTD.
SEAL, BULB, MED. DENSITY
GASKET, MAGNUM, 3 HOLE
BADGE, VICTORY, PITBOSS
GASKET, TAILLIGHT (MCMASTER CARR PN
6322K12)
WHEEL, CHROME PLATED 15X7 82 SERIES
HARNESS, TAILLIGHT
HARNESS, TRUNK ACTUATOR
MANUAL, OWNER’S
LINER, TRUNK
BRACKET, AUTO CANCEL MODULE
S001034
S001039
1
1
S001045
CS4027
GT1970
WK0029
1
4
2
1
SPACER, LICENSE PLATE MOUNT
BRACKET, LICENSE PLATE (VENDOR PART
# 49-0044)
REFLECTOR, RED, ASSEMBLY
SCREW, 8/32” PHILLIPS, MACH.
TIRE, REAR, P205/70R-15
KIT, WHEEL, 5-SPOKE CHROME, (SET)
23
Location
ASSM., BODY
ASSM., WHEEL
ASSM., WHEEL
ASSM.,
VARIOUS
ASSM.,
VARIOUS
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM.,
TAILLIGHT
ASSM., WHEEL
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM.,
VARIOUS
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., BODY
ASSM., WHEEL
ASSM., WHEEL
Vendor
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
VARIOUS
LEHMAN
LEHMAN
LEHMAN
VARIOUS
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
LEHMAN
BIG BIKE
PARTS
LEHMAN
VARIOUS
VARIOUS
LEHMAN
2008
Service Supplement
Supplement to Victory®
Kingpin™ Service Manual
S001016
Reader’s Comments
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Please comment on this manual’s completeness, accuracy, organization, usability and readability.
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Dealership __________________________ Department __________________
Street_________________________________________________________________
City _______________________ State ______________________ Zip __________
2008 Pit Boss
Clip out and mail or fax to:
Lehman Trikes USA, Inc.
Technical Communications
125 Industrial Drive
Spearfish, SD 57783
Fax- 605-642-1182
FOREWARD
This manual is designed primarily for use by authorized Lehman Pit Boss dealer technicians in a properly equipped shop and should remain available for reference in the shop area. All references to left and
right side of the trike are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require sound knowledge of mechanical theory, tool use, and
shop procedures in order to perform the work safely and correctly. Read the text and become familiar
with the service procedures before starting any work. Some procedures require the use of special tools.
Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this service manual, contact an authorized Lehman Pit Boss dealer for service.
PB0208V2GR
© 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 the state of this product at the time of its publication, and may not reflect the product in the future.
Lehman Trikes® is a registered trademark. All other brands and product names are trademarks or registered trademarks of their respective
holders. Printed in the United States of America.
Table of Contents
Safety Information................................................................................................................. 29
Battery .................................................................................................................................... 30
Brake Hose............................................................................................................................. 31
Brake Line .............................................................................................................................. 32
Residual Valve ....................................................................................................................... 33
Body ....................................................................................................................................... 34
Differential.............................................................................................................................. 36
Disc Brakes............................................................................................................................ 39
Drive Belt ............................................................................................................................... 40
Drive Belt Tensioning/Tracking ........................................................................................... 44
LED License Plate Light ....................................................................................................... 46
Mufflers/Exhaust ................................................................................................................... 47
Park Brake.............................................................................................................................. 49
Rear Tires............................................................................................................................... 52
Shock...................................................................................................................................... 53
Swingarm ............................................................................................................................... 54
Taillight................................................................................................................................... 56
Trunk Latch Adjustment....................................................................................................... 57
Trunk Release Solenoid/In-Line Fuse ................................................................................. 58
Torque Specifications........................................................................................................... 59
Wiring Diagrams.................................................................................................................... 60
Safety Information
UNDERSTANDING SAFETY LABELS & INSTRUCTIONS
READ AND BECOME FAMILIAR WITH ALL WARNING, CAUTION SYMBOLS AND STATEMENTS
LISTED BELOW AND IN THE TEXT OF THIS MANUAL BEFORE YOU BEGIN WORK.
DANGER, WARNINGS & CAUTION SYMBOLS
This is the safety alert symbol. When you see this
symbol on your machine or in this manual, be alert
to the potential for personal injury. Your safety is
involved!
WARNING
SAFETY ALERT WARNING indicates a potential hazard
that may result in severe injury or death to the operator, bystander or person (s) inspecting or servicing the vehicle.
CAUTION
Indicates a potential hazard that may result in minor personal 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.
Battery Replacement
Removal
1. Remove left and right side covers from trike,
using side cover removal tool (Fig. 1).
2. Disconnect trunk-release solenoid switch from
within left side cover (Fig. 2).
3. Remove (2) 6mm Allen head bolts from operator seat and remove operator seat (Fig. 3).
4. Remove (2) 10mm battery cover nuts and remove battery cover (Fig. 4).
5. Remove (1) 10mm upper, rear battery box bolt.
6. Disconnect negative (-) battery cable (cable
end is exposed) using tool supplied on battery
cover.
Caution: Disconnecting positive cable first can
produce an electric shock that could result in
damage or injury.
7. Disconnect positive (+) cable (cable is covered
with a red boot).
8. Carefully slide battery out between park brake
bracket and motorcycle frame.
Installation
1. Before installing new battery, make sure it is
fully charged and clean.
2. Slide battery into position in battery tray with
positive (+) terminal to rear of trike.
3. Connect positive (+) battery cable, tighten securely and install red boot.
4. Connect negative (-) cable and tighten securely. Be sure cables have acceptable side
cover clearance.
Caution: Connecting negative cable first can
produce an electric shock that can result in injury or damage. Connecting battery cables to
the wrong terminals can severely damage the
electrical system.
5. Reinstall battery cover.
6. Reinstall upper, rear battery box bolt.
7. Reinstall operator seat.
8. Reinstall trunk-release solenoid switch.
9. Reinstall left and right side covers.
Fig. 1
Seat removal
Side-cover removal
Fig. 2
Release switch
Disconnect
Fig. 3
Operator seat bolt
Fig. 4
Battery cover bolts
Brake Hose Replacement
Removal
Caution: Brake fluid can damage paint and
other parts it touches. Prepare to drain fluid
into an approved container and avoid spills or
leakage.
1. Loosen and remove brake hose extension
clamp with a 1/4” nut driver and remove hose
from splice (Fig. 1).
2. Loosen and remove brake hose extension
clamp at master cylinder reservoir with a 1/4”
nut driver (Fig. 2).
Installation
1. Install extension clamps on new brake hose
extension.
2. Install new brake hose and tighten clamps.
3. Bleed brakes (See Brake Bleeding p. 8).
4. Check for leaks.
5. Fill reservoir with DOT 4 brake fluid if necessary (Fig. 3).
Fig. 1
To reservoir
Brake hose ext. clamp at splice
Fig. 2
Brake hose ext. clamp at reservoir
Fig. 3
Top of reservoir shelf-full
Brake Line Replacement
Removal
leakage.
1. Remove left and right side covers.
3. Remove master cylinder reservoir cover.
4. Lift trike using a jack under differential carrier
housing and two safety jack stands under left
and right rear axles.
5. Remove left and right rear tires (See Rear
Tires).
6. Remove braided brake line from brass “T” with
a 7/16” wrench (Fig. 2).
7. Remove brake line from caliper using a 7/16”
wrench and a 12mm wrench on caliper fitting
(Fig. 3).
8. Drain brake fluid into an approved container.
Installation and Brake Bleeding
1. Install new brake line and tighten bolts securely.
2. Bleed brakes as follows starting with an outside brake bleeder valve first (Fig. 4):
a. Fill brake fluid reservoir with DOT 4 brake
fluid. Replace cover.
b. Attach brake bleeder hose to outside brake
bleeder valve.
c. Pump up brake pedal and hold before opening bleeder valve.
d. Open bleeder valve using a 1/4” wrench.
e. Tighten bleeder valve before you release
pressure from brake pedal.
f. Bleed all valves until you eliminate all air
bubbles (4 total).
g. Fill reservoir with DOT 4 brake fluid.
h. Install reservoir gasket and cover.
3. Tighten all connections and check for leaks.
4. Reinstall left and right rear tires.
5. Torque lug nuts to 85 ft-lbs.
6. Reinstall side covers and operator seat.
Fig. 1
Operator seat bolts
Fig. 2
Braided brake line
Brass “T”
Fig. 3
7/16” wrench
12mm wrench
Fig. 4
Inside brake bleeder valve
Rear view
Outside brake bleeder valve
Residual Valve Replacement
Removal
leakage.
5. Remove left and right rear tires (See Rear
Tires).
6. Remove banjo bolt and brake line from residual
valve adaptor with a 12mm wrench (Fig. 2).
7. Drain brake fluid into an approved container.
8. Remove residual valve adaptor with a 5/8”
wrench.
9. Remove residual valve with a 5/8” wrench (Fig.
3).
Installation and Brake Bleeding
1. Install new residual valve and tighten securely.
2. Reinstall residual valve adaptor, brake line and
banjo bolt and tighten securely.
3. Tighten all connections and check for leaks.
4. Bleed brakes (see Brake Bleeding on previous page).
4. Reinstall left and right rear tires.
5. Torque lug nuts to 85 ft-lbs.
6. Reinstall side covers and operator seat.
Fig. 1
Operator seat bolts
Fig. 2
Residual valve adaptor
Banjo bolt
Fig. 3
Residual valve
PASSENGER SEAT REMOVAL
Fig. 1
Removing Passenger Seat
1. Remove rear tires (see Tire Removal in
Owner’s Manual).
2. Remove left and right side covers using seat
removal tool located in document bag.
3. Remove left and right operator seat bolts with
6mm Allen socket and remove operator seat.
4. See Fig. 1. Remove reinforcement brackets
using the following:
Reinforcement brackets
• Remove front grab handle bolts
• See Fig. 2. Remove inner jam nuts
• Slide reinforcement bracket off front bolt
5.
6.
7.
8.
9.
10.
• See Fig. 2. Back off outer jam nuts 5/8”
See Fig. 3. Remove rear chrome frame rail
bolt. Loosen front chrome frame rail bolt and
back out 5/8” allowing rail to slide out and
swing downward.
NOTE: If front bolt cannot back out 5/8”,
proceed to step 6. Otherwise, proceed to
step 10.
Remove left and right foot pad nuts (4 each
side) and remove foot pads.
Remove carpet trunk liner and remove (2) rear
body mount bolts.
Remove left and right front body mount bolts.
CAUTION: Be extremely careful when moving body as contact points are close on all
sides.
See Fig. 4. Lift front of body 4”-6” and place
support blocks (2” x 4” or equivalent) on body
mount brackets to support body and repeat
step 5.
Remove (4) passenger seat bolts.
Fig. 2
Inner jam nut
Outer jam nut
Fig. 3
Remove rear bolt
Back front bolt out 5/8” inches
and lower rail to access seat bolts
Fig. 4
Elevate body with support block
PASSENGER SEAT INSTALLATION
Fig. 5
Installing Passenger Seat
1. Reinstall passenger seat with original hardware.
2. See Fig. 5. Reinstall chrome frame rail and
tighten bolts.
CAUTION: Be extremely careful when moving
body as contact points are close on all sides (if
applicable).
NOTE: Before lowering body, examine rubber
body shims and ensure they are in proper position and still in tact. Replace if necessary.
3. See Fig. 6. Remove support blocks and lower
body onto body mount brackets (if applicable).
NOTE: When reinstalling left and right front
body mount bolts, check left-to-right and frontto-back body alignment before tightening bolts
(fit to side covers-if applicable).
4. Reinstall rear body mount bolts in trunk (if applicable).
5. Reinstall carpet trunk liner (if applicable).
6. Reinstall front body mount bolts (if applicable).
7. See Fig. 7. Reinstall reinforcement bracket
using the following:
Reinstall rear bolt
Chrome frame rail
Fig. 6
Remove support block
Fig. 7
• Slide reinforcement bracket onto front bolt
• Install front grab handle bolt
• See Fig. 8. Reinstall outer jam nuts and
hand-tighten to bracket
8.
9.
10.
11.
• See Fig. 8. Reinstall inner jam nuts and
tighten both to bracket
Reinstall passenger foot pads.
Re-install operator seat.
Reinstall both side covers.
Reinstall rear tires and torque lug nuts to 85 ft.lbs.
Reinforcement brackets
Fig. 8
Inner jam nut
Outer jam nut
Body
Removal
2. Remove rear tires (See Rear Tires).
3. Remove left side cover with side cover/seat
removal tool, disconnecting trunk release
switch from inside cover before fully removing
cover (Fig. 1).
4. Remove right side cover.
6. Remove left and right passenger footboards
with a 7/16” socket with extension.
Caution: Carefully lift passenger footboards
straight up and away from body.
7. Remove cable tie that holds trunk release cable to battery cover.
8. Move trunk release cable to rear section of
body for removal.
9. Disconnect taillights from connectors, disconnect rear solenoid connector at front of trunk
body and remove wires from clips on body
(Fig. 3).
10. Open trunk door, move trunk carpet and locate
rear body mount bolts (Fig. 4).
11. Remove rear body mount bolts with a 1/2”
socket wrench on bolt inside trunk.
Fig. 1
Seat removal
Side-cover removal
Fig. 2
Operator seat bolts
Fig. 3
Turn signal/taillight connectors
Rear solenoid connector
Fig. 4
Rear body mount bolts
located inside trunk
Body (Continued)
12. Remove left and right front body mount bolts
with a 3/16” Allen head socket wrench on bolt
and a 1/2” wrench on the nut (Fig. 7).
13. Remove left and right grab handle bracket
bolts and brackets with a 13 mm wrench (Fig.
8).
Caution: Use an assistant when removing body
from trike. Be sure you and your assistant do
not damage body paint. The body comes close
to clutch actuator on left side and sprocket
cover on right side.
14. With an assistant’s help, slide body up and
away from trike.
Body Installation
1. After placing body on trike, center the body leftto-right and front-to-back.
2. Install body mount bolts and tighten. Torque
bolts to proper specification (See Torque
Specifications).
3. Reinstall left and right grab handle brackets.
4. Reinstall new cable tie at trunk release cable.
5. Re-connect taillights and rear solenoid.
8. Install rear tires.
9. Torque lug nuts to 85 ft.-lbs.
Fig. 7
Front body mount bolts
Fig. 8
Grab handle bracket bolts
Fig. 9
Chrome frame rail covers
Fig. 10
Passenger seat bolts
Differential/Axle Bearing Replacement
The Pit Boss differential has one short axle (right
side) and one long axle (left side). The appropriate
tire will need to be removed depending on which
axle or axle bearing is being replaced.
Removal
2. Remove appropriate rear tire (See Rear Tires).
3. Remove brake caliper and place in a secure
location (not hanging by brake line).
4. Remove brake rotor.
5. Remove axle flange retaining nuts (Fig. 1).
6. Remove axle from axle tube (Fig. 2).
7. Remove and discard locking collar (a grinder or
chisel is recommended) (Fig. 3).
8. Remove and save axle shim for reinstallation
(Fig. 3).
9. Place a bearing splitter tool under bearing,
place axle in a press and press bearing off.
Installation
1. Install new bearing using a press.
2. Reinstall axle shim between new bearing and
axle collar.
3. Install new locking collar (provided with the
new bearing).
Note: Make sure axle shim aligns with bearing
surface before tightening collar (Fig. 4).
4. Reinstall axle into axle tube.
5. Reinstall axle flange nuts. Torque to 44 ft.lbs.
6. Reinstall brake rotor.
7. Reinstall brake caliper.
8. Reinstall rear tire (See Rear Tires).
Fig. 1
Axle flange retaining nuts
Fig. 2
Axle
Axle tube
Fig. 3
Remove and discard
locking collar
Remove and
save axle shim
Fig. 4
Align shim with bearing surface
Differential/Carrier/Carrier Bearing Replacement
Removal
3. Remove body (See Body).
4. Remove left brake caliper and place in a secure location (not hanging from brake line).
5. Remove left-side axle (See Differential-Axle
Bearing Replacement).
6. Remove park brake assembly by removing
park brake bracket bolts (Fig. 1).
7. Remove park brake cables from backing plates
(See Park Brake Cable Replacement).
8. Loosen jam nuts on adaptor plates with a 9/16”
wrench and turn adjuster bolts inward to remove tension on plates (Fig. 2).
9. Remove left-side adaptor plates from differential bolts with a 3/4” socket wrench and a 3/4”
wrench.
Note: Replace shim washers in the same location you remove them from (Fig. 3).
10. Remove lower shock mount bolt.
11. Remove stabilizer bar from stabilizer bar
bracket (Fig. 4).
Fig. 1
Park brake
bracket bolts
Fig. 2
Jam nut
Remove tension by
turning bolt clockwise
Fig. 3
Shim washer location
Fig. 4
Remove stabilizer bar
Differential/Carrier/Carrier Bearing Replacement (Continued)
12. At this point, relocate jack directly under differential plug hole for extra support.
13. Remove (2) inside, right adaptor plate bolts
and remove the inside, right adaptor plate from
differential (Fig. 5).
Note: Leaving outside adaptor plate connected
allows the differential to remain attached to the
swingarm.
14. Remove (4-inside and out) adaptor plate bolts
and plates from left side of differential (Fig. 6).
15. Remove (8) differential housing bolts with a
9/16” socket wrench.
16. Lift differential slightly with jack to split differential halves.
Note: If necessary, insert a 3/8” bolt into
tapped hole (Fig. 7) of differential to split differential halves.
17. Remove left side of differential.
18. Work belt off pulley and remove the carrier simultaneously.
Note: If carrier hangs up on left side of differential, remove left side axle and drive carrier
out.
19. After carrier assembly is removed, install a
splitter plate underneath the carrier bearing
and place carrier in a press.
Note: If splitter plate is too small to remove the
bearing with sprocket attached, you can remove sprocket, but this will require checking
the run-out with a dial indicator.
20. Press carrier bearing off carrier shaft.
Installation
1. Press new bearing onto carrier shaft bottoming
out bearing on shoulder of shaft.
2. Begin reinstallation procedure in reverse order.
3. Torque bolts to proper specifications (See
Torque Specifications).
Fig. 5
Remove inside,
right adaptor plate
bolts/inside adaptor plate
Fig. 6
Remove both
adaptor plates and
all bolts
Fig. 7
Insert 3/8” bolt to split
differential halves if
necessary
Disc Brake Pad Replacement
Removal
Caution: Prepare to drain brake fluid out of reservoir when you push on caliper pistons. Pressure will likely build and displace brake fluid,
causing it to leak out of reservoir and damage
body paint or other parts.
6. Remove 3/8” caliper mounting bolts with a
9/16” socket wrench (Fig. 2).
7. Slide caliper away from brake rotor.
Note: Lehman recommends a thorough inspection of the rotor for warping or irregularities in
rotor surface anytime you replace the pads. In
addition, you can examine the park brake
shoes while the rotor is off.
8. Remove brake pad retainer pin (Fig. 3).
9. Remove pads from the caliper.
10. Push both caliper pistons outward into caliper.
Installation
1. Insert new brake pads.
2. Reinstall brake pad retainer pin.
3. Reinstall caliper and tighten bolts securely
(See Torque Specifications).
4. Pump brake pedal to seat pads to rotor.
5. Check level in reservoir and fill with DOT 4
brake fluid if necessary (Fig. 4).
8. Reinstall rear tires.
Fig. 1
Operator seat bolts
Fig. 2
3/8” caliper bolts
Fig. 3
Brake pad retainer pin
Fig. 4
Top of reservoir shelf-full
Drive Belt Replacement
Removal
4. Remove left brake caliper and place in a secure location (not hanging from the brake line).
5. Remove left-side axle (See Differential/Axle
7. Remove park brake cables from backing plates
(See Park Brake Adjustment/Cable Replacement).
8. Loosen jam nuts on adaptor plates with a 9/16”
wrench and turn adjuster bolt inward to remove
tension on plate (Fig. 2).
9. Remove left-side adaptor plates from differential bolts with a 3/4” socket wrench and a 3/4”
wrench.
Note: Replace shim washers in same location
you remove them from (Fig. 3).
10. Remove lower shock mount bolt.
11. Remove stabilizer bar nuts and bolts; remove
stabilizer bar (Fig. 4).
Fig. 1
Park brake
bracket bolts
Fig. 2
Jam nut
Remove tension by
turning bolt clockwise
Fig. 3
Shim washer location
Fig. 4
Remove
Remove stabilizer
stabilizer bar
bar
Drive Belt Replacement (Continued)
12. At this point, relocate jack directly under differential plug hole for extra support.
13. Remove upper shock bolt; remove shock.
14. Remove (2) inside, right adaptor plate bolts
and remove inside, right adaptor plate from
differential (Fig. 5).
Note: Leaving outside adaptor plate connected
allows differential to remain attached to swingarm.
15. Remove (4-inside and out) adaptor plate bolts
and plates from left side of differential (Fig. 6).
16. Remove (8) differential housing bolts, including
the debris shield, stabilizer bar bracket and
shock bracket, with a 9/16” socket wrench.
17. Lift differential slightly with jack to split differential halves.
Note: If necessary, insert a 3/8” bolt into
tapped hole (Fig. 7) of differential to split differential halves.
18. Remove left side of differential.
19. Work belt off pulley and remove carrier simultaneously.
20. Remove exhaust up to, and including rear
header pipe using a 1/2” wrench on header
pipe and a 15mm socket wrench on exhaust
clamps (Fig. 8).
Fig. 5
Remove inside,
right adaptor plate
bolts/inside adaptor plate
Fig. 6
Remove both
adaptor plates and
all bolts
Fig. 7
Insert 3/8” bolt to split differential halves if necessary
Fig. 8
Remove exhaust
21. Remove right-side frame brace with a 9/16”
socket wrench (Fig. 9).
22. Remove sprocket cover with a 4mm Allen head
socket wrench.
23. Remove right-side front body mount with an
8mm Allen head socket wrench, and a 1/2”
socket wrench and extension (Fig. 10).
Installation
1. Slide new belt into differential housing.
2. Lift differential housing using jack to align swingarm adaptor plates with differential.
3. Install differential to right side of swingarm by
drawing bushings together while hand starting
nuts to bolts. Tighten nuts using a ¾” shallow
socket wrench and ¾” wrench.
4. Insert pulley and carrier into differential housing with grease fitting facing left side (Fig. 11).
5. Walk belt around pulley.
6. Reinstall an adaptor plate to outside (left) of
differential by hand starting bolts. Tighten bolts
using a ¾” swivel socket wrench and a ¾”
wrench.
7. Pull differential halves together by hand starting bolts in a cross pattern. Tighten bolts using
a 9/16” deep socket wrench and a 9/16”
wrench.
8. Reinstall an adaptor plate to the inside (right)
of the differential by hand starting bolts.
Tighten bolts using a ¾” swivel socket wrench
and a 3/4” wrench.
9. Install differential to left side of swingarm by
drawing bushings together while hand-starting
nuts to bolts. Tighten nuts using a ¾” shallow
socket wrench and a ¾” wrench.
10. Reinstall stabilizer bar bracket to topmost bolts
on differential housing by hand-starting bolts.
Tighten bolts using a 9/16” deep socket wrench
(Fig. 12).
Fig. 9
Right-side frame brace
Fig. 10
Right-side front body mount
Fig. 11
Left-side carrier
housing
Grease fitting
Fig. 12
Remove stabilizer bar
11. Install top bolt of debris shield to front bolt-hole
on the differential by hand starting bolt.
Tighten bolt using a 9/16” deep socket wrench
(Fig. 9).
12. Reinstall lower shock mount bracket to bottom
three bolts on differential housing and bottom
of debris shield by hand starting bolts. Tighten
bolts using a 9/16” deep socket wrench (Fig.
10).
13. Reinstall shock.
14. Reinstall stabilizer bar.
15. Torque (8) differential housing bolts to 35 ft.
lbs using 9/16” deep socket wrench and torque
wrench (Fig. 11).
16. Torque (4) adaptor plate-to-swingarm bolts to
75 ft. lbs. using a ¾” torque adaptor, torque
wrench and ¾” wrench.
17. Torque (8) adaptor plate-to-differential bolts to
75 ft. lbs using a ¾” shallow socket wrench
and torque wrench (Fig. 12).
18. Reinstall park brake cables (See Park Brake
Adjustment/Cable Replacement).
19. Reinstall park brake assembly.
20. Reinstall left-side axle (See Differential/Axle
21. Reinstall left brake caliper.
22. Adjust belt tension and tracking (See Belt Tensioning/Tracking).
23. Reinstall body (See Body).
24. Reinstall rear tires (See Rear Tires).
Fig. 9
Top bolt of debris shield
Fig. 10
Lower shock
mount bracket
Debris shield bottom bolt
Fig. 11
Differential housing bolts
Fig. 12
Adaptor plate-to-differential bolts
Drive Belt Tensioning/Tracking
3. Loosen adaptor plate-to-swingarm bolts.
4. Loosen jam nuts on stabilizer bar (Fig. 1).
5. Place transmission in neutral.
6. Measure and mark 4 locations on belt by rotating wheel 90° in forward direction between
measurements. The tightest spot will be used
for adjustment and tensioning.
7. Move 4 adjuster bolts exactly the same distance for any adjustment (Fig. 2). Push differential assembly back until belt has 5/16”- 3/8”
slack with 10lbs. pressure at midpoint of bottom run of belt (Fig. 3).
8. Rotate pulley forward for at least three revolutions of rear pulley by pulling backwards on
bottom run of belt. Pull belt straight back to
get an accurate reading.
9. Check belt to ensure it is not contacting flanges
on rear pulley.
10. Correct belt tension by moving adjusters in or
out from side to side to achieve proper tracking.
Note: Stabilizer bar requires adjustment when
adjuster bolts are moved. Clockwise rotation of
stabilizer bar pushes top of differential down
and forward. Counter-clockwise rotation of stabilizer bar pulls top of differential up and rearward.
11. Torque adaptor plate-to-swingarm bolts to 75
ft.-lbs. with torque wrench and 3/4” torque
adaptor.
12. Tighten jam nuts on stabilizer bar (Fig. 1).
13. Once proper tracking is obtained, recheck belt
tension. The correct deflection is 5/16”-3/8”
with 10 lbs. pressure applied.
14. Any adjustment requires checking belt tracking
again.
Fig. 1
Jam nut
Fig. 2
Adjuster bolts
Fig. 3
Midpoint of bottom run of belt
Drive Belt Tensioning/Tracking (Continued)
15. Ensure belt clearance of carrier housing on top
and bottom of housing (Fig.’s 4 & 5).
16. Reinstall rear tires.
Fig. 4
Clearance at top of carrier housing
Fig. 5
Clearance at bottom of carrier housing
LED License Plate Light Replacement
Removal
1. Disconnect license plate light from wiring harness: wires will have to be cut and connectors
removed (Fig. 1).
2. Pull license plate wires through license plate
frame hole as shown (Fig. 2).
3. Remove (4) license plate frame screws with
Phillips screw driver (Fig. 2).
4. Remove license plate frame and discard.
Fig. 1
Disconnect light wires from harness
Installation
1. Install new license plate frame.
2. Tighten frame plate screws with Phillips screwdriver.
3. Route license plate wires through hole (Fig. 2)
and trim excess wire to appropriate length.
4. Using new connectors, splice license plate
wires to wire harness according to the following: white wire to blue wire on harness; black
wire to black wire on harness.
Fig. 2
Frame screws
Pull wires through here
Mufflers/Exhaust Replacement
Muffler Removal
1. Lehman recommends removing appropriate
tire for ease of access in changing a muffler.
3. Remove appropriate tire (See Rear Tires) to
change muffler.
4. Remove rear muffler mounting bolts with
13mm wrench (Fig’s. 1 & 2).
5. Loosen muffler-to-exhaust pipe clamp with a
15mm socket wrench (Fig. 3).
6. Slide muffler out and away from exhaust pipe
(If necessary, apply lubricant to joint to aid in
removing muffler from exhaust pipe).
Muffler Installation
1. Apply high-temperature silicone to new muffler
where it inserts over pipe.
2. Install new muffler into exhaust pipe.
3. Reinstall rear muffler mounting bolts and
tighten all clamps.
4. Reinstall tire.
Fig. 1
Right side muffler clamp bolts
Fig. 2
Left side muffler clamp bolt
Fig. 3
Muffler-to-exhaust clamp
Mufflers/Exhaust Replacement (Continued)
Exhaust Pipe Removal
1. For replacement of pipes LP6601, LP6602 and
LP6603 (Fig. 4), repeat Muffler Removal
steps 1-5 and proceed as follows.
2. Loosen appropriate clamps with a 10mm
socket wrench and extension (Fig. 5, 6 & 7).
3. Remove appropriate pipe.
Exhaust Pipe Installation
1. Apply high-temperature silicone to pipe at the
insertion points.
2. Install new pipe.
3. Tighten all clamps securely.
4. Reinstall tire.
Fig. 4
LP6601
LP6602
LP6603
Fig. 5
Exhaust clamp
Fig. 6
Exhaust clamp
Fig. 7
Exhaust clamp
Park Brake Cable Replacement/Adjustment
Cable Removal
2. Remove left rear tire (See Rear Tires).
4. Remove left frame brace.
5. Slide park brake assembly rearward into wheel
opening.
6. Loosen cable adjuster nuts with a 1/2” openend wrench (Fig. 2).
7. Loosen cable retainer nuts with two 7/8”
wrenches (Fig. 3).
8. Remove cables from park brake bracket.
9. Remove cable ties that hold cables to rear axle
assembly.
10. Remove cir-clip from backing plate bracket.
11. Pull cable and remove loop from brake lever
(Fig. 3).
Cable Installation
1. Place loop of new cable over brake lever.
2. Install a cable retainer nut on cable and place
through park brake bracket. Install other cable
retainer nut.
3. Install end of cable through cable pulling
bracket with one nut on either side of bracket.
4. Repeat steps 1-3 for both cables.
5. Install new cable ties and left frame brace.
7. Reinstall left rear tire.
Park Brake Adjustment
1. Adjust cable retainer nuts as shown in Fig. 1
with roughly 2 threads exposed on front end
creating a slight and consistent drag on both
sides.
2. Adjust drag on park brake shoes for a slight
drag while still allowing the rotor to turn.
3. Adjust park brake handle to engage in 3rd position ensuring the handle does not contact left
side cover when engaged.
4. Reinstall tire. Torque lug nuts to 85 ft.-lbs.
Fig. 1
Park brake
bracket bolts
Fig. 2
Cable retainer nuts
Cable pulling bracket
Cable adjuster nuts
Fig. 3
Cable loop
Brake lever
Park Brake Handle Replacement
Removal
4. Remove left frame brace.
5. Disconnect park brake cables from park brake
bracket (See Park Brake Cable Replacement/
Adjustment).
6. Remove snap ring from pin in park brake handle (Fig. 2).
7. Remove pin from handle and park brake
bracket; remove handle.
Installation
1. Attach new park brake handle to park brake
bracket by sliding pin through bracket into handle and insert pawl on handle into catch on
bracket.
2. Reinstall snap ring to pin using snap ring pliers.
3. Install cable-pulling bracket (if being replaced)
to park brake handle, install clevis pin and cotter pin, and bend cotter pin around clevis pin
(Fig. 3).
4. Reinstall park brake cables (See Park Brake
Cable Replacement/Adjustment).
5. Reinstall left frame brace.
Fig. 1
Park brake
bracket bolts
Fig. 2
Snap ring
Fig. 3
Cotter key
Pin
Park Brake Handle Replacement (Continued)
Installation (Continued)
8. Install (1) 5/16” nut to cable before installing
cable into cable-pulling bracket. Install another
5/16” nut to end of cable (Fig. 3).
Note: Leave adjustment nuts with the most adjustment possible.
9. Repeat steps 5 and 6 for the long park brake
cable, inserting cable to right side of park brake
bracket.
10. Install park brake bracket behind front body
mount by hand starting bolts. Tighten bolts using a 1/2” socket wrench.
11. Wrap each cable around the left side of the
differential.
12. Attach the loop on the cables to the brake lever
on the rotors and slide plated portion of cables
into brake bracket (Fig. 4).
13. Tighten 5/16” nuts around the cable pulling
bracket using (2) 1/2” wrenches.
14. Tighten larger nuts around park brake bracket
using a 7/8” wrench and a 90° offset 7/8”
wrench.
15. Reinstall body (See Body).
16. Reinstall rear tires (See Rear Tires).
Fig. 3
5/16” nuts
Fig. 4
Cable loop
Brake lever
Brake bracket
Rear Tires
Removal
1. Remove (2) center cap bolts with center cap
removal tool (located in document bag in trunk)
(Fig. 4).
Caution: Only (2) of what appear to be (5) bolts
holding the center cap are real. Attempting to
loosen any other than the (2) real bolts will destroy the center cap (Fig. 4).
2. Loosen lug nuts with a thin-wall 13/16” socket
wrench and extension.
housing (Fig. 1) and two safety jack stands
under left and right rear axles (Fig. 2).
4. Remove lug nuts.
5. Remove left and right rear tires by sliding them
out and away from body.
Caution: When changing or removing tires for
any reason, do not allow tire to “free” stand.
The wheel will suffer damage if tire is dropped
on the wheel side (Fig. 3).
6. Always face tire with wheel facing outward to
avoid wheel damage.
Installation
1. Install left and right rear tires by sliding them in
and toward the body.
2. Install and tighten lug nuts with a thin-wall
13/16” wrench and extension.
3. Lower trike from jack and jack stands; remove
jack and jack stands.
5. Reinstall center caps.
Fig. 1
Place jack under diff. housing
Fig. 2
Place jack under rear axle
Fig. 3
Fig. 3
Spokes will suffer
damage if wheel
is dropped
Fig. 4
Bolts used to secure center cap
Fig. 4
Shock Replacement
Removal
3. Remove lower shock bolt with a ¾” socket
wrench and extension (Fig. 1).
4. Place jack under differential housing and jack
up differential to keep mounting holes aligned
during shock replacement (Fig. 2).
Note: Lehman recommends the use of a ratchet
strap for load suspension during shock replacement.
5. Remove upper shock bolt with a ¾” socket
wrench and a ¾” wrench.
6. Remove shock.
Installation
1. Install shock bushings into holes of new shock.
2. Install shock to top shock mount by hand starting nut to bolt. Tighten the nut using a ¾” shallow socket wrench with 2” extension and a ¾”
wrench.
3. Install shock to lower shock mount by handstarting bolt. Tighten bolt using a ¾” shallow
socket wrench. Torque bolts to proper specifications (See Torque Specifications).
4. Remove ratchet strap.
5. Adjust shock with a spanner wrench as shown
(Fig. 3). A clockwise adjustment will increase
preload while a counterclockwise adjustment
will decrease preload.
Fig. 1
Lower shock mount bolt
Fig. 2
Place jack under
differential housing
Fig. 3
Shock adjustment
Swingarm Replacement
Removal
4. Remove exhaust up to, and including, rear
header pipe with a 15mm socket wrench (Fig.
1).
5. Remove sprocket cover with a 4mm Allen head
socket wrench.
6. Remove right-side front body mount with an
8mm Allen head socket wrench, a 1/2” socket
wrench and extension (Fig. 2).
7. Work belt off front sprocket.
8. Remove both brake calipers (See Disc Brake
Pad Replacement).
9. Remove both brake rotors (necessary to remove adaptor plate bolts).
10. Remove the Pit Boss shock (See Shock Adjustment/Replacement).
11. Remove stabilizer bolts and nuts; remove stabilizer bar.
13. Remove brass “T” from brake line. Remove all
cable-ties from swingarm.
14. Remove left-side frame brace with a 9/16”
socket wrench.
15. Remove left-side front body mount with an
8mm Allen head socket wrench and a 1/2”
socket wrench and extension.
16. Slide differential slowly backward to get clearance for swingarm removal.
17. Loosen and remove the swingarm nut from left
side of trike.
18. Remove swingarm pin (Fig. 4).
19. Remove swingarm shaft.
20. Remove swingarm.
21. Remove snap ring from left side of old swingarm.
Fig. 1
Remove exhaust
Fig. 2
Right-side front body mount
Fig. 3
Park brake bracket bolts
Fig. 4
Swingarm pin
Swingarm Replacement (Continued)
22. Remove shouldered bushing from left side of
old swingarm.
23. Remove steel spacer from right side of old
swingarm bearing.
Installation
1. Press (2) bearings (GB1024) into left side of
new swingarm (Fig. 5) and install snap ring to
outside bearing (Fig. 6).
2. Press (1) needle bearing (GB1032) into right
side of swingarm (Fig. 7) and install a new
needle bearing seal (Victory part # 3610096)
on each side of bearing (Fig. 8).
3. Install shouldered bushing from old swingarm
into left side of new swingarm bearing.
4. Install steel spacer into bearing on right side of
new swingarm.
5. Place new swingarm over lower swingarm
mounts.
6. Insert swingarm pivot shaft from left side
through lower swingarm mounts and swingarm.
7. Apply Loctite 242 to pivot shaft nut and insert
pivot shaft on right side of swingarm.
8. Torque right side pivot shaft nut to 65 ft. lbs.
using a 15/16” socket and torque wrench while
holding left side with a 1 1/16” socket wrench
and adaptor.
9. Move swingarm up and down to check for binding.
10. Reinstall removed parts in reverse order.
11. Reinstall new cable-ties.
Fig. 5
GB1024 Bearing
Fig. 6
Snap ring
Fig. 7
GB1032 Needle bearing
Fig. 8
3610096 Needle bearing seal
Taillight Replacement
Removal
1. Lehman recommends you remove the appropriate tire for ease of access to taillight assemblies (See Rear Tires).
2. Disconnect taillight wiring (Fig. 1).
3. Remove bolts from taillight bracket located under body (Fig. 1).
4. Lift bottom of taillight assembly out of body and
slide out of slotted groove (Fig. 2).
Installation
1. Install 8” of 1/4” gasket as shown around base
of taillight and secure with adhesive (Fig. 3).
2. Slide new taillight assembly (top first at slotted
groove) into body.
3. Tighten bolts securely.
4. Connect taillight wiring.
5. Test taillight.
6. Reinstall tire.
Fig. 1
Taillight wiring
Taillight bolts
Fig. 2
Slide taillight out from the bottom
Fig. 3
Taillight gasket
Trunk Door Latch Adjustment
1. Trunk door adjustment begins by ensuring
proper distance (14”) between bottom of hinge
bracket and trunk floor (Fig. 1).
2. Hinge bracket can be adjusted as shown to
achieve proper measurement (Fig. 1).
3. Additional hinge adjustments can be made as
shown in Fig. 2. Striker pin bracket adjustments can be made as shown in Fig. 3.
4. Close door gently and apply light pressure to
determine if striker pin engages 1st position
inside latch. (Fig. 4).
5. If latch 1st position cannot be obtained, latch
may need to be adjusted slightly. Use slotted
hole adjustments to adjust latch accordingly.
6. Repeat step 4.
7. After striker pin engages latch 1st position, apply pressure to door to engage 2nd latch position If striker pin engages latch 2nd position,
move to step 10.
8. If 2nd position cannot be obtained, latch may
need to be adjusted slightly. Striker pin may
be adjusted as well. Loosen striker pin bracket
bolts with a 7/16” wrench and adjust accordingly. Tighten bolts.
9. Repeat step 5.
10. When door closes with two clicks consistently,
check door seal by placing a piece of paper in
door seal on all sides of door, close door and
try to remove paper. The door seals properly
when paper slides out with a fair amount of
tension.
Fig. 1
Slotted hole adjustment-vertical
14” from floor to bottom of bracket
Fig. 2
Slotted hole adjustment-horizontal
Fig. 3
Slotted hole adjustment-vertical
Striker pin bracket
Fig. 4
Trunk latch
Striker pin
Trunk Release Solenoid Replacement/In-Line Fuse Replacement
Trunk Release Solenoid-Removal
1. Remove (2) latch bolts with a 5/32” Allen head
socket (Fig. 1).
2. Remove (2) rear latch cover bolts with a 7/16”
wrench and remove latch cover (Fig. 2).
3. Remove (2) solenoid bolts with a #25 Torx
socket (Fig. 3).
4. Remove solenoid.
Trunk Release Solenoid-Installation
1. Install new solenoid, replace and tighten solenoid bolts.
2. Reinstall parts in reverse order.
Fig. 1
Latch bolts
Fig. 2
Trunk Release Fuse Replacement
1. Remove (2) 6mm Allen head bolts from operator seat and remove operator seat.
2. Locate trunk release fuse under operator seat
(Fig. 4).
3. Replace fuse.
Rear latch cover bolts
Fig. 3
Solenoid bolts
Fig. 4
Trunk release fuse
Torque Specifications
Axle flange nuts .........................................................................................................44 ft.-lbs.
Adaptor plate-to-differential bolts ............................................................................75 ft.-lbs.
Adaptor plate-to-swingarm bolts..............................................................................75 ft.-lbs.
Banjo bolt (Brass “T”)-disc brakes ..........................................................................16 ft.-lbs.
Caliper-to-bracket bolts.............................................................................................30 ft.-lbs.
Caliper-bracket to backing plate bolts.....................................................................17 ft.-lbs.
Differential housing bolts..........................................................................................35 ft.-lbs.
Frame brace bolts ......................................................................................................44 ft.-lbs.
Frame rail bolts ..........................................................................................................35 ft.-lbs.
Front body mounts/brace bolts ................................................................................24 ft.-lbs.
Lower shock mount bracket bolts............................................................................35 ft.-lbs.
Master cylinder reservoir bracket ............................................................................12 ft.-lbs.
Muffler mount brackets .............................................................................................35 ft.-lbs.
Pulley-to-carrier-bolts................................................................................................44 ft.-lbs.
Rear tire lug nuts........................................................................................................85 ft.-lbs.
Right-side pivot shaft (swingarm) ............................................................................65 ft.-lbs.
Shock bolts.................................................................................................................35 ft.-lbs.
Shock pin ....................................................................................................................44 ft.-lbs.
Stabilizer bar upper/lower .........................................................................................35 ft.-lbs.
Upper shock mount bracket bolts............................................................................19 ft.-lbs.
Upper/lower minor pivot mount bolts ......................................................................35 ft.-lbs.
Trunk Release Wiring Diagram
Body Wiring Diagram

Part Number - Lehman Trikes

Transcription

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