2009 TRAMP SERVICE PROCEDURES

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2009 SERVICE INFORMATION
SERVICE PROCEDURES
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FLAT RATE TIMES
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2009 Tramp Service Supplement
Print and mail or fax to:
Lehman Trikes USA - Product Support Dept.
125 Industrial Drive
Spearfish, SD 57783
Fax- 605-642-1182
Email: [email protected]
FOREWARD
2009 TRAMP SERVICE SUPPLEMENT
FOR PREVIOUS MODEL YEARS, PLEASE CONTACT LEHMAN TRIKES USA
This service supplement is designed for use by authorized Lehman Trikes dealer technicians. Online
copies of this supplement may be printed for internal use in your shop. This supplement is for use in a
properly equipped shop and should remain available for reference in the shop area. All references to
left hand (LH) and right hand (RH) side of the trike are from the operator’s perspective when seated in a
normal riding position.
Some procedures outlined in this supplement require sound knowledge of mechanical theory, tool use,
and shop procedures in order to perform work safely and correctly. Illustrations may show a trike body
or other component removed for clarity. These illustrations are for photographic purposes only and may
or may not indicate removing such components. If you are unsure about how to perform any procedure,
call Lehman Trikes before you start work.
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 supplement or within the posted
flat rate times, contact Lehman Trikes before you start work at 1-888-394-3357.
© 2009. 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.................................................................................................................... 5
AXLE BEARING ................................................................................................................................. 6
AXLE SEAL ........................................................................................................................................ 7
BODY ............................................................................................................................................. 8-11
BRAKE BLEEDING .......................................................................................................................... 12
BRAKE SHOES ................................................................................................................................ 13
DIFFERENTIAL ........................................................................................................................... 14-17
DIFFERENTIAL COVER GASKET .................................................................................................. 18
EXHAUST, MUFFLER ASSEMBLY................................................................................................. 19
PARK BRAKE CABLES ............................................................................................................. 20-23
PARK BRAKE LEVER ..................................................................................................................... 24
PASSENGER FOOTPADS............................................................................................................... 25
PASSENGER GRAB HANDLES...................................................................................................... 26
PINION SEAL .............................................................................................................................. 27-29
REAR WHEEL(S) ............................................................................................................................. 30
SWINGARM ................................................................................................................................. 31-34
TAIL LIGHT....................................................................................................................................... 35
TRUNK DOOR .................................................................................................................................. 36
TRUNK DOOR LATCH..................................................................................................................... 37
TRUNK DOOR SEAL ....................................................................................................................... 38
TURN SIGNAL.................................................................................................................................. 39
REAR U-JOINT................................................................................................................................. 40
WIRE HARNESS .............................................................................................................................. 41
TORQUE SPECS.............................................................................................................................. 42
4
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.
5
R & R AXLE BEARING
1.
2.
3.
4.
5.
6.
7.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
REMOVAL
Place trike on lift.
Loosen lug nuts with 11/16” shallow socket.
Lift trike using a jack under differential carrier
housing and two safety jack stands under left
and right rear axles.
Remove lug nuts.
Remove left and right rear wheels by sliding
them out and away from body.
Remove brake drum.
See Fig. 1. Line up holes in axle flange with
retaining nuts and remove all (4) retaining nuts.
NOTE: Axle can be tapped from back side
of flange for removal.
Remove axle and backing plate from tube.
See Fig. 2. Remove and discard locking collar
using a grinder or chisel.
Place a bearing splitter tool under bearing,
place axle in a press and press bearing off.
REPLACEMENT
Install new bearing using a press.
Install new collar (provided with new bearing).
Reinstall backing plate and axle into axle tube.
Reinstall axle flange nuts. Torque to 44 ft. lbs.
Reinstall brake drums.
Reinstall rear wheels.
Torque lug nuts to 75 ft. lbs.
Fig. 1
Axle flange retaining nuts
Fig. 2
Remove and discard
locking collar
6
AXLE SEAL
R &R &RRAXLE
SEAL
1.
2.
3.
4.
5.
6.
7.
7.
8.
9.
10.
1.
2.
3.
4.
5.
6.
7.
REMOVAL
Place trike on lift.
Lift trike using a jack under differential carrier
housing and two safety jack stands under left
and right rear axles.
Remove lug nuts.
Remove left and right rear wheels by sliding
them out and away from body.
Remove brake drum.
See Fig. 1. Line up holes in axle flange with
retaining nuts and remove all (4) retaining nuts.
NOTE: Axle can be tapped from other side
of flange for removal.
Remove axle and backing plate from tube.
See Fig. 2. Remove axle seal with puller or
equivalent.
Clean area where new seal will be installed.
NOTE: Handle new seal carefully when installing. Seal can easily become damaged.
Set seal into position and secure with proper
seal installation tool.
REPLACEMENT
Reinstall backing plate and axle into axle tube.
Reinstall axle flange nuts. Torque to 44 ft. lbs.
CAUTION: Do not over-fill differential. Possible axle seal failure and contamination of
rear brake linings can occur. Check differential vent tube to be sure it is free of any
blockage. Blockage can potentially lead to
axle seal failure.
Remove differential fill plug and check level of
differential fluid. Apply .9L (30 oz.) of 80w90
gear oil as necessary. Replace fill plug.
Torque fill plug to 40 ft-lbs.
Fig. 1
Axle flange retaining nuts
Fig. 2
Axle seal
7
R & R BODY
Fig. 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1.
2.
REMOVAL
Lift trike with jack and support with jack stands
or center stand.
Remove lug nuts and remove wheels.
Remove operator and passenger seats.
Disconnect wiring harness located under operator seat behind battery.
See Fig. 1. Remove footpads (See R&R Passenger Footpads).
See Fig. 2. Remove front body mount bolts
located under footpads.
Remove rear body to exhaust bracket.
See Fig. 3. Remove back (1 on each side)
bolts on top support rail (located inside trunk).
Remove grab handles.
Remove grab handle brackets. Remove remaining body mount bolts from top chrome rail.
NOTE: Get help to support body while removing the last two bolts.
Carefully remove body and set safely aside.
REPLACEMENT
CAUTION: Use caution when adding equipment to new body. Paint can become easily
damaged.
NOTE: If installing new body, begin at step
1. If reinstalling old body, begin at step 4.
Transfer taillights, turn signals, body support
bar, rubber grommets and well nuts to new
body.
Add reflectors to new body.
Remove footpads
Fig. 2
Remove front body mount bolts
Fig. 3
Remove back (2) bolts
8
R & R BODY CONTINUED
3. Insert (2) original fender washers saved from
disassembly to inside frame rails (front location).
CAUTION: Use caution when placing body
as rear fender braces may cause paint
damage.
4. Using two people, carefully lift prepped body
onto trike.
5. With two people holding body on either side of
motorcycle, slide body forward in between
fender braces.
NOTE: The order of installation for the body
mounting hardware is as follows:
 Nut (inside body)

Fender washer (inside body)

Body

Rubber washer (inside body)

Bushing (outside body)

See Fig. 5. Grab handle brackets
(outside body)

Frame (outside body)

Lock washer (outside body)

Bolt (outside body)
6. See Fig. 4. While one person steadies body
from behind, insert (2) 5/16” x 3 NC buttonhead bolts (front), (2) rubber washers, (2)
5/16” x 1-1/2” plated fender washer, (2) body
mount bushing, (2) 1/4”-20 lock nut, and (2)
5/16” SS lock washer and leave bolts loose for
body adjustment.
7. The rear fender brace holes will include the
following: (2) 5/16” x 3 NC button-head bolts,
(2) rubber washer, (2) 5/16” x 1-1/2” plated
fender washer, (2) body mount bushing, (2)
1/4”-20 lock nut, and (2) 5/16” SS lock washer.
NOTE: See Fig. 6. The body mount bushing
must be inserted with taper facing inward.
8. Snug rear two bolts using 1/2” wrench and
3/16” Allen head socket.
Fig. 4
Front fender brace bolts
Fig. 5
Attach
front
section
first
Hook
rear
section
into
place
Fig. 6
body mount bushing
Taper faces inward
9
9. Center body to motorcycle using a framer’s
square.
10. See Fig. 7. Obtain a height measurement for
both sides, adjusting body until equal measurements are obtained on both sides.
11. See Fig. 8. Obtain a center-to-center measurement for both sides, adjusting body until
equal measurements are obtained on both
sides.
12. See Fig. 9. Obtain a front-to-back measurement for both sides, adjusting the body until
equal measurements are obtained on both
sides.
13. The body has been centered when all measurements are within 1/8” of each other.
Fig. 7
Obtain same measurement
for both sides + or - 1/8”
Fig. 8
Fig. 9
10
14. See Fig. 10. Insert (2) M6 x 1 x 30 bolts
through left and right front body mount holes
and fasten with (2) M6 x 1 plated flange locking
nut and (2) washers. Leave bolts loose for body
adjustment.
15. Tighten front body mount bolts with 4mm Allen
head socket and 10mm ratchet wrench. Be
sure front body mount brackets are flush with
body footrests.
16. Re-check body alignment with framing square.
17. Tighten front body mount bolts and torque to 16
ft.-lbs.
18. Snug up top frame rail body mount bolts, making sure to tighten evenly on both sides so as to
not pull the body to one side or the other.
Tighten using 3/16” Allen head socket and 1/2”
wrench.
19. Torque top frame rail body mount bolts to 16 ftlbs.
20. Reconnect wiring harness and test lights.
21. Reinstall operator and passenger seats.
Fig. 10
Front body mount bolt
11
BRAKE BLEEDING
1. Remove operator and passenger seat.
2. See Fig. 1. Remove reservoir cover screws,
gasket and reservoir cover.
3. See Fig. 2. Fill brake fluid reservoir with DOT
4 brake fluid.
4. Massage reservoir hose to remove any air that
may be present in it.
5. See Fig. 3. Starting with left side brake drum,
attach brake bleeder to bleeder screw making
sure to install 1/4” wrench to bleed screw first.
6. Suck out all air from brake line with brake
bleeder until fluid begins to come through by
turning on brake bleeder and opening bleeder
screw slightly.
7. Tighten bleeder screw and remove brake
bleeder and 1/4” wrench.
Note: Maintain fluid level in reservoir to prevent more air from entering brake system.
8. Repeat previous steps on right side bleeder
screw using proper sequence.
9. On left side, attach 1/4” wrench and brake
bleeder to bleeder screw.
10. Pump brake pedal 7-8 times and hold pedal
down after last pump.
11. With brake pedal held down, open bleeder
screw with a 1/4” wrench. Bubbles will surface
into brake bleeder hose.
Note: Maintain fluid level in reservoir to prevent more air from entering brake system.
12. Close bleeder screw with a 1/4” wrench.
13. Turn on brake bleeder to remove any fluid that
may have collected in hose.
14. Repeat previous steps for right side bleeder
screw until no bubbles emerge from brake system.
15. Fill reservoir with brake fluid to within 1/8” from
top.
16. Install reservoir gasket and cover by handstarting screws.
12
Fig. 1
Remove reservoir cover
Fig. 2
Fill reservoir with DOT 4 brake fluid
Fig. 3
Bleeder screw
R & R REAR BRAKE SHOES
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
REMOVAL
or center stand.
Remove lug nuts and remove rear wheels.
Remove brake drums.
See Fig. 1. Using brake drum pliers, remove
green and white return spring on top of brake
assembly.
Remove cable adjuster from top stud on brake
assembly and off bottom adjuster plate.
Remove red spring from adjuster plate.
See Fig. 2. Remove chrome shoe-to-shoe fork
and coil spring on end of fork.
See Fig. 3. Remove hold-down springs on
each shoe and remove shoes.
REPLACEMENT
Install new shoes with smaller shoe on front
and larger shoe on back. Be sure adjuster
plate is behind shoes.
Install hold-down springs on shoes and reinstall chrome fork with spring.
Reinstall bottom brake adjuster and attach red
spring to adjuster plate.
Reinstall cable adjuster to top stud of brake
housing while keeping shoulder in place.
Using brake pliers, reinstall green spring on
right side and white spring on left side.
Adjust brake shoes until a slight drag occurs
and brakes are fully engaged on both sides
with 3 clicks of the park brake handle.
Fig. 1
Green spring
White spring
Red spring
Fig. 2
Chrome fork and spring
Fig. 3
Remove hold-down springs
13
R & R DIFFERENTIAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
REMOVAL
and center stand under motorcycle frame.
See Fig. 1. Remove exhaust bracket under
rear of trike body.
See Fig. 2. Loosen (4) band clamps on exhaust.
Loosen clamps on exhaust pipes and crossover pipe.
Remove bolts from rear head pipe.
Remove band clamps.
Remove exhaust.
Disconnect and remove park brake cables from
backing plate (See “R & R Park Brake
Cables”).
Remove cable ties holding park brake and
brake lines to swingarm.
See Fig. 3. Remove U-bolts from U-joint.
CAUTION: Differential is very heavy. Get
help with removal.
See Fig. 4. Mark area around bolt heads to
reference location when reinstalling mounting
plates.
Remove (8) mounting bolts and nuts that hold
differential to swingarm plates.
Remove differential.
Drop differential out over park brake bracket
and set on lift.
Remove brake lines from brake tee (located on
LH side of differential) and drain fluid into pan.
Fig. 1
Exhaust bracket-2009+
Fig. 2
Loosen band clamps
Fig. 3
Remove U-bolts
Fig. 4
Reference bolt head location
14
R & R DIFFERENTIAL CONTINUED
1.
2.
3.
4.
5.
6.
7.
REPLACEMENT
See Fig. 5. Support new differential under rear
of motorcycle with jack stands.
See Fig. 6. Position differential with pinion
shaft to left of motorcycle centerline and vent
tube pointing upward.
Use original mounting hardware to attach differential to swingarm.
Make sure differential is in the highest possible
position relative to swingarm and drive shaft is
centered to bike.
CAUTION: Driveshaft interference with
swingarm housing may cause equipment
damage or lead to an accident. Verify
proper clearance and adjust as needed.
See Fig. 7. Center differential to body using a
framer’s square. Adjust differential until equal
measurements are obtained on both sides.
Spin drive shaft to check clearance in both
front and rear locations.
Torque differential mounting bolts to 47 ft-lbs.
Fig. 5
Support differential with jack stands
Fig. 6
Pinion shaft
Vent tube
Fig. 7
15
Fig. 8
8. Ensure adequate clearance between drive
shaft and tunnel in swingarm.
9. See Fig. 8. Install (2) u-bolts, (4) lock washers
and (4) nuts to install yoke to pinion shaft.
10. Tighten bolts using 1/2” wrench. Be sure to
tighten both sides equally from both side to
side and top to bottom.
11. Torque u-bolts to 20 ft-lbs.
CAUTION: Do not over-tighten u-bolts. The
bearing cups may distort, causing premature joint failure or u-bolts may break.
12. Remove differential fill plug and apply .9L (30
oz.) of 80w90 gear oil. Replace fill plug.
13. Torque fill plug to 40 ft-lbs.
CAUTION: Do not over-fill differential. Possible axle seal failure and contamination of
rear brake linings can occur.
14. See Fig. 9. Attach braided brake line from
master cylinder to brass brake "T" with banjo
bolt and two sealed washers.
15. Tighten banjo bolts at brass “T” using 3/8”
wrench.
16. Torque banjo bolt to 16 ft-lbs.
17. Tighten all brake line fittings to banjo bolts and
brake drums.
16
Install u-bolts
Fig. 9
Attach brake line
Fig. 10
BRAKE BLEEDING
18. Fill brake fluid reservoir with DOT 4 brake fluid.
19. Bleed brakes until air bubbles are eliminated
(See Brake Bleeding).
20. Reinstall and adjust park brake (See Park
Brake Cables).
21. See Fig. 10. Secure left side braided brake
line and park brake cable to left side of swingarm using (3) black zip-ties.
22. See Fig. 11. Secure park brake cables using
(3) high-temp zip-ties.
23. See Fig. 12. Secure vent tube using (2) black
zip ties.
CAUTION: Do not pinch or block vent tube.
Check differential vent tube to be sure it is
free of any blockage. Blockage can potentially lead to axle seal failure.
24. Reinstall exhaust (See Exhaust).
25. Reinstall wheels. Torque lug nuts to 75 ft-lbs.
Secure brake line
Fig. 11
Secure park brake cables
Fig. 12
Secure vent tube
17
R & R DIFFERENTIAL COVER GASKET
Fig. 1
REMOVAL
1. Place drain pan under differential housing.
2. See Fig. 1. Remove (8) differential cover
bolts.
3. Use a flat blade screwdriver or small pry
bar to separate cover from housing.
CAUTION- Take care not to bend cover
while removing.
4. Allow all fluid to drain. Wipe out remaining
oil from bottom of housing.
5. Clean gasket mounting surface on cover
and housing.
REPLACEMENT
1. See Fig. 2. Apply a bead of silicone
(Permatex Ultra Black 22072) around
mounting surface on housing.
2. See Fig. 2. Set new gasket in place and
install cover with original hardware.
3. Torque bolts to 18 ft-lbs.
4. See Fig. 3. Remove fill plug on cover and
add 30oz. of 80w90 gear oil.
5. Reinstall fill plug and torque to 40 ft-lbs.
6. Check for leaks.
Remove differential cover bolts
Fig. 2
Apply silicone
to mounting
surface
Cover
Gasket
Fig. 3
Remove fill cover
18
R & R EXHAUST, MUFFLER ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
REMOVAL
Remove RH side cover.
Protect edge of RH foot pocket area above
exhaust using masking tape.
Remove head pipe mounting bolts.
See Fig. 1. Loosen exhaust clamps on LH &
RH muffler-to-head pipe connections and
crossover clamp.
Loosen (2) hose clamps attaching RH muffler
to park brake bracket/exhaust bracket. Repeat
for LH muffler.
Disconnect RH muffler from exhaust hanger
bracket (disconnect band clamps).
Remove RH muffler from trike by pulling it
straight out.
Pull up on rear exhaust pipe while dropping LH
muffler down to disengage crossover pipe from
rear pipe. Remove pipes.
REPLACEMENT
Install LH pipe into front head pipe and loosely
attach band clamps. Ensure that gasket is in
place.
See Fig. 2. Attach crossover pipe by pushing
and turning to seat it fully into pipe.
Pull front pipe into place while positioning rear
head pipe to head.
Install rear head pipe bolts and tighten while
pulling LH pipe forward onto front head pipe.
Tighten band clamps on exhaust/park brake
bracket; use clamps as a guide to mount rear
muffler so they line up evenly at rear of trike.
RH muffler can be moved out a little to line up
pipes at rear of trike.
Tighten all clamps.
Ensure that all head pipe bolts are tight.
Check for any exhaust leaks.
19
Fig. 1
Loosen and remove clamps
Fig. 2
Crossover pipe
R & R PARK BRAKE CABLES
1.
2.
3.
4.
5.
6.
7.
Fig. 1
REMOVAL
or center stand.
Remove lug nuts and remove rear wheels.
See Fig. 1. Loosen and remove outer nuts
from cable-pulling bracket. Pull brake lever up
and remove inner nuts.
See Fig. 2. Loosen and remove hardware
from park brake bracket.
See Fig. 3. Cut and remove all cable ties attaching park brake cables to differential and
swingarm.
Remove left and right brake drums.
Remove outer nuts
Fig. 2
Remove hardware
Fig. 3
(4) Black cable ties
2
(3) White, high-temp cable ties
20
R & R PARK BRAKE CABLES CONTINUED
Fig. 4
8. See Fig. 4. Place a round file (or equivalent),
inside brake drum, under end of park brake
cable and release park brake cable from ushaped lever.
9. See Fig. 5. Compress fingers of cable insert
with needle-nose pliers (or equivalent) to allow
cable insert to slide out of backing plate and
remove cable from drum.
Release cable from lever
Fig. 5
Compress fingers on cable insert
21
R & R PARK
BRAKECABLES
CABLE CONTINUED
R & R PARK
BRAKE
CONTINUED
REPLACEMENT
1. Route new cables through backing plate slot
and connect ends of park brake cables to park
brake levers inside drum brake assemblies.
2. Pull cable insert shoulder through backing
plate hole. Insert fingers will spread apart locking cable into place.
3. See Fig. 6. Route both cables around outside
of and under differential, and to right of differential pumpkin.
4. See Fig. 7. Re-install long (left, inside) park
brake cable to inside (left) park brake bracket
slot and fasten with hardware.
5. See Fig. 8. Re-install short (right, outside)
park brake cable to outside (right) park brake
bracket slot and fasten with hardware.
6. Re-install cable clamp in same location.
7. Bend cable clamp away from exhaust.
Fig. 6
Short cable, outside hole
Long cable, inside hole
Fig. 7
(4) Black, cable ties
2
Fig. 8
Left, inside cable
Right, outside cable
22
R & R PARK
BRAKECABLES
CABLE CONTINUED
R & R PARK
BRAKE
CONTINUED
8. See Fig. 9. Re-install park brake cables to
park brake cable pulling bracket and fasten
with hardware.
9. Adjust brake shoes until a slight drag occurs
and brakes are fully engaged on both sides
with 3 clicks of park brake handle.
CAUTION: Check differential vent tube to
be sure it is free of any blockage. Blockage
can potentially lead to axle seal failure.
10. See Fig. 10. Re-install cable ties in same location.
11. Reinstall park brake boot and hardware.
12. Reinstall rear wheels.
13. Torque lug nuts to 75 ft.-lbs.
Fig. 9
Re-install bracket hardware
Fig. 10
(4) Black cable ties
2
23
R & R PARK BRAKE LEVER
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
REMOVAL
See Fig. 1. Cut cable ties attaching park brake
boot to lever; remove boot.
See Fig. 2. Loosen hardware on cable pulling
bracket.
Pull up on brake handle to free cable pulling
bracket from threads on park brake cables.
Remove cotter pin and cross pin holding handle to bracket.
Remove snap ring and large clevis pin securing park brake handle.
Remove park brake handle.
REPLACEMENT-See Fig. 3.
Place new park brake lever within park brake
bracket, ensuring ratchet is secure on crossbrace. Attach with large clevis pin using snap
ring pliers.
Attach cable pulling bracket to hand brake using small clevis pin and cotter key using needle
nose pliers.
Adjust jam nuts on park brake cable until full
engagement of park brake is achieved with
three clicks of park brake lever. Tighten jam
nuts.
Reinstall park brake boot with new cable ties.
Fig. 1
Remove park brake boot
Fig. 2
Loosen hardware
Clevis/cotter pins
Fig. 3
24
Snap ring
R & R PASSENGER FOOTPADS
1.
2.
3.
4.
1.
2.
Fig. 1
REMOVAL
See Fig. 1. Remove RH side cover.
See Fig. 2. Remove LH side cover with ignition key and remove tool box cover.
See Fig. 3. Remove lock nuts and washers
from all (6) footpad studs (3 per side).
Remove footpads by lifting outside edge and
rear of footpad and turn toward inside of trike.
Lift remainder of footpad and stud out of body
pocket.
REPLACEMENT
NOTE: Do not over-tighten hardware.
Install new footpads and secure with original
hardware.
Reinstall side covers.
Remove right side cover
Fig. 2
Remove left side cover
Fig. 3
Remove hardware
25
R & R PASSENGER GRAB HANDLES
Fig. 1
REMOVAL
1. See Fig. 1. Remove mounting hardware from
frame rails and grab handles.
2. Carefully remove grab handles.
REPLACEMENT
1. Install new grab handles with same hardware.
Remove grab handles
26
R & R PINION SEAL
1.
2.
3.
4.
5.
6.
7.
8.
REMOVAL
Lift trike with jack and support motorcycle
frame with center stand and differential with
jack stands.
Remove cable ties holding park brake and
brake lines to swingarm.
See Fig. 1. Remove U-bolts from driveline. Leave rear driveshaft yoke and U-joint in
place on driveshaft maintaining phase alignment to front U-joint.
Apply park brake.
See Fig. 2. Make a mark on mounting plates
to use as a reference when reinstalling differential.
See Fig. 3. Remove (8) mounting bolts and
nuts that hold differential to swingarm plates
and move differential rearward to gain clearance.
Fig. 1
Remove U-bolts
Fig. 2
Make a reference line
Fig. 3
Remove mounting bolts (8 total)
27
R & R PINION SEAL CONTINUED
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
REMOVAL CONTINUED
Tilt front of differential downward to access
front pinion nut.
Apply park brake and remove pinion nut with a
1 1/16” socket.
See Fig. 4. Remove yoke and clean seal surface, looking for defects (pits, grooves, etc.)
that may affect seal.
See Fig. 4. Use Loctite Aviation Sealant
30517 or equivalent between yoke and speedy
sleeve. Apply sealant to seal surface of
yoke. Install speedy sleeve onto differential
yoke using tool supplied with speedy sleeve kit.
See Fig. 4. Remove old seal with a pry bar
and clean housing surface.
See Fig. 4. Apply silicone to edge of new seal
where it will mate into housing.
Carefully tap seal into housing. Apply a thin
coat of oil to seal surface.
Apply a small amount of silicone to splines on
backside of yoke and install until it bottoms
against front pinion bearing.
Install pinion nut; torque to 120 ft. lbs. Make
sure yoke spins and has no endplay or side to
side movement.
See Fig. 5. Align differential to swingarm using
reference line made during disassembly.
28
Fig. 4
Apply silicone
Pinion
bearing
race
Pinion bearing
Pinion seal
Yoke
Pinion nut
Fig. 5
Use reference line to align swingarm and diff.
R & R PINION SEAL CONTINUED
20.
21.
22.
23.
24.
25.
26.
27.
28.
REMOVAL CONTINUED
Using original hardware, attach differential to
swingarm.
Torque differential mounting bolts to 47 ft.-lbs.
See Fig. 6. Install (2) u-bolts, (4) lock washers
Tighten bolts using 1/2” wrench. Be sure to
Torque u-bolts to 20 ft-lbs.
Check differential fluid and add appropriate
amount of 80w90 fluid if necessary. Differential fluid capacity for the Tramp is 30 oz.
Install new wheels on wheel studs.
Install lug nuts and tighten in a criss-cross
pattern.
29
Fig. 6
Install u-bolts
R REAR WHEEL(S)
WHEELS
R & RR&REAR
1.
2.
3.
4.
1.
2.
3.
Fig. 1
REMOVAL
CAUTION: Do not use impact tools to remove or install lug nuts.
See Fig. 1. Loosen lug nuts with 11/16” shallow socket.
or center stand.
Remove lug nuts and remove rear wheel.
Repeat procedure on other side.
REPLACEMENT
Install new wheels on wheel studs.
CAUTION: Use caution to not cross-thread
studs
Install lug nuts and tighten in a criss-cross
pattern.
Remove lug nuts
30
R & R SWINGARM
REMOVAL
1. Remove rear wheels (See R&R Rear Wheel).
2. Remove operator and passenger seats located
behind battery box.
3. Disconnect main wire harness.
4. Remove body (See R&R Body).
5. Remove differential (See R & R Differential).
6. Remove driveshaft from swingarm.
7. See Fig. 2. Remove electrical box and let it
hang on trike.
8. See Fig. 3. Remove cushion rod-to-swingarm
bolt (save and reuse bushing in this location).
9. Remove RH swingarm nut and pin.
10. Remove LH swingarm pin.
11. Remove swingarm by tilting drive side up and
remove from trike.
12. Remove shock link sleeve from swingarm.
Fig. 1
Leave front bolts to support body
Fig. 2
Remove electrical box
Fig. 3
Shock link bolt
Cushion rod to swingarm bolt
31
R & R SWINGARM CONTINUED
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
REPLACEMENT
Install shock link sleeve
into new swingarm. Apply
EP grease and ensure that
sleeve moves freely.
Install new swingarm in
same fashion as old one
was removed.
Install driveshaft through
swingarm tunnel and into
front yoke.
See Fig. 4. Install LH
swingarm pin bolt (3) first,
ensuring that dowel of pin
3
is seated inside bearing
bore.
Install RH hand swingarm
pin (4). Fully seat pin,
then back it out slightly,
and finally snug up again, creating “zero
lash” (no resistance between swingarm pin and
bearing).
Install RH pivot pin lock nut to left side swingarm pin using Loctite 242 on threads.
Torque RH jam nut to 72 ft-lbs.
Torque LH swingarm pin to 72 ft-lbs.
Check for free movement of swingarm.
See Fig. 5. Install OEM bolt and nut to
swingarm through shock links.
Torque shock link bolt to 56 ft-lbs.
32
Fig. 4
4
Item #
0
1
2
3
Part #
OEM
LS6200
LD1113
OEM
Qty
(1)
(1)
(1)
4
OEM
(1)
Description
OEM parts
Swingarm
Drive shaft
Left-side
swingarm pin
Right-side
swingarm pin
and lock nut
Fig. 5
Shock link bolt
12. See Fig. 6. Support differential under rear of
motorcycle with jack stands.
13. See Fig. 7. The pinion shaft is located to left of
the motorcycle centerline and vent tube points
up.
14. Use original mounting hardware to attach differential to swingarm face.
CAUTION: Driveshaft interference with
swingarm housing may cause equipment
damage or lead to an accident. Verify
proper clearance and adjust as needed.
15. Make sure differential is in the highest possible
position relative to swingarm.
16. Center differential to motorcycle frame.
17. Torque differential mounting bolts to 47 ft.-lbs.
Fig. 6
Support differential with jack stands
Fig. 7
Pinion shaft
33
Vent tube
Fig. 8
18. Ensure adequate clearance between drive
shaft and swingarm tunnel.
19. See Fig. 8. Install (2) u-bolts, (4) lock washers
20. Tighten bolts using 1/2” wrench. Be sure to
21. Torque u-bolts to 20 ft-lbs.
22. Reconnect braided brake line to brass “T.”
Torque banjo bolt to 16 ft.-lbs.
23. Fill brake fluid reservoir with DOT 4 brake fluid.
24. Secure left side braided brake line and park
brake cable to left side of swingarm using (3)
black zip-ties.
25. See Fig. 9. Secure vent tube and park brake
cables using (3) high-temp zip-ties.
26. See Fig. 10. Secure vent tube using (2) black
zip ties.
27. Re-attach electrical box.
28. Install new cable ties to attach brake lines to
swingarm.
29. Install park brake bracket to frame rail.
30. Install park brake bracket hardware.
31. See “R & R Exhaust” for reinstallation procedure.
32. See “R & R Body” for re-installation procedure.
33. Install rear wheels.
34. Torque lug nuts to 75 ft.-lbs.
34
Install u-bolts
Fig. 9
High-temp. cable ties
Fig. 10
Black cable ties
R & R TAIL LIGHT
Fig. 1
1.
2.
1.
2.
3.
4.
REMOVAL
See Fig. 1. Disconnect tail light wiring from
main harness.
See Fig. 2. Remove self-tapping nuts from
back of light housing and remove light and gasket from body.
REPLACEMENT
Install new light housing and gasket to body.
Reinstall nut to threads of housing.
Connect tail light wiring to main harness.
Test lights.
Disconnect tail light wiring from harness
Fig. 2
Remove self-tapping nuts
35
R & R TRUNK DOOR
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
8.
9.
REMOVAL
See Fig. 1. Disconnect license plate light
wiring.
See Fig. 1. Depress release tabs on door
hinges and remove hinges from door.
See Fig. 2. Remove license plate bracket.
See Fig. 3. Remove door latch assembly.
Use an electrical pin removal tool to release
pin from socket.
Remove license plate light.
Remove hinge plate from door.
REPLACEMENT
Install new weather seal around new door.
Install hinge plate to new door.
Install license plate light.
Install trunk door latch assembly (see R&R
Trunk Door Latch Assembly).
Install license plate bracket to new door.
Install new door to hinges. Door will clip into
hinge assembly.
Connect license plate light. Test light.
Adjust door for proper fitment by closing door
with a strip of paper between door and body in
different locations. Door seals properly if paper
has tension when removed
If necessary, adjust door by loosening two Phillips screws located on bottom side of hinges.
Tighten screws when adjustment is complete.
36
Fig. 1
Disconnect license plate light wiring
Depress tabs; remove door hinges
Fig. 2
Remove license plate bracket bolts
Fig. 3
Remove door latch assembly
R & R TRUNK DOOR LATCH ASSEMBLY
1.
2.
3.
1.
2.
REMOVAL
See Fig. 1. Open trunk door and loosen pushbutton latch nut.
When latch nut reaches latch, push in button to
remove nut and star washer.
Remove latch assembly.
REPLACEMENT
See Fig. 2. Install new latch and fasten with
latch nut and star washer. Hand tighten only.
Make any necessary latch adjustments.
Fig. 1
Loosen latch assembly
Fig. 2
Star washer
37
Latch nut
R & R TRUNK DOOR SEAL
1.
2.
3.
4.
1.
2.
3.
4.
Fig. 1
REMOVAL
See Fig. 1. Open trunk door and disconnect
license plate light.
See Fig. 1. Remove hinges from door.
See Fig.’s 2 & 3. Remove door and body
seals.
Thoroughly clean areas where previous seals
were installed.
REPLACEMENT
NOTE: Start door seal below latch assembly and carefully apply seal to finished,
smooth edge of door. Apply body seal in
the same manner.
Install new door and body seals.
Connect hinges to door.
Connect license plate light.
Perform door seal test by placing strip of paper
between door and body at different locations
and closing door. Door seals properly if paper
has tension when removed.
Remove door hinges
Disconnect license plate light
Fig. 2
Remove door seal
Fig. 3
Remove body seal
38
R & R TURN SIGNAL
1.
2.
3.
1.
2.
3.
1.
2.
3.
1.
2.
3.
4.
5.
2009+ REMOVAL
Disconnect turn signal from wire harness.
Using an electrical pin removal tool, remove
pins from connector block.
Remove clamp and washer from taillight; remove turn signal.
2009+ REPLACEMENT
See Fig. 1. Install new turn signals ensuring
that screws in signals are facing inward, toward
each other.
See Fig. 2. Secure turn signal with (1) clamp
and (1) washer. Tighten clamp bolts and set
screws on each side of signal. Tighten outside
screw first (which will pull it to outside of body),
then tighten inside screw to level turn signal.
Repeat procedure for other side.
NOTE: Wire harness lead with brown wire
goes on right side of body.
2005-2008 REMOVAL
Disconnect turn signal from wire harness.
Using an electrical pin removal tool, remove
pins from connector block.
Remove self-threading nut from turn signal;
remove turn signal.
2005-2008 REPLACEMENT
Install turn signals ensuring that screws in turn
signals are facing inward, toward each other.
See Fig. 3. Install left side turn signal with (1)
self-threading nut. Tighten nut using 14mm
wrench
Repeat previous steps for right side turn signal
installation.
Connect taillights and turn signals to wire harness and route through body clips.
NOTE: Wire harness lead with purple wire
goes on right side of body.
Test turn signals.
39
Fig. 1
Turn signals screws face inward
Fig. 2
Turn Signal
Washer
Clamp
Fig. 3
Secure signal with self-threading nut
R & R REAR U-JOINT
REMOVAL
1. Loosen lug nuts with 11/16” shallow socket.
2. Lift trike with jack; support with jack stands or
center stand.
3. Remove lug nuts and remove wheels.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
Fig. 1
NOTE: See Fig. 1. To ensure proper phasing of driveshaft, mark u-joint and yoke with
a paint marker prior to disassembly.
Cut ties securing brake line/cable to swingarm.
Remove U-bolts from rear yoke at differential.
Use a paint marker to mark a line across differential and swingarm mounting plates to ensure
side alignment during reassembly.
See Fig. 2. Remove hardware securing differential to swingarm. Slide differential to rear of
trike allowing U-joint and yoke to be removed
from drive shaft.
Remove retaining rings using needle-nose pliers and press existing u-joint from yoke.
REPLACEMENT
Install new U-joint into yoke being sure to orient grease zerk toward front of trike.
Replace yoke and U-joint assembly onto end of
driveshaft, ensuring paint marks match between yoke and drive shaft for proper phasing.
Reposition differential so that U-joint and rear
yoke at differential mate together and that paint
marks between differential-to-swingarm mounting plates align.
Reinstall diff. hardware; torque to 47 ft.-lbs.
Replace (2) U-bolts, (4) lock washers and nuts;
tighten nuts on both sides of U-joints equally
from side to side and top to bottom; torque to
20 ft.-lbs.
CAUTION: Check differential vent tube to
be sure it is free of any blockage. Blockage
can potentially lead to axle seal failure.
1. See Fig. 3. Secure brake lines and cables to
swingarm with new cable ties.
2. Reinstall rear wheels and torque lugs to 75 ft.lbs.
40
Driveshaft alignment
Fig. 2
Remove hardware
Fig. 3
Secure brake lines to swingarm
R & R WIRING HARNESS
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
REMOVAL
Loosen RH lug nuts with 11/16” shallow
socket.
or center stand.
Remove RH lug nuts and remove RH wheel.
Remove operator and passenger seats.
See Fig. 1. Disconnect main (6-pin) wiring harness connector.
See Fig. 2. Remove existing wiring harness
from body mount clips and disconnect from
taillights, turn signals and license plate connector.
REPLACEMENT
See Fig. 3. Connect new harness to body
mount clips and connect harness to taillights,
turn signals and license plate connector.
Re-connect main (6-pin) wiring harness connector.
Test turn signal operation.
Install operator and passenger seats.
Install RH wheel.
Fig. 1
Disconnect main (6-pin) wiring harness
Fig. 2
Body mount clips
Fig. 3
Connect taillights and license plate wiring
41
TORQUE SPECS
AXLE FLANGE NUTS .................................................................................................44 ft.-lbs.
DIFFERENTIAL MOUNTING BOLTS .........................................................................47 ft.-lbs.
DIFFERENTIAL COVER BOLTS ................................................................................18 ft. -lbs
U-JOINT U-BOLTS......................................................................................................20 ft.-lbs.
SHOCK LINK BOLT ....................................................................................................56 ft.-lbs.
DIFFERENTIAL FILL PLUG .......................................................................................40 ft.-lbs.
REAR WHEEL LUG NUTS..........................................................................................75 ft.-lbs.
BANJO BOLTS ...........................................................................................................16 ft.-lbs.
FRONT BODY MOUNT BOLTS..................................................................................16 ft.-lbs.
FRAME RAIL BODY MOUNT BOLTS ........................................................................16 ft.-lbs.
RH SWINGARM PIVOT PIN LOCK NUT ....................................................................72 ft.-lbs.
LH SWINGARM PIVOT PIN ........................................................................................72 ft.-lbs.
42
TRAMP FLAT RATE TIMES
Jump to Parts Procedures
PROCEDURE
BODY
Trunk Door Seal R&R
Trunk Door R&R
Passenger Footpad R&R
Jump to Service Procedures
QTY.
TIME
1
1
1
2
1
2
1
1
1
2
1
2
1
1
0.30
0.50
0.20
0.40
0.20
0.40
0.50
0.20
0.20
0.40
0.20
0.40
2.00
1.00
1
2
1
2
1
0.75
1.50
0.60
1.00
0.50
Differential Cover Gasket
1
2
1
2
1
1
1
1
1
2
1
2
1
1.50
2.75
1.00
1.75
2.50
4.00
3.00
1.50
0.50
0.75
0.75
1.50
0.50
SERVICE BULLETIN
SB20
SB21
SB30
2
2
2
1.20
1.20
2.00
Passenger Grab Handle R&R
Wiring Harness R&R
Trunk Door Latch Assembly R&R
Taillight R&R
Turn Signal R&R
Body R&R (new body)
Body R&I (existing body)
BRAKE
Brake Shoes R&R
Park Brake Cables R&R
Park Brake Lever R&R
DRIVE
Axle Bearing R&R
Axle Seal R&R
Pinion Seal R&R
Swingarm R&R
Differential R&R
Rear U-joint R&R
Exhaust, Muffler Assembly R&R
Axle R&R
u_joint_gu1072.jpg
dust_shield_yoke_ls1420.jpg
badge_tramp_gb1322.jpg
grab-handle_lh6202.jpg
bar_spreader_lb1357.jpg
bracket_master_cylinder_lb6216.jpg
bracket_reservoir_lb6218.jpg
differential_ld6200.jpg
swingarm_ls6200.jpg
heat_shield_ls6209.jpg
bracket_parkbrake_exhaust_s001361.jpg
bracket_muffler_s001362.jpg
bracket_grab handle_s001364.jpg
bracket_license_plate_s001365.jpg
passenger_footrest-left_lp6210.jpg
passenger_footrest_right_lp6211.jpg
bracket_switch_sidestand_lb6201.jpg
bracket_turnsignal_S001047.JPG
park-brake-handle_gb1099m.jpg
bracket_cable_park_brake_lb1294.jpg
debris_shield_differential_ls1018.jpg
shaft_drive_ls1404.jpg
yoke_ly1002.jpg
cable_park_brake_GB1115_16.jpg
badge_25year_s001532_REV_00.jpg
latch_striker_ls6208.jpg

2009 TRAMP SERVICE PROCEDURES

Transcription

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