lehman Trikes TRAMP 2009 Operating and installation instructions

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2009 SERVICE INFORMATION
2009 SERVICE INFORMATION
SERVICE PROCEDURES
SERVICE PROCEDURES
FLAT RATE TIMES
FLAT RATE TIMES
PARTS/PRICE LIST
PARTS/PRICE LIST

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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: [e-mail]
THIS IS YOUR MANUAL - HELP US MAKE IT BETTER
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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 proce-
dures 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.
FOREWARD
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4
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
TABLE OF CONTENTS
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5
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:
SAFETY INFORMATION
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6
REMOVAL
1. Place trike on lift.
2. Loosen lug nuts with 11/16” shallow socket.
3. Lift trike using a jack under differential carrier
housing and two safety jack stands under left
and right rear axles.
4. Remove lug nuts.
5. Remove left and right rear wheels by sliding
them out and away from body.
6. Remove brake drum.
7. 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.
7. Remove axle and backing plate from tube.
8. See Fig. 2. Remove and discard locking collar
using a grinder or chisel.
9. Place a bearing splitter tool under bearing,
place axle in a press and press bearing off.
REPLACEMENT
1. Install new bearing using a press.
2. Install new collar (provided with new bearing).
3. Reinstall backing plate and axle into axle tube.
4. Reinstall axle flange nuts. Torque to 44 ft. lbs.
5. Reinstall brake drums.
6. Reinstall rear wheels.
7. Torque lug nuts to 75 ft. lbs.
Fig. 1
Fig. 2
Remove and discard
locking collar
R & R AXLE BEARING
Axle flange retaining nuts
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7
R & R AXLE SEAL
REMOVAL
1. Place trike on lift.
2. Loosen lug nuts with 11/16” shallow socket.
3. Lift trike using a jack under differential carrier
housing and two safety jack stands under left
and right rear axles.
4. Remove lug nuts.
5. Remove left and right rear wheels by sliding
them out and away from body.
6. Remove brake drum.
7. 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.
7. Remove axle and backing plate from tube.
8. See Fig. 2. Remove axle seal with puller or
equivalent.
9. Clean area where new seal will be installed.
NOTE: Handle new seal carefully when in-
stalling. Seal can easily become damaged.
10. Set seal into position and secure with proper
seal installation tool.
REPLACEMENT
1. Reinstall backing plate and axle into axle tube.
2. Reinstall axle flange nuts. Torque to 44 ft. lbs.
3. Reinstall brake drums.
4. Reinstall rear wheels.
5. Torque lug nuts to 75 ft. lbs.
CAUTION: Do not over-fill differential. Pos-
sible axle seal failure and contamination of
rear brake linings can occur. Check differ-
ential vent tube to be sure it is free of any
blockage. Blockage can potentially lead to
axle seal failure.
6. Remove differential fill plug and check level of
differential fluid. Apply .9L (30 oz.) of 80w90
gear oil as necessary. Replace fill plug.
7. Torque fill plug to 40 ft-lbs.
Fig. 1
Fig. 2
Axle seal
R & R AXLE SEAL
Axle flange retaining nuts
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8
REMOVAL
1. Loosen lug nuts with 11/16” shallow socket.
2. Lift trike with jack and support with jack stands
or center stand.
3. Remove lug nuts and remove wheels.
4. Remove operator and passenger seats.
5. Disconnect wiring harness located under op-
erator seat behind battery.
6. See Fig. 1. Remove footpads (See R&R Pas-
senger Footpads).
7. See Fig. 2. Remove front body mount bolts
located under footpads.
8. Remove rear body to exhaust bracket.
9. See Fig. 3. Remove back (1 on each side)
bolts on top support rail (located inside trunk).
10. Remove grab handles.
11. Remove grab handle brackets. Remove re-
maining body mount bolts from top chrome rail.
NOTE: Get help to support body while re-
moving the last two bolts.
12. Carefully remove body and set safely aside.
REPLACEMENT
CAUTION: Use caution when adding equip-
ment 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.
1. Transfer taillights, turn signals, body support
bar, rubber grommets and well nuts to new
body.
2. Add reflectors to new body.
Fig. 2
Fig. 1
Fig. 3
Remove footpads
Remove back (2) bolts
R & R BODY
Remove front body mount bolts
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9
Fig. 5
Fig. 4
3. Insert (2) original fender washers saved from
disassembly to inside frame rails (front loca-
tion).
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 button-
head 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.
Attach
front
section
first
Hook
rear
section
into
place
Front fender brace bolts
Fig. 6
Taper faces inward
body mount bushing
R & R BODY CONTINUED
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10
Fig. 7
Fig. 8
Fig. 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 measure-
ments are obtained on both sides.
11. See Fig. 8. Obtain a center-to-center meas-
urement for both sides, adjusting body until
equal measurements are obtained on both
sides.
12. See Fig. 9. Obtain a front-to-back measure-
ment for both sides, adjusting the body until
equal measurements are obtained on both
sides.
13. The body has been centered when all meas-
urements are within 1/8” of each other.
Obtain same measurement
for both sides + or - 1/8”
Obtain same measurement
for both sides + or - 1/8”
Obtain same measurement
for both sides + or - 1/8”
R & R BODY CONTINUED
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