lehman Trikes TRAMP TOUR BOX LCK5093 User manual

2 PUB 751-0012
Rev. C—1/12/2012
LEHMAN TRAMP TOUR BOX
INSTALLATION INSTRUCTIONS
LCK5093
PUB0011

3PUB 751-0012
Rev. C—1/12/2012
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

4 PUB 751-0012
Rev. C—1/12/2012
THIS TOUR BOX ASSEMBLY HAS BEEN DESIGNED FOR IN-
STALLATION ON THE INCLUDED LEHMAN LUGGAGE RACK
FOR TRAMP MODELS. TOUR BOX INSTALLATION PROCE-
DURES AND WARRANTY WILL NOT APPLY IF INSTALLED
ON A NON-LEHMAN LUGGAGE RACK.
CAUTION: WHEN TOUR BOX IS POWERED, AUTO-LOCK IS
ENABLED 10 SECONDS AFTER TOUR BOX LID IS CLOSED.
BE SURE TO REMOVE KEYS AND REMOTE FROM TOUR
BOX BEFORE CONNECTING TO POWER.
BE SURE TO READ MANUFACTURER’S INSTRUCTIONS
INCLUDED WITH TOUR BOX BEFORE PROCEEDING TO
INSTALLATION.
© 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
IMPORTANT INFORMATION

5PUB 751-0012
Rev. C—1/12/2012
PARTS LIST/TOOLS/SUPPLIES
QTY. DESCRIPTION
1 3/8” RATCHET
1 5MM ALLEN HEAD SOCKET
1 6MM ALLEN HEAD SOCKET
1 13MM WRENCH
1 PHILLIPS SCREWDRIVER
1 TAPE MEASURE
1 PAINT MARKER OR EQUIVALENT
1 1/4” DRILL BIT AND DRILL
ELECTRICAL TAPE
LOCTITE 242
TOOLS REQUIRED
1 3/16” ALLEN HEAD SOCKET
1 4MM SOCKET
1 9MM SOCKET
QTY. PART # DESCRIPTION
12 CB1084 SCR, BN, SK, .25-20 X 0.75, SS
4 CN3054 NUT, HX, .25-20, SS, 18.8
1 CN3111 NUT, NL 8-32
1 CS4051 SCR, PN, PH 8-32 X 1.00
3 CT1014 TIE, NYLON, BLACK, 5.5”
4 CW2006 WSH, FL, .25, SS
4 CW2041 WSH, LK, .25, SS
2 CW2090 WSH, FL, #8
2 HB1115 SIDEPLATE, LUGGAGE RACK, CHROME
4 MB1300 BAR, CROSS, 9 1/4”, LUGGAGE RACK
1 S001399 PLATE, REINFORCEMENT, TOUR BOX
1 S001401 TOUR BOX, TRAMP (INCLUDES
MOUNTING HARDWARE AND POSI-LOCK
CONNECTORS FOR WIRE HARNESS)
1 S001403 NAME PLATE, OVAL, 1.56 X 3.13
1 S001422 BACKREST, TOUR BOX
PARTS LIST
1 PUB0011 INSTALLATION INSTRUCTIONS, LCK5093

6 PUB 751-0012
Rev. C—1/12/2012
NOTE: A trunk hinge stop bolt prevents
trunk lid from opening completely and con-
tacting tour box.
1. See Fig. 1. Open trunk lid and locate trunk
hinges.
2. See Fig. 2. Look at right-side trunk hinge to
determine if you have a hinge stop bolt. If not,
complete step 3.
3. See Fig. 3. Install trunk hinge stop bolt through
the access hole on right side trunk hinge as
shown using (1) 8-32 x 1 screw (CS4051), (2)
#8 flat washers (CW2090), and (1) 8-32 Nylock
nut (CN3111).
TRUNK HINGE STOP BOLT
Fig. 1
Fig. 2
Locate trunk hinges
Hinge stop bolt installed
Fig. 3
Install hinge stop bolt here

7PUB 751-0012
Rev. C—1/12/2012
1. Temporarily remove stock grab handles.
CAUTION: When installing side plates, be extremely careful not to scratch body paint or
frame rail paint. Use protective cloth or foam to safeguard trike body and get an assistant’s
help while installing side plates.
2. See Fig. 1. Attach side plates (HB1115) and grab handles to trike using grab handle hardware.
Leave bolts loose.
3. See Fig. 1. Install cross bars (MB1300) to side plates using (8) 1/4-20 X 3/4” (CB1084) and apply
Loctite 242 to threads of bolts and tighten securely.
4. Ensure that side plates are level and tighten grab handle/side plate hardware.
LUGGAGE RACK INSTALLATION
Fig. 1
1/4-20 X 3/4” SS button head bolt (CB1084)
Use original grab
handle hardware

8 PUB 751-0012
Rev. C—1/12/2012
1. See Fig. 1. Remove passenger seat.
2. See Fig. 2. Remove operator seat.
3. See Fig. 3. Align reinforcement plate
(S001399) on luggage rack so that front mount-
ing holes (spaced closer together) are between
1st and 2nd cross bars and rear mounting holes
(spaced further apart) are between 2nd and 3rd
cross bars.
TOUR BOX INSTALLATION
Fig. 1
Fig. 2
Fig. 3
Remove passenger seat
Remove operator seat
Front mounting holes
Rear mounting holes
1
2
3
4

9PUB 751-0012
Rev. C—1/12/2012
4. See Fig. 4. Set tour box base on reinforcement
plate and align holes in plate with holes in tour
box base.
5. See Fig. 5. Insert hardware spacers included
with tour box hardware in locations above
mounting holes on reinforcement plate.
6. See Fig. 6. Install reinforcement brackets
using hardware supplied in tour box to under-
side of luggage rack as shown. Leave bolts
loose.
TOUR BOX INSTALLATION CONTINUED
Fig. 4
Fig. 5
Fig. 6
Insert spacers
Tour box base Align holes
Reinforcement brackets

10 PUB 751-0012
Rev. C—1/12/2012
7. See Fig. 8. Center tour box base creating equal
distances of 1 3/8” from edges of tour box base
and luggage rack side plates.
8. When base is centered, tighten mounting hard-
ware.
9. See Fig. 9. Install tour box base cover included
with tour box by snapping into place. Remove
rubber pin cover from tour box base.
10. Install tour box on base by latching front section
first and pressing rear of tour box into place.
11. Route tour box wiring harness along inside of
right hand luggage rack side plate and toward
battery. Do not secure harness at this point.
NOTE: Wiring instructions reference a 2009
model unit. For 2008 and older models, be
sure to reference your OEM service manual
for specific wiring diagrams and use tour
box wiring diagram included with your tour
box.
12. See Fig. 10. Locate trike body wiring harness
on right side of battery (looking from rear) and
carefully remove heat shrink to expose wiring.
13. See Fig. 10-A. With heat shrink removed, lo-
cate brake light wire (white wire with black
stripe).
TOUR BOX INSTALLATION CONTINUED
Fig. 8
Fig. 9
Luggage rack side plates
Edge of tour box base
Fig. 10
Tour box base cover
Remove heat shrink from wiring harness
Locate brake light wire
Fig. 10-A
Remove pin cover

11 PUB 751-0012
Rev. C—1/12/2012
NOTES:
1. See Fig. 11. Included with tour box are (2-
blue, 2-red) Posi-lock taps for connecting to
power (be sure to read manufacturer’s in-
structions included with tour box).
2. Cover end of gray wire with heat shrink.
GRAY WIRE ON TOUR BOX BASE PLATE IS
NOT USED. One red Posi-lock tap will not
be used.
3. Use dielectric grease (included with connec-
tors) with all Posi-lock terminals.
14. See Fig. 12. Connect blue wire to trike brake light
wire (red wire on trike body harness) using blue
Posi-lock tap).
15. See Fig. 12. Connect green wire to trike running
light wire (blue wire on trike body harness) using
blue Posi-lock tap.
16. See Fig. 13. Connect yellow wire to tour box plate
yellow wire with red Posi-lock tap.
TOUR BOX INSTALLATION CONTINUED
Fig. 11
Fig. 12
Fig. 13

12 PUB 751-0012
Rev. C—1/12/2012
17. See Fig. 14. Install black extension wire to
black wire from top tour box harness with red
Posi-lock tap. Connect eyelet connector to
negative terminal of battery.
18. See Fig. 15. Install red extension wire to red
wire from tour box harness with in-line fuse cap.
Connect eyelet connector to positive terminal of
battery.
19. Insert 3-amp fuse in fuse receptacle.
20. Turn on power and test tour box lighting and
remote.
21. Using electrical tape, cover exposed wires on
body wiring harness where heat shrink was re-
moved.
NOTE: See Fig. 16. Before securing tour
box wiring harness with cable ties, adjust
tour box wiring harness sheath to ensure
coverage of exposed wires coming from bot-
tom of tour box base. Also, be sure harness
isn’t positioned to get pinched by operator
seat when re-installed.
TOUR BOX INSTALLATION CONTINUED
Fig. 14
Fig. 15
Fig. 16
2. Connect eyelet to negative terminal
1. Connect red cap to black wire of
tour box wiring harness.
2. Connect eyelet to positive terminal
1. Connect in-line fuse cap to red
wire of tour box wiring harness.
Red
Adjust sheath to
ensure wires are
not exposed

13 PUB 751-0012
Rev. C—1/12/2012
22. See Fig. 17. Secure tour box wiring harness by
installing cable ties (CT1014) as shown.
23. See Fig. 18. Place tour box back rest template
included with tour box as shown on front of tour
box.
24. See Fig. 17. Using a paint marker or equivalent,
mark hole locations on tour box as shown.
25. Drill (2) 1/4” holes through tour box.
26. See Fig. 19. Install tour box back rest (S001422)
with hardware included in tour box.
27. Install oval Lehman badge on top of tour box lid.
28. Install tour box liners with Velcro patches (included
with tour box).
29. Reinstall operator seat. Be sure tour box wiring
harness is not pinched during re-installation.
30. Reinstall passenger seat.
TOUR BOX INSTALLATION CONTINUED
Fig. 17
Fig. 18
Fig. 19
Mark hole locations
Install tour box back rest
Secure wiring harness with cable ties