lehman Trikes CROSSFIRE User manual

2010+ Victory Cross Country / Cross Roads
Installation Guide
Nov 2014
125 Industrial Drive | Spearfish, SD 57783 | Toll Free 888.3WHEELS
w w w . l e h m a n t r i k e s . c o m

2
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!
SAFETY ALERT WARNING indicates a potential hazard
that may result in severe injury or death to the operator, by-
stander or person (s) inspecting or servicing the vehicle.
WARNING
Indicates a potential hazard that may result in minor per-
sonal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken
to avoid vehicle damage or property damage.
CAUTION
NOTE provides key information by clarifying instructions.
NOTE:
IMPORTANT provides key reminders during disassembly,
assembly and inspection of components.
IMPORTANT:

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General Information
This kit is designed to be installed by a competent technician. Improper installation can affect
the safe operation of your trike, which could also result in serious injury or death. Make sure you
have a complete understanding of the work to be preformed. Unqualified installers are urged to
have the unit installed by a trained technician.
• Always protect yourself when the vehicle is in the air. Make sure the vehicle is properly supported
anytime you use a hoist or jack.
• Always use the proper tools.
• Protect your eyes by using proper safety glasses or goggles.
• Read through the installation instructions before you begin. Make sure you have all the proper tools,
parts and skill set to perform the installation safely and completely.
• Verify that you have all components before assembly.
• Before installing your new Lehman kit, we recommend that your motorcycle be inspected and ser-
viced by a qualified technician. Replace any worn or damaged parts before installing the trike kit.
• If the motorcycle has more than 12,000 miles, Lehman Trikes recommends installing a new drive
belt during the trike conversion.
• CAUTION: This kit is not designed for use on lowered motorcycles. Interference between the
tires and body may occur.
OverallWidth 57.75"
OverallLength(w/EZ‐Steer)106"
WheelBase(w/EZ‐Steer)67"
CurbWeight1170lb
RearTireSize 205/70‐15
RearTirePressure26PSI
RearSuspensionDoubleA‐ArmIndependent
Storage5Cubicfeet
RearWheelSize15x7,4x4.5,+35mmOffset

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Disassembly
NOTE: Refer to the Victory service manual for detailed instructions on removal of OEM parts.
1. Load motorcycle on lift and secure front wheel.
2. Place motorcycle on center stand or scissor style jack.
3. Disconnect negative battery cable.
4. Remove seat, save mounting hardware.
5. Remove side covers.
NOTE: Save tour box mounting hardware
6. Disconnect wiring and Remove tour box. (if
equipped)
7. Remove saddlebags (if equipped).
8. Remove saddlebag frames (if equipped).
9. Remove antenna and wiring. Plug is located
behind front fairing (Can be removed during
EZ Steer installation if applicable)
10. Remove mufflers and rear heat shields.
11. Remove rear wheel.
12. Disconnect rear brake line at caliper and
remove caliper.
13. Remove rear fender.
14. Remove passenger floorboard assemblies,
save hardware.
NOTE: See Fig. 1. for steps 15-17.
15. Remove shock linkage from swingarm.
16. Remove swingarm pivot shaft and remove
swingarm. Save pivot shaft and hardware.
17. Remove shock from motorcycle frame.
NOTE: See Fig. 2. The Lehman differential is
preassembled for shipping purposes. Swin-
garm, rear frame and top frame must be re-
moved for belt installation. RH park brake
cable must also be disconnected from the
balance bar.
Swingarm
Rear Frame
Top Frame
Fig. 1
Fig. 2

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ABS Pump Relocation– ABS Models Only
1. Remove ABS Pump mounting hardware from frame. Do not remove front brake lines from
pump.
2. Remove mounting bracket from pump. Remove grommets and spacers from bracket.
3. See Fig. 1. Remove entire rear brake line assembly from motorcycle. Disconnect line at master
cylinder and ABS pump.
4. See Fig. 2. Install original grommets and spacers to new ABS pump bracket as shown.
Fig. 1
Front brake line assembly ABS Pump
Install grommets and
spacers to Lehman
ABS pump bracket
Fig. 2

6
5. See Fig. 3. Install new bracket to ABS pump
using original hardware.
• (1) ABS Bracket– S002350
6. See Fig. 4. Install banjo bolts, spacers and
washers to block off rear brake line ports on
pump. Torque banjo bolts to 16 ft-lbs.
• (2) Banjo Bolts– CB6001
• (4) Banjo Washers- CGC6002
• (2) Spacer– S001067
7. Set pump assembly above frame until differ-
ential assembly is installed.
8. Apply “ABS Disabled” sticker over ABS light
on instrument cluster.
Block off ports for rear lines
Fig. 3
Fig. 4

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Swingarm Installation
1. See Fig. 1. Apply grease to plastic bushings and press into swingarm. Insert steel sleeves in
bushings.
2. See Fig. 2. Install swingarm to motorcycle and slide the pivot bolt though. Place two OEM wash-
ers on the RH side as shown below.
3. See Fig. 2. Reattach both floorboards supports with OEM hardware in lower holes. For the LH
side, Torque the lower 8mm screw to 19 ft-lbs. For the RH side, attach the floor board and torque
the lower 10MM screw to 35 ft-lbs. Place the OEM washers and nuts onto the pivot bolt. Hand
tighten pivot hardware.
1
2
2
3
4
3
1
2
Item # Description Part # QTY
1 OEM Nut OEM 2
2 OEM Washer OEM 4
3 Sleeve S002349 2
4 Bushing S002348 2
5 Swingarm S002347 1
6 OEM Pivot Shaft OEM 1
5
6
Fig. 1
Fig. 2

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Top Frame Installation
1. See Fig. 1. Mount Top Frame to the motorcycle sub-frame using the hardware indicated below.
Torque hardware to 19 ft-lbs evenly across all screws.
• (2) M8x35 Hex Bolt– CB1622
• (2) M8x40 Socket Head Bolt– CB1975
• (4) M8x45– CB1986
• (8) M8 Lock Washers– CW2168
• (8) M8 Flat Washers– CW2167
M8x35 Hex Bolt
w/ Flat and Lock Washer
M8x45 SHCS
w/ Flat and Lock Washer
M8x40 SHCS
w/ Flat and Lock Washer
Fig. 1

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Differential Installation
1. See Fig. 1. Remove 3 of the 4 cross tubes as shown below.
2. Pass drive belt over differential assembly and position onto rear pulley.
3. Reinstall the cross tubes and spacers. Apply anti seize to all bolts and torque the 3/4” x 2-1/2”
hex head screws to 150 ft-lbs. Torque the 1/2” x 2-1/4” hex head cap screw to 50 ft-lbs.
4. Guide differential under rear motorcycle frame while reinstalling belt past swingarm and onto front
drive pulley.
5. See Fig. 2. Attach body mounts to top frame using the 3/8” x 1-1/4” hex head cap screws. Torque
to 45 ft-lbs.
Front
Body mount
3/8” x 1-1/4” Hex Bolts
w/ Flat Washers and Lock Nuts
Leave front lower
tube installed
Fig. 1
Fig. 2
Top frame

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Rear Frame and Swingarm
1. See Fig. 1. Position lower rear body frame inside of swing arm and install the 1/2” bolts through
the mounting holes.
• (4) 1/2” x 3-1/2” Hex Head Bolts– CB2178
• (8) 1/2” Washers– CN3060
2. See Fig. 2. Attach the adjuster plate to swingarm as
shown with adjuster bolt in place. Torque adjuster
plate mounting hardware to 45 ft-lbs.
• (2) 3/8” x 1-1/4” Hex Head Bolts– CB2018
• (2) 3/8” Flat Washers– CW2180
• (2) 3/8” Lock Nuts– CN3051
3. See Fig. 3. Leave approximately a 1/16” gap be-
tween the top of the stud and the face of the nut for
both sides on swingarm pivot shaft. It is critical to
have correct spacing. Torque pivot shaft nuts to 85
ft-lbs.
4. The floorboards need to be swapped with the op-
posite side such that the LH floorboard will be in
the reversed position on the RH. Torque the re-
place RHS to 18 ft-lbs. Do not attach the floorboard
onto the LHS. The park brake will need to be in-
stalled which is later in the instructions.
Fig. 1
Fig. 2
Fig. 3
Swingarm
Rear Frame
1/16” Gap
Attach plate
to Swingarm
Aduster bolt