2006-2013 DYNA Renegade Installation Instructions - WI … · 2006-2013 FXD Renegade Rev. 6 DYNA...

2006-2013 FXD Renegade Rev. 6

DYNA

2006-2013 H-D FXD MODELS Installation Instructions

*Excludes Fat Bob

July 2014


Table of Contents

SECTION INTRODUCTION AND GENERAL INFORMATION Unpacking Your Kit Preparing the Motorcycle Installing Lehman Swingarm Carrier Assembly and Pulleys Installing the Differential Assembling the Carrier/Pulley Unit in the Differential Belt Tensioning and Tracking Attaching, Adjusting and Bleeding the Brake System Installing the Lehman Frame & Suspension Installing the Exhaust Body Prep, Lights and Wiring Fitting the Body Door Install and Adjstment Neck Race Preload Renegade Torque Specifications Replacement Parts *2006 Dyna models use a 66 tooth pulley assembly *2007-2013 Dyna models use a 70 tooth pulley assembly

1


INTRODUCTION AND GENERAL INFORMATION Statements in these instructions preceded by the words WARNING, CAUTION, or NOTE and printed in bold face are important.

** WARNING ** Indicates a strong possibility of severe personal injury or loss of life if instructions are not

followed. ** CAUTION **

Indicates a possibility of personal injury or equipment damage if instructions are not followed. ** NOTE **

Gives helpful information to make a step or procedure easier or more clear. Throughout these instructions, “Front” or “Forward” refers to the front of the bike. The “Left” and “Right hand” sides refer to the position of the parts as viewed by a rider sitting on the seat, facing forward. All of the procedures covered in the manual should be performed by Lehman factory-trained installers. A few steps may require special skills using power tools. These steps should be completed by qualified personnel only. These instructions do not include information, specifications, or repair procedures relating to the motorcycle itself. Please reference a factory service manual for motorcycle information. The information in these instructions is provided to Lehman Trikes dealers. It is proprietary to Lehman Trikes, Inc. and provided solely for use by dealers. Any unauthorized duplication or distribution is a violation of international copyright law.

** NOTE ** Compliance with national (DOT-USA, MOT-Canada), State, Provincial, and local vehicle

standards is the responsibility of the installer. Installation of the parking brake is necessary to achieve compliance with DOT/MOT.

** NOTE ** The symbol H-D refers to Harley-Davidson.

The symbol LH refers to left hand side while seated on the bike. The symbol RH refers to right hand side while seated on the bike.

2


Unpacking Your Kit The crate contains the following:

1. Differential with brakes 6. Hardware box (small parts & bolt bags) 2. Wheel kit. 7. Shock absorbers. 3. Renegade Body. 8. Warranty Book. 4. Swingarm. 9. Owners Manual. 5. Lehman frame. 10. Packing/parts list

Check your kit to the parts list and the order when it arrives.

3


4

MODULAR DIFFERENTIAL


Preparing Motorcycle Note: During installation you will use various products on different areas of the trike. The following are products to have on hand before starting the conversion. Loctite 242- Medium strength blue Loctite 262- High strength red Loctite 5920- High temp sealer Note: Refer to H-D service manual for detailed instructions on the removal of the following parts:

1. Note motorcycle year, model and VIN number, as well as Lehman serial number located inside body, on left side of swingarm and on warranty registration form in owner’s manual.

2. Place motorcycle on center stand, preferably on a motorcycle lift. Secure front wheel to lift with compression strap.

3. Remove seat and disconnect battery. Note: Always disconnect negative battery cable first. If positive cable should contact a grounded object while the negative cable is installed, the sparks may cause an explosion.

4. Raise motorcycle so that rear wheel is off lift. 5. Use a level on HD frame to confirm bike is straight. Locate a reference point on frame that is level. 6. Remove side stand and side covers. 7. Disconnect rear wiring harness. 8. Remove rear turn signals from fender. These will be reused with Lehman body. 9. Remove rear fender assembly from motorcycle.

10. Remove mufflers and heat shields from motorcycle, save all exhaust hardware, these parts will be reused. 11. Remove muffler support from transmission. Save hardware. 12. Remove belt cover. 13. Remove master cylinder cover. Evacuate brake fluid from system through bleeder screw on caliper. 14. Cover master cylinder to prevent contamination. 15. Remove brake line from caliper. Save banjo washers for use on Lehman brake system. 16. Remove shocks. 17. Remove rear tire and brake assembly. 18. Remove swingarm pin, discard pin and save flange nut. 19. Remove swingarm from motorcycle. 20. Remove snap ring and bearing from left side

of swingarm. 21. Remove inner race, dust cap and bushing

from right side of swingarm. Note position of parts for reassembly.

22. Support rear of motor with a jack and remove (2) top rear motor mount bolts through transmission case.

Caution: See Fig. 1. Plates will spring apart; hold with clamp before removing nuts.

Fig. 1

5


Installing Lehman Swingarm

Note: Provided they are in good working order, all original components of Harley-Davidson swingarm may be re-used. 1. Clean and inspect original components, replace if necessary. 2. See Fig. 1. Install components into Lehman swingarm in same orientation as original swingarm.

Fig. 1 3. Install motor mount braces (LB6111) and aluminum

spacers. Long spacer (LS6126) will go on RH side and short spacer (LS6125) will go on LH side.

4. See Fig. 2. Fasten transmission brace and spacers with supplied (CB1270) GR. 8 bolts and (CN3053) stake nuts. Using Loctite 262 install bolt with head on RH side of motorcycle. Torque to 33 ft. lbs.

5. Use new pivot shaft bolt (LP6105) to align brace plates. The pivot bolt should be free to rotate or pull out when locknuts are tight.

Fig. 2 LB6111 Motor Mount Brace (RH Side)

6

LB6111 Brace- LH Side


6. 06-07 Models: See Fig. 3. Install swingarm pin brace (LB6110) to RH side of transmission housing with original hardware from case. Leave bolts for this bracket loose until swingarm installation is complete.

7. 08-13 Models: See Fig. 4. Install swingarm pin brace (LB6110) to RH side of transmission housing with original hardware from case. Install (S001057- Fig. 4) spacer between case and pin brace. Leave bolts for this bracket loose until swingarm installation is complete.

All Models 8. Install Lehman swingarm with word “TOP” (stamped into

swingarm collar) facing upward. 9. See Fig. 4.Place swingarm pivot bolt spacer

(LS6129) on RH side of swingarm between swingarm bearing and LB6110 bracket.

10. On pivot bolt (LP6105) install a new (CW2032) washer against bolt head.

11. Holding swingarm in place, insert pivot bolt assembly through RH side and into swingarm and transmission case. Start stock flange nut as bolt emerges from bearing on LH side. Use Loctite 242 on threads. Torque to 150 ft. lbs.

Note: Make sure bolt end does not contact primary case. 12. See Fig. 3. Using Loctite 242 tighten all fasteners for LB6110 swingarm pin bracket. Torque to 20 ft.

lbs. 13. Be sure swingarm moves freely up and down with no side to side movement.

Fig. 3 LB6110 Pin Brace, 06-07 Models

S001057 Spacer-2008+ Models LS6129

CW2032

Fig. 3

7

Fig. 4


Differential Installation 1. See Fig. 1. Attach LH adapter plate (LP1038) to

swingarm as shown. Leave hardware loose. 2. See Fig. 2. Attach RH adapter plate to swingarm as

shown with park brake bracket mounted to lower holes. Leave hardware loose.

3. See Fig. 1 and 2. Install 3/8” nut to adjuster bolt and thread into adapter plate from backside. Run bolt completely into adapter plate.

Fig. 2

Fig. 1

8


4. See Fig. 3 and 4. Loosely install hardware to pinch blocks before installing differential to swingarm.

Fig. 3

Fig. 4

9


5. Support swingarm with jack stands. 6. See Fig. 5. With differential assembly on lift, slide

belt over LH axle tube and against center housing. 7. See Fig. 5. Set differential assembly on swingarm

adapter plates. Slide differential as far forward as possible. Set jack stands under axle tubes.

8. Tighten pinch block hardware just enough to allow differential to slide on swingarm adapter plates.

9. See Fig. 5. Remove upper, lower and rear housing plates.

10. See Fig. 6. Carefully slide belt over pulley. 11. Reinstall housing plates with original hardware using

Loctite 242. Install all hardware before tightening. Torque hardware to 17 ft. lbs.

Install belt

Fig. 6

Fig. 5

Remove plates

10


Belt Tensioning and Tracking 1. See Fig. 1.Center differential to motorcycle frame.

Make sure distance is equal on both sides. This is critical for proper body and seat pan alignment.

2. See Fig. 2. Using adjusters, push differential assembly back until belt has about 3/8” slack with 10 lbs. pressure at midpoint of bottom run

3. Measure between mount plates on swingarm and welded pinch blocks on differential to ensure equal distances.

4. Rotate pulleys forward at least 3 revolutions of rear pulley by pulling backwards on bottom run of belt. Pull belt straight back to get an accurate reading. Check that belt is running about 0.030” from flange on rear pulley. Tap differential left or right to achieve this reading.

5. Tighten socket head screws (8) that hold mount plates to swingarm. Leave bolts loose to adjust differential.

6. Once tracking is obtained, re-check belt tension. Raise and lower differential assembly slowly with a jack while checking belt tension. When tightest position is determined, apply 10lbs. of force at midpoint of lower strand of belt. The correct deflection is 5/16” - 3/8”.

7. Correct tension by adjusting tensioner bolts equally on both sides. Any adjustment requires checking belt tracking again.

8. Look along top of belt to check belt alignment on front pulley. There should be about 0.030” clearance between pulley flange and belt. If adjustment is required, loosen cap screws that hold mount plate to swingarm, and tap differential housing with a rubber mallet in desired direction. Check rear alignment and belt tension again if adjustment is required.

Note: If necessary, apply chalk to edge of belt to aid in getting proper clearance between belt and pulley flanges. If visible clearance cannot be obtained, be sure belt is not climbing up side of pulley or squeaking as belt is rotated.

9. After all adjustments are made, tighten adjuster lock nuts. Tighten left adapter plate bolts first. Then tighten left-hand pinch block in a criss-cross pattern.

10. Tighten right hand adapter plate bolts and right hand pinch block bolts in a criss-cross pattern. 11. After all adjustments are made, tighten adjuster lock nuts and tighten pinch block bolts. Tighten pinch

blocks in a crosswise pattern. Go over both sides at least 2 times to seat blocks over pins. Torque bolts to 25 ft. lbs.

Figure H-1

Drive belt deflection

Fig. 2

Fig. 1

11


Brake System

CAUTION: Brakes are a critical safety component of the trike. Verify all brake components have been properly installed before test riding. Improper brake operation could result in death or serious injury. Do not allow dirt or debris to enter master cylinder reservoir. Brake pads will need to be seated in during initial test ride. Brake System 1. See Fig. 1. Attach brass tee to differential brace using

the following hardware. (1) Brass Tee– CF5105 (1) Spacer– S001530 (2) 1/4” x 1-3/4” Hex Bolt– CB1100 (2) 1/4” Flat Washers– CW2005 (2) 1/4” Lock Nut– CN3042

2. See Fig. 1. Install original brake line from master cylinder and rear braided lines to brass tee using the following hardware. Torque banjo bolt to 16 ft. lbs.

(1) Banjo Bolt– S002022 (2) Banjo Washers- GC6002 (2) 45” M10 Braided Line– S001976

3. See Fig. 2. Install (2) braided brake lines to rear calipers as shown. Torque bolts to 16 ft. lbs.

(2) M10 Banjo Bolt– CB6001 (4) M10 Banjo Washers- GC6002

4. Secure brake lines to swingarm with cable ties.

Fig. 2

Install brake lines to LH/RH

Fig. 1

12


Park Brake Assembly Note: Verify all brake lines and hardware are tight before bleeding system. 5. Add brake fluid (refer to OEM reservoir cap for brake fluid requirements) to brake system and work

brakes to fill lines. 6. Remove rubber caps on bleeder valves. Install clear brake bleeder hose over bleeder valve on caliper. 7. Pump brake pedal to build pressure. While holding the brake pedal, open bleeder valve to release

pressure and remove air from system. Repeat bleeding on both calipers until fluid is solid without bubbles in bleeder hose.

8. Tighten bleeder valves and check for leaks. 9. Install master cylinder reservoir cap with new screws. Do not over tighten cap screws. Park Brake Assembly 1. See Fig. 1. Install park brake cable to caliper brackets. Secure cable to bracket with cir-clip provided on

cables.

13

Fig. 1

RH Side

Secure to bracket

Attach to caliper


1. See Fig. 2. Remove snap ring from one side of large clevis pin

on brake lever. Hold park brake lever on its side and push release button at end of park brake lever to allow clevis pin to slide out.

2. See Fig. 2.Place park brake lever within park brake bracket, ensuring ratchet is secure on cross brace. Attach with large clevis pin.

3. See Fig. 2. Attach park brake cable pulling bracket to brake lever using small clevis pin and cotter pin.

(1) Cable Pulling Bracket– LB1294 (1) Clevis Pin– CC3106 (1) Cotter Pin- CC4017

4. See Fig. 3. Route left park brake cable above differential and under motorcycle frame, attaching cable ties to cable and frame, and install in left hole in handle mount.

5. See Fig. 4. Route right park brake cable up around axle and forward to right hole in handle mount.

6. See Fig. 4. Secure both cables to upper rear pinch block with clamp (GC0108).

7. See Fig. 5. Secure cable retaining nuts to handle mount with 7/8” wrench.

8. Check for tire clearance. 9. See Fig. 5. Thread one 5/16” NF nut onto each brake

cable. Place threaded end of brake cables through holes in cable bracket. Thread second nut onto each brake cable.

10. Adjust park brake cables at handle to engage at 3–4 clicks. Note: Take up slack in cables before tightening ends to ensure good adjustment range with threaded end of brake cables.

Fig. 6

Cable retaining nuts

Adjuster nuts

Left park brake cable

Fig. 4

Cable routing

Attach clamp

14

Fig. 3

Fig. 2

Fig. 5


Installing Lehman Frame & Suspension 1. See Fig. 1.Insert (4) small frame spacers (LS6130) into H-D

frame where trike frame will attach. 2. See Fig. 2.Set frame in place by using 3/8” x 2 1/2” bolts with

.875 rear frame spacers (LS6128). Use flat washers (CW2015) on both sides and secure with locknut (CN3050). Bolt head should be toward outside of frame.

3. Secure front of frame by using supplied 3/8” x 3” bolts (S001080) with 1” frame spacer (LS6127) between Lehman frame and H-D frame and a smaller spacer (LS1189) between outside of H-D frame and floorboard brace (LB6112) with slots to top. Bolt head should be toward outside of frame. Use flat washers (CW2015) on both sides and secure with a locknut (CN3050).See Fig. 2.

Small spacer

Fig. 1

15

Fig. 2


4. See Fig. 3. Install front frame mounting tab bolt

through trike frame, spacer and H-D using the following hardware. (1) Spacer- S001050 (1) 1/4” x 1-3/4” Hex Bolt- CB1100 (2) 1/4" Flat Washers- CW2005 (1) 1/4” Lock Nut- CN3040

5. Tighten rear bolts and lower front tab bolt. Leave upper front bolts until floorboard mounts are adjusted.

6. See Fig. 4. Use 1/2" x 2-1/2” bolts to mount floor board brackets to H-D frame. Secure using the following hardware. (2) 1/2" x 2-1/2” Hex Bolts- CB1417 (4) 1/2” Flat Washer- CW2015 (2) 1/2” Lock Nut- CN3060

7. See Fig. 5. Install cross brace between frame braces and floorboard mounts using the following hardware. Do not tighten floorboard mounts until later in build. (1) Cross Brace- LB6113 (2) 3/8” x 1-1/4” Bolt- CB1240 (2) 3/8” Lock Washer- CW2050 (2) 3/8” Flat Washer- CW2015

Fig. 3

Front frame tab

S001050 Spacer

16

Fig. 4

Cross Brace

Floorboard Mount

Fig. 5


Note: The lower shock eye is offset to one side. Be sure to install correctly. 8. See Fig. 6.Install 1/2” x 2 1/4” bottom shock bolt and GB0320 bushings through lower shock eye, and

thread it into shock plate. Use (1) washer under head of bolt. Lock bolt in with a lock nut. 9. Raise differential and install top of shock using 1/2” x 2 1/4” bolt, GB0320 bushing and one washer

under head of bolt. Shock should run parallel to frame tube when viewed from rear. Torque shock bolts to 40ft-lbs.

Fig. 6

17


10. See Fig. 7. Install stabilizer bar LB6101 into tab on right side of Lehman frame. Use a 3/8” NC nylock

nut, washers and grommet GG6100 to attach sway bar to frame. Leave loose.

Fig. 7

11. Attach left-hand side of sway bar to sway bar bracket (S001883) using a 3/8” NC nylock nut, (2)

washers and (2) grommets (GG6100). Shim with flat washers as needed. Leave loose. See Fig. 8.

Fig. 8

18

S001883


12. See Fig. 9. Sway bar bracket is attached to upper rear of differential housing.

Fig. 9

13. Tighten 3/8” nuts on stabilizer bar until there is no play in grommets. DO NOT COMPRESS GROMMETS.

Caution: Make sure sway bar is not pulling or pushing on Lehman frame when trike is at rest as this could alter power train alignment. Make sure shocks are running vertical after sway bar is tightened. There are (6) 3/8” flat washers supplied to shim grommets on sway bar if needed.

Dyna Head Bolt Procedure (Bolt Bag LCK5064)

1. Remove existing 3/8” head bolts and washers from engine mount bracket on LH side. 2. Apply Loctite 242 to threads of 3/8” x 1 ½” hex flange locking bolts. 3. Assemble bolt, spacer (LS1189) and external tooth lock washer in appropriate order. 4. Torque bolts to 42 ft.-lbs.

19


Installing Exhaust

1. All heat shields should be removed. Mufflers, muffler support and rear bracket should be

disassembled. 2. Stock rear header pipe will need to be cut approximately 3 ½” back from center of cross-over tube.

Install exhaust pipes LP6100 and LP6101 onto stock header pipes. Slide exhaust clamps into position and leave loose. Install mufflers onto Lehman exhaust pipes with muffler mounting plates pointing up.

NOTE: Lehman pipes may need to be cut depending on muffler location.

Fig. 1

20


Position exhaust system with jack stand, then install muffler bracket (LB6104) to mufflers with (2) 5/16” x 3/4” carriage bolts (CB1529) and 5/16” flange nuts. Position mount so it is pointing toward front of motorcycle.

3. Install rubber isolator (GM0300) into slot on muffler bracket (LB6104).

Fig. 2

4. Insert bracket (GB1200) into rubber isolator. Attach bracket to Lehman frame using (2) 5/16” x 1 1/2”

bolts, four (4) 5/16” flat washers, exhaust spacers (LS6101) and lock nuts.

Fig. 3

5. Adjust mufflers and pipes so they run even and parallel to one another. 6. Fasten exhaust clamps to joint. Position clamps so they do not squeeze a slit open on the sides, and

clamp opening does not line up with slits in pipe. 7. Inspect exhaust system for exhaust leaks and install heat shields. Trim rear head pipe head shields

as needed.

21


Body Prep, Lights and Wiring

1. Drill (2) 5/16” holes for signal mounting; (1) for wire

and (1) for mounting bolt. 2. See Fig. 1.Mount HD factory turn signals on flat below

taillights. Center turn signal with inside edge of taillights.

NOTE: Do not over tighten taillight mounting hardware. Damage to housing may occur.

3. See Fig 2. Mount taillight assemblies to body with gaskets. Attach ground wire to stud with flange nut after taillight mounting hardware is installed. (2) Taillight Assembly-S002204 (2) Gaskets– BG0200 (4) 1/4” Flat Washer– CW2006 (4) Lock washer– Provided with light (4) Nut– Provided with light (2) 1/4” Flange Nut– CN3007

4. If required- Install female terminals and male connectors to taillight wiring Use appropriate tool for crimping terminals to wires. (Mac Tools– TCT1028).

5. Inspect crimps before installing into connector. Distortion should be minimal.

6. See Fig. 3. Install thin weather seal (CW2505) on bottom outside edge of seat shell.

7. See Fig. 3. Install 1/4” studs to seat shell using Loctite 242. (5) 1/4” Studs- S001343

8. Install seat shell to body with flat washers and flanged lock nuts. (5) 1/4” Washers- CW2005 (5) 1/4” Flange Lock Nuts- CN3007

Fig. 1

22

Fig. 2

Attach ground wire to stud

Apply trim to seat shell

Fig. 3

Install studs to seat shell


Fig. 3

Fig. 4

23


Renegade Wiring Harness 1. See Fig.’s 1-2. Attach wiring harness to body clips on

underside of body. 2. Connect 8 position connector on wiring harness (Fig. 3)

to OEM harness, located under rider seat at rear of OEM frame.

3. See Fig.’s 4-5. Before connecting license plate and light bar (optional) to harness, terminals and

connectors will need to be installed to each before connecting to wiring harness. Use appropriate tool for crimping terminals to wires. (Mac Tools– TCT1028, Blue Point– PWC47 or H-D 41609).

4. See Fig. 5. Inspect crimps before installing into connector. Distortion should be minimal.

Fig. 1

Body clips

Light bar connector on RH side

Taillight connector

Fig. 3

8-position connector on wiring harness-main

6-position connector on wiring harness for trailer

Fig. 2

Body clip

License plate connector

Fig. 4

Male terminal

Female terminal

Fig. 5

Wire core crimp

Insulation crimp

24


Body Installation Note: To meet DOT and MOT requirements one of the following must be installed- stock grab handles, stock grab strap or Lehman-supplied grab handles.

1. Position body on frame so that wheel clearance is equal on both sides and front of each fender is an equal distance from front of each tire. Center tire in wheel cut-out when viewed from side. Shims are provided to level body to frame.

2. Insert (3) (CW2097) rubber body washers between frame and bottom of trunk.

3. See Fig. 1.Install thin weather seal (CW2505) on edge of floorboards and set them in place

4. Install ¼” x ¾” bolts (CB1080) with washers (CW2006) through body and into foot pocket inserts.

5. Align steel mounting bracket to foot pocket and install ¼” x 1” bolts (CB1086) and washer (CW2006) through center mounting hole with washer and locknut (CN3041) on bottom. Leave loose.

6. See Fig. 2. Once foot pocket is aligned, drill holes through existing holes in body into foot pocket. Use ¼” x 1” bolts (CB1086) with bolt head on foot pocket side, through body and secured with washer (CW2006) and locknut (CN3041).

7. Tighten front frame bolts and foot pocket mounting bracket. 8. Tighten all foot pocket mounting hardware. 9. Install rubber footpads through foot pocket and mounting bracket

using washers (CW2005) and locknuts (CN3040).. 10. Verify that body is still square with motorcycle. 11. From underside of body, drill a ¼” hole in body through each of

four mounting tabs. Keep hole centered in slot of each of tabs. 12. Fasten body as follows:

a) (4) ¼” x 2” NC button head bolts (CB1099), ¼” x 1 ¼” fender washers (CW2108) and (FG1002) foam sealing washers install from inside trunk. b) (CW2097) rubber body washers between frame and bottom of trunk c) (4) ¼” flat washers (CW2006)and locknuts (CN3040) underneath frame tab to secure body to frame

13. See Fig. 3.Grab handles- place rubber standoff (S001701) between grab handle and body.

14. Install grab handles (S001035) to body using (4) 5/16” x 1” socket head bolts (CB1159), (4) lock washers (CW2047) and (4) fender washers (CW2109).

15. Place seat on trike. Center rear mounting tab on seat shell and mark hole. Using a 19/64” bit, drill mounting hole into seat shell. Drill hole at least 7/8” deep.

16. See Fig. 4.Install brass seat insert (FI0010) into shell: fit should be tight

17. Place seat back on trike and secure with bolt (S001077) and washer (CW2006).

Fig. 3

Tapered ends to inside of handle

Fig. 1

Install seal to boards

Fig. 2

Fig. 4

Install seat insert

25


License Plate Light

1. See Fig. 5. Install license plate bracket to door with 1/4” x 1” bolts, washers, lock nuts and rubber washers. Use rubber washers between bracket and door. Install U-nuts to bracket

(2) 1/4” x 1” Button head bolt (CB1086) (2) 1/4” Rubber washer (FG1002) (2) 1/4” Flat washer (CW2005) (2) 1/4” Lock nut (CN3040) (2) 1/4” U-nut (CN3301)

2. See Fig. 6. Install license plate light and support plate to bracket using (2) 1/4” x 1 bolts.

3. See Fig. 5. Run wiring through lower hole in door.

(1) License plate light (S001469) (1) Support plate (S001601)

(1) 1/4” x 1 Button head bolt (CB1086) (2) M6 Flat washer- CW2175

4. See Fig. 6. Install lower license plate mounting hardware into place on support bracket using 1/4” x .50” bolts and (2) lock nuts

(2) 1/4” x .50 Button head bolt (CS4032) (2) 1/4” Lock nut (CN3040)

5. Solder and heat shrink light wiring to trunk wiring harness. Attach wire as follows-

Black wire on light to Black wire on trunk harness Red wire on light to Red wire on trunk harness

6. Seal wiring through door with silicone (Ultra Black).

26

Fig. 5

Fig. 6

Install rubber washers between bracket and door

Install wire through lower hole

U-nut


Trunk Door Installation

Note: Lip on weather seal will face away from door opening; top of seal is flush with top of door. 1. See Fig. 1.Install (1) 6’ weather stripping (CW2536) around

edge of body, starting at center on bottom. Trim using scissors; glue ends together.

2. See Fig. 2.Insert cable through top bend on stop bracket (FB1036). Make a small loop in the end of (1) cable (S001686) and crimp using (1) aluminum clip CC1900 (see inset figure M-2). There should be 7-1/2” between the stop and pre-made end of lanyard. See Fig. 2.

3. Apply masking tape to body just below hinge mounting holes to prevent scratching of paint by hinges.

4. See Fig. 3.Install (2) door hinges (GH0093) and stop cable brackets to body with (2) hinge gaskets (FG1003) underneath hinge using (4) screws (CS4024-0) and (4) plated star nuts (CN1898).

5. Fasten door to hinges using (4) 10/32 x 3/8” screws CS4024-1.

6. Attach stop cables to door using (2) 1/4”-20 x .438” shoulder screws (CB1151) with flat washers under cable.

7. See Fig. 3.Torque shoulder screws to 10ft-lbs using 5/32” Allen socket.

8. Install latch cable bracket onto key switch.

9. Install rear door key latch using 7/8” wrench and adjust bracket in an upright position.

10. See Fig. 4.Attach cable to key mechanism while key is in vertical position with head of screw from cable facing out.

Note: Tape emergency release cable to inside front of body during body installation.

Fig. 1

Fig. 2

7 1/2”

Insert through bracket

Loop and crimp

Fig. 3 Shoulder Screw

Fig. 4

Key switch

Cable bracket

Washer under cable end

27


11. See Fig. 5. Install (1) striker pin GL2041 to (1) striker pin bracket LB1297 using (1) 5/16” plated lock nut CN3045.

12. Attach striker pin bracket to door using (2) 1/4” lock washers CW2040 and (2) 1/4 -20 x 1/2” bolts CB1075.

13. Install (1) Renegade badge to bottom right side of door. 14. Install (1) Lehman badge GB1320 to bottom left side of door. 15. Fasten door to hinges using (4) 10/32 x 3/8” screws CS4024-1. 16. Attach stop cables to door using (2) 1/4”-20 x 1/2” hex head

bolts CB1075 (from body bolt bag) and (4) 1/4” Gr. 8 washers CW2005.

17. Cut license plate wire from body to length (approx 12-14”) 18. Install shrink tubing over license plate wires. 19. Strip and solder ends of license plate wires from the body and door together. 20. Slide shrink tubing over soldered connections and heat. 21. Fasten wiring to trunk door.

Fig. 5

Striker pin and bracket

28

2006-2013 FXD Renegade

Final Assembly 1. Reflectors can be installed to body. See Fig. 1. Install

rear reflector 3” below taillights on body. See Fig. 3. Install side reflectors using wheel center caps as a reference, ¼” above wheel opening on body.

2. Install rear wheels. Torque lug nuts to 85 ft.-lbs. (wire wheels 75 ft.-lbs.)

28

Fig. 3


Door Adjustment Procedures

Figure 0-10

Fig. 1

29


Fig. 2

Fig. 3

30


Neck Race Preload Steering head should be approximately twice as tight as factory specifications for a trike conversion. Refer to H-D service manual for adjustment procedure. Caution: Do not tighten bolts past factory specifications. Only bearing adjustment collar should be tightened past factory settings.

31


Renegade Torque Specifications Park brake bracket 31 ft-lbs Pinch block bolts 25 ft-lbs Head bolts 42 ft.-lbs LP1038 adapter plate 31 ft-lbs Banjo bolts 16 ft-lbs LB6111 Transmission Brace Bolts 33 ft-lbs LB6110 Swingarm Pin Brace 20 ft-lbs Shock bolts 40 ft-lbs Wheels aluminum 85 ft-lbs Wheels wire 75 ft-lbs Caliper to bracket bolts 38 ft-lbs Caliper bracket to axle flange bolts 38 ft-lbs Axle tube bolts 38 ft-lbs Differential housing plate bolts 17 ft-lbs

32

2006-2013 DYNA Renegade Installation Instructions - WI … · 2006-2013 FXD Renegade Rev. 6 DYNA...

Documents

Transcript of 2006-2013 DYNA Renegade Installation Instructions - WI … · 2006-2013 FXD Renegade Rev. 6 DYNA...