lehman Trikes TRAMP 2009 Operating and installation instructions
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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: info@lehmantrikes.com
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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11
Fig. 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, mak-
ing 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 ft-
lbs.
20. Reconnect wiring harness and test lights.
21. Reinstall operator and passenger seats.
R & R BODY CONTINUED
Front body mount bolt
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12
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 pre-
vent 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 pre-
vent 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 sys-
tem.
15. Fill reservoir with brake fluid to within 1/8” from
top.
16. Install reservoir gasket and cover by hand-
starting screws.
Fig. 2
Fig. 1
Fig. 3
Bleeder screw
BRAKE BLEEDING
Remove reservoir cover
Fill reservoir with DOT 4 brake fluid
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13
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 rear wheels.
4. Remove brake drums.
5. See Fig. 1. Using brake drum pliers, remove
green and white return spring on top of brake
assembly.
6. Remove cable adjuster from top stud on brake
assembly and off bottom adjuster plate.
7. Remove red spring from adjuster plate.
8. See Fig. 2. Remove chrome shoe-to-shoe fork
and coil spring on end of fork.
9. See Fig. 3. Remove hold-down springs on
each shoe and remove shoes.
REPLACEMENT
1. Install new shoes with smaller shoe on front
and larger shoe on back. Be sure adjuster
plate is behind shoes.
2. Install hold-down springs on shoes and rein-
stall chrome fork with spring.
3. Reinstall bottom brake adjuster and attach red
spring to adjuster plate.
4. Reinstall cable adjuster to top stud of brake
housing while keeping shoulder in place.
5. Using brake pliers, reinstall green spring on
right side and white spring on left side.
6. Reinstall brake drums.
7. Adjust brake shoes until a slight drag occurs
and brakes are fully engaged on both sides
with 3 clicks of the park brake handle.
8. Reinstall rear wheels.
9. Torque lug nuts to 75 ft. lbs.
Fig. 2
Fig. 1
Red spring
Green spring
White spring
Chrome fork and spring
Fig. 3
R & R REAR BRAKE SHOES
Remove hold-down springs
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14
REMOVAL
1. Loosen lug nuts with 11/16” shallow socket.
2. Lift trike with jack and support with jack stands
and center stand under motorcycle frame.
3. Remove lug nuts and remove wheels.
4. See Fig. 1. Remove exhaust bracket under
rear of trike body.
5. See Fig. 2. Loosen (4) band clamps on ex-
haust.
6. Loosen clamps on exhaust pipes and cross-
over pipe.
7. Remove bolts from rear head pipe.
8. Remove band clamps.
9. Remove exhaust.
10. Disconnect and remove park brake cables from
backing plate (See “R & R Park Brake
Cables”).
11. Remove cable ties holding park brake and
brake lines to swingarm.
12. See Fig. 3. Remove U-bolts from U-joint.
CAUTION: Differential is very heavy. Get
help with removal.
13. See Fig. 4. Mark area around bolt heads to
reference location when reinstalling mounting
plates.
14. Remove (8) mounting bolts and nuts that hold
differential to swingarm plates.
15. Remove differential.
16. Drop differential out over park brake bracket
and set on lift.
17. Remove brake lines from brake tee (located on
LH side of differential) and drain fluid into pan.
Fig. 1
Exhaust bracket-2009+
Fig. 3
Remove U-bolts
Fig. 2
Loosen band clamps
R & R DIFFERENTIAL
Fig. 4
Reference bolt head location
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15
REPLACEMENT
1. See Fig. 5. Support new differential under rear
of motorcycle with jack stands.
2. See Fig. 6. Position differential with pinion
shaft to left of motorcycle centerline and vent
tube pointing upward.
3. Use original mounting hardware to attach dif-
ferential to swingarm.
4. 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.
5. See Fig. 7. Center differential to body using a
framer’s square. Adjust differential until equal
measurements are obtained on both sides.
6. Spin drive shaft to check clearance in both
front and rear locations.
7. Torque differential mounting bolts to 47 ft-lbs.
Fig. 6
Fig. 5
Support differential with jack stands
R & R DIFFERENTIAL CONTINUED
Obtain same measurement
for both sides + or - 1/8”
Fig. 7
Pinion shaft Vent tube
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16
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 prema-
ture 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. Pos-
sible 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.
Fig. 8
Fig. 9
Attach brake line
Install u-bolts
R & R DIFFERENTIAL CONTINUED
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17
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 swin-
garm 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 poten-
tially lead to axle seal failure.
24. Reinstall exhaust (See Exhaust).
25. Reinstall wheels. Torque lug nuts to 75 ft-lbs.
Fig. 10
Fig. 11
Fig. 12
Secure brake line
Secure vent tube
R & R DIFFERENTIAL CONTINUED
Secure park brake cables
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18
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.
Fig. 1
Fig. 2
R & R DIFFERENTIAL COVER GASKET
Fig. 3
Remove fill cover
Apply silicone
to mounting
surface
Gasket
Cover
Remove differential cover bolts
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19
REMOVAL
1. Remove RH side cover.
2. Protect edge of RH foot pocket area above
exhaust using masking tape.
3. Remove head pipe mounting bolts.
4. See Fig. 1. Loosen exhaust clamps on LH &
RH muffler-to-head pipe connections and
crossover clamp.
5. Loosen (2) hose clamps attaching RH muffler
to park brake bracket/exhaust bracket. Repeat
for LH muffler.
6. Disconnect RH muffler from exhaust hanger
bracket (disconnect band clamps).
7. Remove RH muffler from trike by pulling it
straight out.
8. Pull up on rear exhaust pipe while dropping LH
muffler down to disengage crossover pipe from
rear pipe. Remove pipes.
REPLACEMENT
1. Install LH pipe into front head pipe and loosely
attach band clamps. Ensure that gasket is in
place.
2. See Fig. 2. Attach crossover pipe by pushing
and turning to seat it fully into pipe.
3. Pull front pipe into place while positioning rear
head pipe to head.
4. Install rear head pipe bolts and tighten while
pulling LH pipe forward onto front head pipe.
5. 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.
6. RH muffler can be moved out a little to line up
pipes at rear of trike.
7. Tighten all clamps.
8. Ensure that all head pipe bolts are tight.
9. Check for any exhaust leaks.
Fig. 2
Fig. 1
R & R EXHAUST, MUFFLER ASSEMBLY
Loosen and remove clamps
Crossover pipe
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20
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 rear wheels.
4. See Fig. 1. Loosen and remove outer nuts
from cable-pulling bracket. Pull brake lever up
and remove inner nuts.
5. See Fig. 2. Loosen and remove hardware
from park brake bracket.
6. See Fig. 3. Cut and remove all cable ties at-
taching park brake cables to differential and
swingarm.
7. Remove left and right brake drums.
Fig. 1
Remove outer nuts
Fig. 2
Remove hardware
Fig. 3
2
(4) Black cable ties
(3) White, high-temp cable ties
R & R PARK BRAKE CABLES
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