lehman Trikes Monarch II Honda GL1800 User manual

2001-2010
Honda GL1800 Models
Solid Axle Installation Instructions
Oct 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

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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.
© 2008. 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. Leh-
man Trikes is a registered trademark. All other brands and product names are trademarks or registered trademarks of their respective hold-
ers. Printed in the United States of America.
WARNING
SAFETY INFORMATION

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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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DISASSEMBLY .........................................................................................................................5
TRIMMING FENDER .................................................................................................................9
DRIVELINE DISSASEMBLY.................................................................................................. 11
SPRING REPLACEMENT...................................................................................................... 13
BRAKE SYSTEM MODIFICATION........................................................................................ 14
SWINGARM INSTALLATION ................................................................................................ 17
AUXILIARY SHOCK............................................................................................................... 20
DIFFERENTIAL INSTALLATION........................................................................................... 21
BRAKE SYSTEM INSTALLATION........................................................................................ 23
FRAME INSTALLATION........................................................................................................ 26
AMPLIFIER INSTALLATION ................................................................................................. 29
LATCH ASSEMBLY............................................................................................................... 30
TAILLIGHT MODIFICATION.................................................................................................. 32
BODY PREPARATION........................................................................................................... 33
DOOR SWITCH WIRING........................................................................................................ 34
DOOR INSTALLATION.......................................................................................................... 35
BODY INSTALLATION .......................................................................................................... 37
LICENSE PLATE BRACKET INSTALLATION...................................................................... 39
EXHAUST INSTALLATION.................................................................................................... 41
FINAL ASSEMBLY................................................................................................................. 43
TIRE PRESSURE MONITORING SYSTEM (TPMS) ............................................................. 44
ABS DISABLE........................................................................................................................ 46
HARDWARE BREAKDOWN.................................................................................................. 47
CONTENTS

5
PREPARING THE MOTORCYCLE
Disassembly
NOTE: Refer to Honda service manual for de-
tailed instructions on removal of OEM parts.
1. Load motorcycle on lift and secure front wheel.
2. Place motorcycle on center stand.
3. Remove seat with 6mm Allen socket. Save
grab handles and hardware.
4. See Fig. 1. Remove LH and RH side covers.
Remove and save short screws from exten-
sions. Side cover extensions will not be reused.
5. See Fig. 2. Remove and save side cover grom-
mets from front of saddlebags.
6. Disconnect battery by removing negative cable
first.
7. Disassemble tour box. Remove side and cen-
ter trim molding. Remove lower cover and in-
ner latch cover. Save all hardware as tour box
will be reinstalled on trike.
8. Disconnect saddle bag latch cables from re-
lease levers inside tour box.
9. Remove lights from tour box with an 8mm
socket.
10. Remove cable ties holding tour box harness to
frame. Remove connector holding harness to
rear tab on tour box.
11. Disconnect all wiring for tour box located under
seat. Make note of wiring locations as harness
will need to be installed in same location during
reassembly.
12. Remove tour box mounting hardware with 8mm
socket. Save all hardware. Carefully remove
tour box from motorcycle. Store all tour pack
hardware and trim in tour box as it will be re-
used.
13. Remove helmet holders from tour pack frame
and discard.
14. Raise trike on lift.
15. See Fig. 3. Remove rear fender cover. Save
(2) upper mounting screws only. Remove li-
cense plate bracket and save nuts.
Fig. 3
Fig. 1
Fig. 2

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PREPARING THE MOTORCYCLE
Disassembly
16. Remove saddlebags from motorcycle.
17. See Fig. 4. Remove and save the following
from LH and RH saddlebags.
• Taillights and mounting nuts
• Large rubber plugs
• Upper front saddlebag mounting washers
18. See Fig. 5. Remove and save the following
from the LH saddlebag only.
• Latch assembly and mounting screws
• Door strikers and mounting screws
• Latch cable
19. Remove and save LH/RH passenger foot
boards and mounting hardware.
20. See Fig. 6. Remove and save rear frame
covers. Save front mounting bolts (2) only.
21. See Fig. 6. Remove and save swingarm pin
covers and hardware.
22. Remove and discard rear crash guards and
hardware.
Fig. 6
Fig. 4
Fig. 5
Discard rear bolt
Pin cover
Frame
cover
LH hardware
shown

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PREPARING THE MOTORCYCLE
Disassembly
23. See Fig 7. Loosen muffler clamps. Remove
and save muffler mounting bolts and remove
mufflers. Remove and save rubber inserts from
heat shields.
24. See Fig. 7. Remove and save metal inserts
and rubber bushings from saddlebag supports.
25. Remove and save (4) nuts from heat shield on
RH muffler. Discard heat shield.
26. See Fig. 8. 2006+ MODELS Remove and
save (4) amplifier box mounting bolts. Remove
amplifier from rear fender.
NOTE: Long bolts (upper) will be reused for
brake line clamp installation and side stand
switch disabling. Short bolts (lower) will be
used for amplifier installation on trike.
27. See Fig. 9. 2006+ MODELS Remove and
save rear inner plastic fender mounting bolts.
28. Remove rear wheel with 19mm socket. Dis-
card wheel nuts.
29. Remove battery and battery box to access re-
verse module. Remove and save reverse
module. Remove mounting bracket from re-
verse module. Temporarily leave battery out
and box loose for easier access to upper shock
mounting hardware.
Fig. 9
Fig. 7
Fig. 8
Save mounting
hardware
Save rubber
inserts

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PREPARING THE MOTORCYCLE
Disassembly
30. See Fig. 10. Remove side stand switch as-
sembly. Disconnect sensor from side stand
while stand is in the “up” position.
31. See Fig. 11. Secure sensor from turning using
the following hardware.
• (1) Original Upper Amp Mounting Bolt
• (1) Original Upper Saddlebag Washer
• (1) M6 Flange Lock Nut- CN1902
Tour Box Frame Modification
ALL MODELS
1. See Fig 1. Mark and cut tour box frame as
shown with reciprocating saw or equivalent.
2. Remove tour box frame from motorcycle frame.
And discard mounting hardware. Use touchup
paint on bottom of tour box frame where cuts
were made.
Fig. 10
Remove side stand
Fig. 11
Secure sensor
Fig. 1

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PREPARING THE MOTORCYCLE
Fender Modification
TRIMMING FENDER (2001-05 MODELS)
CAUTION: Do not cut electrical components.
1. See Fig. 1. Mark and trim fender as shown.
2. See Fig. 2. Fender should look as shown when
completed.
Fig. 2
Fig. 1
Cut here
Cut here
Modified fender

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Fig. 3
Fig. 4
Mark and trim 1”
from rubber cover
5-1/2”
Trim here
PREPARING THE MOTORCYCLE
Fender Modification
TRIMMING FENDER (2006+ MODELS)
CAUTION: Do not cut electrical components.
3. See Fig. 3. Mark and Cut amplifier box 1” in
front of rubber cover.
4. See Fig. 4. Mark and cut front half of fender
5 1/2” from rear.

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Driveline and Suspension Disassembly
Special tools
• Snap On A26 drag link socket
• Honda pivot lock nut wrench 07ZMA-
MCAA100
• 19mm Allen socket
Swingarm Parts
• Swingarm LS6300
• Right swingarm pin LP6000
• Left swingarm pin LP6001
NOTE: Temporarily leave brake lines attached
to caliper.
1. See Fig. 1. Remove rear caliper mounting
bolts with 14mm socket. Free brake lines from
final drive assembly clips.
2. See Fig. 2. Remove front and rear brackets
holding brake lines to swingarm. Save front
mounting bracket.
3. See Fig. 3. Remove final drive assembly from
swingarm using 17mm wrench.
4. Remove driveshaft from swingarm tunnel. Re-
move and discard rubber driveshaft boot.
PREPARING THE MOTORCYCLE
Fig. 3
Fig. 1
Fig. 2
Remove
from clips
Save front
bracket
Rear
bracket
Final drive Swingarm

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Driveline and Suspension Disassembly
CAUTION: Do not disconnect oil line from
shock to pump. Contents of Honda shock are
under pressure and shock is non-serviceable.
5. See Fig. 4. Temporarily remove shock com-
pressor mounting bolts. Disconnect compres-
sor from wiring harness to allow more slack in
line.
6. See Fig. 5. Remove upper shock nut through
RH side of frame using a 17mm socket and 6”
extension. Hold bolt head through LH side of
frame with 8mm Allen socket and 6” extension.
7. See Fig. 6. Remove rear linkage bolt with
17mm and 19mm sockets. Remove front link-
age bolt from motorcycle frame using 19mm
socket and 10mm Allen socket.
8. See Fig. 6. Remove lower shock bolt with
14mm and 17mm sockets.
9. See Fig 6. Raise swingarm and remove swin-
garm linkage bolt with 19mm socket and 10mm
Allen socket.
10. Remove and save LH swingarm pin lock nut.
Remove LH and RH swingarm pins with 19mm
Allen socket.
11. Remove OEM swingarm. Feed shock through
top of swingarm during removal.
12. Remove rubber boot from transmission and
discard.
PREPARING THE MOTORCYCLE
Fig. 6
Fig. 4
Fig. 5
RH side shown
Access to upper
shock nut
Shock compressor

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Spring Replacement
Special tools:
• Spring compression tool
1. See Fig. 1. Loosen set screw on spring and
mark orientation of adjuster to shock body.
2. See Fig. 2. Install spring tool to compress
spring.
3. See Fig. 2. Compress spring and remove re-
taining ring.
4. Remove old spring and install new heavy duty
spring.
• (1) Heavy Duty Spring– LS0625
5. Compress new spring with compression tool.
6. Align orientation marks while compressing.
7. Re-install retaining ring and slide ring into
groove.
8. Tighten set screw.
Fig. 1
Loosen set screw
Orientation marks
Fig. 2
Retaining ring
PREPARING THE MOTORCYCLE

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PREPARING THE MOTORCYCLE
Brake System Modification
OEM brake system and trike modifications
The original Honda motorcycle brake system utilizes both front and rear brakes when the foot brake is
applied. During the trike conversion the brake system will be modified.
Once modification is complete, the rear brake pedal will maintain front and rear linked braking. The front
brake lever will operate the front brakes only. The anti-dive valve feature is maintained on both front
and rear braking.
The diagrams below outline the difference between the original Honda GL1800 brake system and the
modified Trikes brake system.
Fig. 1 Fig. 2
Original system Modified system

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Brake System Modification- Rear
NOTE: For ABS Disable see pg. 47
1. See Fig. 1. Disconnect inner rear brake line
(upper line on caliper).
2. Disconnect upper line at caliper and discard
brake line.
NOTE: Allow brake line to drain before blocking
off.
3. Block off inner brake line using the following
hardware.
• (1) M10 Banjo Bolt– CB6001
• (2) Copper Banjo Washers– GC6002
• (1) 1/2” Spacer– S001067
4. See Fig 2. Using cable ties, secure discon-
nected brake line to top of crossbar on frame.
5. Disconnect lower brake line from caliper.
6. See Fig. 3. Route brake line above plastic
panel on RH side below shock compressor
location.
7. Drill 1/4” hole in plastic and mount brake line
using the following hardware that was saved
from disassembly.
• (1) Original Front Brake Line Clamp
• (1) Original Upper Amplifier Mounting Bolt
• (1) Original Saddlebag Washer
• (1) M6 Lock Nut– CN1902
PREPARING THE MOTORCYCLE
Fig. 1
Fig. 2
Disconnect inner
brake line at fitting
Fig. 3
Secure line
above crossbar
Mount to
plastic with
original clamp
Block off line

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Brake System Modification- Front
1. Remove front fenders and wheel covers.
2. See Fig’s. 1 & 2. Remove OEM line from anti-
dive valve and front master cylinder. Line con-
tinues to junction block located on steering
head. Disconnect lower hard line from block.
Remove block from frame and remove entire
line from motorcycle.
3. See Fig. 3. Install new brake line between anti-
dive valve and master cylinder using OEM
banjo bolts and the following hardware. Torque
banjo bolts to 18 ft-lbs.
• (1) Front brake line- S002066
• (4) Copper Banjo Washers– GC6002
PREPARING THE MOTORCYCLE
Fig. 1
Fig. 2
Fig. 3
Anti-dive valve
Master cylinder
New line installed
Remove lower
line from block Disconnect block

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Fig. 1
ITEM PART # QTY. DESCRIPTION
0 OEM PARTS
1 LS6300 1 SWINGARM
2 LP6000 1 PIN, SWINGARM, RH
3 LP6001 1 PIN, SWINGARM, LH
SWINGARM INSTALLATION
Swingarm Installation
1. See Fig. 1. Place Lehman swingarm into motorcycle frame. Make sure factory Honda shock is
through center of swingarm during installation. Shock will be mounted into place later.

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2. Apply anti-seize compound to threads and
ends of swingarm pins that go into swingarm
bearings.
3. See Fig. 2. Start Lehman swingarm pins into
motorcycle frame.
CAUTION: Do not over-tighten left swingarm
pin. Tighten pin enough to seat in bearing and
adjust to eliminate side-play.
4. Install Lehman swingarm and use a Snap On
A26 drag link socket or similar tool to tighten
pins. Torque right swingarm pin to 80 ft.-lbs.
5. Move swingarm up and down several times to
ensure free movement. Check clearance to
sides and torque left swingarm pin to 25 ft.-
lbs. This is ensures no lateral play in bear-
ings. Back off left pin and tighten until resis-
tance is felt.
6. Install LH lock nut using Loctite 242. Torque
pivot nut to 80 ft.-lbs. using Honda pivot lock
nut wrench 07ZMA-MCA100. As torque on
this wrench is multiplied, set wrench to 72 ft.-
lbs.
7. Remove RH front chrome cover and attach
rubber boot to transmission housing. Reinstall
swingarm pn covers with original hardware.
8. See Fig. 3. Install left and right swingarm stop
blocks to motorcycle frame. Apply Loctite 262
to left and right bump stop studs and thread
studs completely into bump stop blocks.
• (1) RH Stop Block- S001100
• (1) LH Stop Block- S001102
• (2) Rubber Bump Stop- S001154
• (2) M8 x 30 Flange Bolt– CB1921
9. See Fig. 4. Guide Honda shock into place.
Check position of oil line to shock before in-
stalling upper shock bolt. Ensure oil fitting is
on left-hand side and oil line is on right-hand
side. Torque top shock bolt to 31 ft.-lbs.
Fig. 2
Fig. 3
Fig. 4
L
R
Install bump stops
Install swingarm
stop blocks
SWINGARM INSTALLATION
RH pin

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10. See Fig. 5 . Install OEM Honda shock
link to Lehman swingarm with original
hardware and M12 washer under nut
and torque bolt to 47 ft.-lbs.
• (1) M12 Washer– CW2150
11. See Fig. 6. Install lower shock linkage
with original hardware and torque lower
shock bolt to 31 ft.-lbs. and linkage bolts
to 47 ft.-lbs.
12. Reinstall shock compressor to original
location on frame.
13. Install urethane and steel bushings to
ends of swingarm.
• (4) Urethane Bushing– LB6301
• (4) Steel Bushing– LB6303
Fig. 5
Fig. 6
USE STOCK
FASTENERS TO
ATTACH SHOCK
LINKAGE
SPACER (CW2150) PLACE
WASHER UNDER NUT
USE OEM FASTENERS
TO ATTACH SHOCK
SWINGARM INSTALLATION

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Fig. 8
Fig. 7
Shock shim
INSTALLATION
Auxiliary Shock
1. See Fig’s. 7 & 8. Install lower end of auxiliary
shock with shim and flange bushing as shown.
Apply a small amount of lube to bushing.
• (1) 5/8 Shim– CS4030
• (1) Flanged Bushing– LB6314
Bushing– Flange
on RH side