Lehman Renegade 2009 User manual

2009-2013
H-D TOURING MODELS
INSTALLATION
INSTRUCTIONS
*FLHX AND FLTR MODELS REQUIRE ADDITIONAL HARDWARE
December 2013
Rev. 8
Powered by Harley Davidson

2009-2013 FLH RENEGADE
This manual is designed for use by authorized Lehman Trikes®dealer technicians. Online copies of this
manual may be printed for internal use in your shop. This manual is for use in a properly equipped shop
and should remain available for reference in the shop area.
Some procedures outlined in this manual require sound knowledge of mechanical theory, tool use, and
shop procedures in order to perform work safely and correctly. Illustrations in this manual 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.
Read the text and become familiar with the procedures before starting any work. Some procedures re-
quire 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 manual, please contact Lehman Trikes®before
you start work at 1-888-394-3357.
FOREWARD
© 2010. 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.
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2009-2013 FLH RENEGADE
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
Throughout these instructions “Front” or “Forward” refers to the front of the bike. The front of any com-
ponent is the end which faces toward the front of the bike. The “Left” and “Right” hand sides refer to the
position of the parts as viewed by a rider sitting on the seat, facing forward.
NOTE: The symbol HD refers to Harley Davidson. The symbol LH refers to left-hand side while seated
on the bike. The symbol RH refers to the right-hand side while seated on the bike.
These instructions do not include information, specifications, or procedures relating to the motorcycle
itself. For this information, refer to the factory service manual.
The information in these instructions is provided to Lehman Trike dealers. It is proprietary to Lehman
Trikes, Inc. and provided solely for use by dealers. Any unauthorized duplication or distribution is a vio-
lation of international copyright law.
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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2009-2013 FLH RENEGADE
UNPACKING THE KIT
PREPARING THE MOTORCYCLE
REMOVING HD SWINGARM
INSTALLING LEHMAN SWINGARM
TOP MOTOR MOUNT LINK
CARRIER/PULLEY
DIFFERENTIAL-LEFT HALF
DIFFERENTIAL-RIGHT HALF
BELT TENSIONING/TRACKING
BRAKE SYSTEMS
FRAME/SUSPENSION
EXHAUST
ELECTRICAL
BODY
REPLACEMENT PARTS
TORQUE SPECIFICATIONS
FINAL TRIKE INSPECTION
HARDWARE DESCRIPTION/BOLT BAG BREAKDOWN
*Notes before starting conversion
*For 2009+ FLHX (Street Glide) and FLTR (Road Glide) installations, the following parts will need
to be ordered from H-D for antenna and turn signal installation:
HD P/N Description Qty.
76252-86 Base, antenna 1
76253-86 Reinforcement plate 1
76255-86 Gasket, base 1
11486 Grommet 1
68713-94A Lamp, rear signal 2
**Dakota Digital offers a hidden antenna kit as an alternative. Part # ANT-2000
*For 2010+ Models, the following parts are required.
HD P/N Description Qty.
73108-96BK Pin Housing 1
73190-96 Terminal Pin 8
*For 2010+ FLTR Models, the following parts are required.
HD P/N Description Qty.
65846-09 Muffler 1
LP1351 Exhaust Extension 1 (Lehman Part)
**ABS Models– Disabling the ABS light will also disable the cruise control light.
SECTION BREAKOUT
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2009-2013 FLH RENEGADE
General Safety 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.
NOTE: Compliance with national (DOT-USA, MOT-Canada), State, Provincial, and local vehicle is
standards is the responsibility of the installer. Installation of the parking brake and grab han-
dles is necessary to achieve compliance with DOT/MOT.
ARB Label Confirmation– California Kits
1. See Fig. 1. California Air Resource Board (ARB) certification label must be affixed on all swin-
garms for kits sold into California.
2. Label should be placed on left side of swingarm 1/2” from rear
weld.
3. Make sure label correlates with correct model year.
GENERAL INFORMATION
5
Fig. 1

2009-2013 FLH RENEGADE
FRAME BRACE-S001266 FRAME BRACE-S001268
BODY BRACE-LB1235 LICENSE PLATE BRACKET-LB1207 ADAPTER PLATE-LP1038
SWINGARM BUSHING-LT-
S001346
SWINGARM BUSHING-RT-
S001347
SWINGARM BUSHING-
S001315 (09-10 MODELS)
ILLUSTRATIONS
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2009-2013 FLH RENEGADE
LS2013-2002+ SWINGARM
S001271-FRAME
ILLUSTRATIONS CONTINUED
7
MODULAR DIFFERENTIAL
GM0142 MOTOR MOUNT LINK

2009-2013 FLH RENEGADE
The following instructions are a guide to preparing the motorcycle to accept the Lehman Trike Con-
version Kit. This will assist you in removing the necessary parts to install the kit. Refer to H-D ser-
vice manual for detailed procedures on motorcycle disassembly.
1. Locate motorcycle year, model and serial number, as well as Lehman serial number, located inside
body, on left-side of swingarm and on warranty registration form in owner’s manual.
2. Make sure motorcycle is standing straight up and handlebars are centered. Support motorcycle un-
der rear of transmission so it is straight up and down and handlebars are straight. The front forks or
handlebars should be anchored to hold bike.
NOTE: Use a small spirit level on rear wheel or disc brake to stand bike straight up. Any
movement of handlebars will move bike off level. Locate reference point on bike frame that
is level and check it frequently.
3. Remove seat and save mounting screw.
4. Disconnect battery.
CAUTION: Always disconnect negative battery cable first. If positive cable should contact a
grounded object while negative cable is installed, resulting sparks may cause an explosion.
5. Remove tour pack.
6. Raise motorcycle lift to working height.
7. Remove side stand mounting bolt and separate side stand from bracket.
8. Remove passenger footboards. Save boards and hardware for re-installation.
9. Remove side covers; they will be re-used.
10. Remove saddlebags (if equipped).
11. Remove mufflers and saddlebag mounts. Keep all muffler mounting hardware including rubber iso-
lators located in saddlebag mounts. These parts will be re-used.
12. Support bike on center stand.
13. Disconnect airlines from shocks and remove shocks. Stand shocks upright to prevent oil leaks.
Save air valve plate and discard original shock mounting bolts.
14. Remove rear fender and save turn signal lights.
15. Remove brake line from caliper and remove caliper.
16. Remove retaining clip from rear axle and remove axle nut with 36mm socket. Axle can now be re-
moved.
17. Remove rear wheel assembly.
18. Support transmission from below with jack and padded block.
PREPARING THE MOTORCYCLE
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2009-2013 FLH RENEGADE
2009-2010 MODELS
1. See Fig. 1. Remove (2) bolts to free swingarm
fork bracket from left side of motorcycle frame.
2. Release rear brake line hose and rear wheel speed
sensor (if ABS equipped) from cable clips on right
side of swingarm.
3. Remove decorative chrome plug from right side.
NOTE: For best results, use an air impact
wrench to remove right-side nut. Applying heat
to right-side nut may also improve removal. If
left-side nut loosens first, remove left-side nut
and use double nuts to hold pivot shaft while
removing right-side nut.
4. See Fig. 2. Hold left-side nut and remove right
side nut from end of pivot shaft. Remove and
discard cup washer.
5. Using a suitable punch, tap pivot shaft toward
left side of motorcycle.
6. See Fig. 1. Pull pivot shaft assembly with nut,
cup washer, rubber mount and outer spacer out
of transmission mount and left side fork. Hold
shaft in padded vise and remove LH nut. Dis-
card LH cup washer.
7. Remove outer spacer from right side of swin-
garm.
8. Remove rubber mount from right side.
2011+ MODELS
1. See Fig. 1. Remove (2) bolts to free swingarm fork bracket from left side of motorcycle frame.
2. Release rear brake line hose and rear wheel speed sensor (if ABS equipped) from cable clips on
right side of swingarm. Remove black plastic plug from right side.
NOTE: For best results, use an air impact wrench to remove right-side bolt. Applying heat to
right-side bolt may also improve removal. If left-side bolt loosens first, use a ¾” socket to
hold LH pivot shaft outer spacer while removing right-side bolt.
3. See Fig. 2. Hold left-side bolt and remove right side bolt from end of pivot shaft.
4. Using a suitable punch, tap pivot shaft toward left side of motorcycle.
5. See Fig. 1. Pull pivot shaft assembly with outer spacer and rubber mount out of transmission mount
and left side fork. Hold shaft in padded vise and remove LH bolt.
6. Remove outer spacer from right side of swingarm. Remove rubber mount from right side.
Fig. 1
Fig. 2
Right-side mount
LH Fork bracket bolts
REMOVING HD SWINGARM
Pivot shaft nut
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2009-2013 FLH RENEGADE
TRIMMING EXHAUST
NOTE: Trimming rear head pipes is more
convenient while swingarm is removed
from frame.
1. Remove LH and RH rear heat shields.
2. See Fig. 4. Using an appropriate cutting tool,
cut 1 5/8” from end of both rear head pipes.
3. Reinstall LH heat shield after cut. Shield will
be placed 1/4” to 1/2” forward to gain clear-
ance for extension pipe installation.
4. Install RH heat shield.
Fig. 4
REMOVING H-D SWINGARM
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2009-2013 FLH RENEGADE
NOTE: Swingarm pivot shaft components are different between
2009-10 and 2011+ models. Be sure to use the correct procedure
for your specific model year. See Fig. 1. Swingarm pivot shaft
bushings for 2011 models (S001661) will have a larger inside di-
ameter.
2009-2010 Models
NOTE: If all original components of H-D swingarm are in good
working order, they may be re-used.
1. Press bearing assemblies out of HD swingarm using appropriate
press collar. Refer to HD service manual.
NOTE: Make sure swingarm bore is clean where bearing will
be pressed in.
2. Press bearings into Lehman swingarm following H-D service man
ual procedure (H-D tool # HD-45327). H-D tool will set bearings at
correct location in Lehman swingarm collar.
3. See Fig. 1 & Fig 2. OEM cup washers will be replaced by new
swingarm reinforcement bushings (S001346-LH, S001347-RH &
S001315).
4. See Fig. 3. Install RH swingarm reinforcement bushings (S001347 & S001315) into original rubber mounts. Be
sure to align offset in mount and bushings.
5. Install Lehman swingarm with word “TOP” (stamped into swingarm collar) facing upward.
6. See Fig. 3. Assemble parts for LH side (S001346 & S001315) as shown.
7. See Fig. 3. Re-install LH swingarm fork bracket. Apply Loctite 242 and torque bolts to 55 ft.-lbs.
8. Apply Loctite 242 to pivot shaft nuts and install. Torque swingarm pivot shaft nuts to 55 ft.-lbs and
reinstall chrome caps.
NOTE: Refer to HD service manual for swingarm installation procedures and torque specifications for spe-
cific model of motorcycle.
9. Verify swingarm assembly moves freely with no side to side play. Light resistance when moving up
and down is normal.
Fig. 2
Fig. 3
INSTALLING LEHMAN SWINGARM
Fig. 1
11

2009-2013 FLH RENEGADE
2011+ Models
NOTE: If all original components of H-D swingarm are in good working order, they may be re-
used.
1. Press bearing assemblies out of HD swingarm using appropriate press collar. Refer to HD service
manual.
NOTE: Make sure swingarm bore is clean where bearing will be pressed in.
2. Press bearings into Lehman swingarm following H-D service manual procedure (H-D tool # HD-
45327). H-D tool will set bearings at correct location in Lehman swingarm collar.
3. See Fig. 1 & Fig 2 on previous page. Swingarm reinforcement bushings (S001346-LH, S001347-
RH & S001661).
4. See Fig. 4. Install RH swingarm reinforcement bushings (S001347 & S001661) into original rubber
mounts. Be sure to align offset in mount and bushings.
5. Install Lehman swingarm with word “TOP” (stamped into swingarm collar) facing upward.
6. See Fig. 4. Assemble parts for LH side (S001346 & S001661) as shown.
7. See Fig. 4. Re-install LH swingarm fork bracket. Apply Loctite 242 and torque bolts to 55 ft.-lbs.
8. Apply Loctite 242 to pivot shaft bolts and install. Torque swingarm pivot shaft bolts to 55 ft.-lbs.
9. See Fig. 4. Discard OEM black plastic pivot shaft plugs and replace with S001662 chrome caps.
NOTE: Refer to H-D service manual for swingarm installation procedures and torque specifi
cations for specific model of motorcycle.
10. Verify swingarm assembly moves freely with no side to side play. Light resistance when moving up
and down is normal. Fig. 4
INSTALLING LEHMAN SWINGARM
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2009-2013 FLH RENEGADE
Top Motor Mount Link Removal: 2009+ Models
NOTE: For 2009+ models, do not disturb
OEM head bolts or lower engine mount bolt.
1. See Fig. 1. OEM top motor mount link will be
replaced with Lehman Motor Mount Link.
2. See Fig. 2. Remove OEM motor mount link.
3. Save all mounting hardware.
Lehman Motor Mount Link
NOTE: Refer to H-D service manual for
proper removal and installation procedures
for all motor mounts.
4. Adjust Lehman motor mount link to same dis-
tance from center of hole to center of hole as
OEM motor mount link.
• (1) Upper Engine Stabilizer Link– GM0142
NOTE: Locate position of eyelet holes and
alignment of OEM link. Lehman link must be
adjusted same as OEM link; when link is ad-
justed, use Loctite 262 and secure lock nuts
in place.
5. Install Lehman link using existing OEM bolts,
blue Loctite 242 and supplied motor mount link
shims. Reinstall OEM washer below link on RH
side.
NOTE: Be sure to shim both sides of link ends.
6. Torque OEM bolts to 33 ft. lbs.
Fig. 1
Fig. 2
Lehman motor mount link
OEM Top motor mount link
Lehman link installed
MOTOR MOUNT LINKS
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2009-2013 FLH RENEGADE
Differential Installation
1. See Fig. 1. Attach LH adapter plate (LP1038) to
swingarm as shown. Leave hardware loose.
2. See Fig. 2. Attach RH adapter plate to swin-
garm as shown with park brake bracket mounted
to lower holes. Leave hardware loose.
3. See Fig. 1 and 2. Install 3/8” nut to adjuster bolt
and thread into adapter plate from backside. Run
bolt completely into adapter plate.
DIFFERENTIAL
14
Fig. 1
Fig. 2

2009-2013 FLH RENEGADE
4. See Fig. 3 and 4. Loosely install hardware to
pinch blocks before installing differential to
swingarm.
NOTE: Shock plate orientation is different
on 09+ models. Make sure shock mount
hole on rear of plate is towards the top.
DIFFERENTIAL CONTINUED
15
Fig. 3
Fig. 4
Hole towards top
Hole
towards
top

2009-2013 FLH RENEGADE
5. Support swingarm with jack stands.
6. See Fig. 5. With differential assembly on lift,
slide belt over LH axle tube and against center
housing.
7. See Fig. 5. Set differential assembly on swin-
garm adapter plates. Slide differential as far
forward as possible. Set jack stands under
axle tubes.
8. Tighten pinch block hardware just enough to
allow differential to slide on swingarm adapter
plates.
9. See Fig. 5. Remove upper, lower and rear
housing plates.
10. See Fig. 6. Carefully slide belt over pulley.
11. Reinstall housing plates with original hardware
using Loctite 242. Install all hardware before
tightening. Torque hardware to 17 ft. lbs.
DIFFERENTIAL CONTINUED
16
Fig. 5
Fig. 6
Remove plates
Install belt

2009-2013 FLH RENEGADE
12. See Fig. 10. Remove RH front plate hardware
and install tapered washers (S001784) into
holes on RH side before installing brace.
13. Bolt rear half of differential brace to housing
using bolts (CB1939).
14. See Fig. 11. Bolt front half of differential brace
to top of swingarm gusset with a 3/8” x 1” bolt,
flat washers and lock nut.
Note: Do not bolt down brace until belt ten-
sioning is completed.
15. Tighten bolts in following order:
a. Front half of brace to swingarm gusset.
Torque bolts to 35 ft. lbs.
b. Rear half of brace to differential housing.
Torque bolt to 25 ft. lbs.
c. Torque LH front plate bolts to 17 ft. lbs.
DIFFERENTIAL CONTINUED
17
Fig. 7
Fig. 8
Tapered washers

2009-2013 FLH RENEGADE
1. Center differential to motorcycle frame– this is critical for proper body and seat pan alignment.
Make sure distance is within 1/16” from side to side.
2. Level swingarm to motorcycle frame. This will help achieve proper ride height and is critical for
proper belt tensioning.
3. See Fig. 1. Using adjusters, push differential assembly back until belt has about 3/8” slack with 10
lbs. pressure at midpoint of bottom run. Measure between adapter plates and pinch blocks to en-
sure that distances are equal.
4. Rotate pulleys forward for at least 3 revolutions of rear pulley by pulling
backwards on bottom run of belt. Pull belt
straight back to get an accurate reading. Check
that belt is running about 0.030” from flange on
rear pulley. Belt may ride next to flange as long
as it’s not trying to climb.
5. Tighten socket head screws (8) that hold adapter
plates to swingarm and torque to 35 ft. lbs.
6. Once tracking is obtained, re-check belt tension.
Raise and lower differential assembly slowly with a jack while checking belt tension. When tightest
position is located, apply 10 lbs. force at midpoint of lower strand of belt. Correct deflection for
various models is as follows:
7. Increase or reduce belt deflection by turning adjuster screw on each side in or out an equal number
of turns.
8. Look along top of belt to check belt alignment on front pulley. There should be about 0.030” clear-
ance between pulley flange and belt. Check rear alignment and belt tension again if adjustment is
required.
NOTE: If necessary, apply chalk to edge of belt to aid in getting proper clearance between
belt and pulley flanges. If visible clearance cannot be obtained, be sure belt is not climbing
up the side of pulleys or squeaking as belt is rotated.
9. After all adjustments are made, tighten adjuster lock nuts and tighten pinch block bolts. Tighten
pinch blocks in a criss-cross pattern. Go over both sides at least 2 times to seat blocks over pins.
Torque bolts to 25 ft. lbs.
MODEL INCHES MILLIMETERS
FLHX 1/4-5/16 6.4-7.9
All other FLH models 3/8-7/16 9.5-11.1
BELT TENSIONING AND TRACKING
18
Fig. 1

2009-2013 FLH RENEGADE
Disc Brakes
CAUTION: Brakes are a critical safety compo-
nent of the trike. Verify all brake components
have been properly installed before test riding.
Improper brake operation could result in death
or serious injury. Do not allow dirt or debris to
enter master cylinder reservoir. New brake
pads and rotors will have a break-in period be-
fore optimum brake operation is achieved.
Note: FOR ABS DISABLE, SEE PAGE 21
Brake System
1. See Fig. 1. Attach brass tee to differential
brace using the following hardware.
• (1) Brass Tee– CF5105
• (1) Spacer– S001530
• (2) 1/4” x 1-3/4” Hex Bolt– CB1100
• (2) 1/4” Flat Washers– CW2005
• (2) 1/4” Lock Nut– CN3042
2. See Fig. 1. Install original brake line from
master cyclinder and rear braided lines to
brass tee using the following hardware. Torque
banjo bolt to 16 ft. lbs.
• (1) Banjo Bolt– S002022
• (2) Banjo Washers- GC6002
• (2) 45” M10 Braided Line– S001976
3. See Fig. 2. Install (2) braided brake lines to
rear calipers as shown. Torque bolts to 16 ft.
lbs.
• (2) M10 Banjo Bolt– CB6001
• (4) M10 Banjo Washers- GC6002
4. Secure brake lines to swingarm with cable ties.
BRAKE SYSTEMS
19
Fig. 1
Fig. 2
OEM line
Spacer
Install brake lines to LH/RH calipers

2009-2013 FLH RENEGADE
Note: Be sure you have correct model year res-
ervoir extension pack before proceeding
(Reminder: packs are labeled 1997-2007 and
2008+).
5. See Fig. 3. Remove original master cylinder
reservoir cap screws and discard. Install ex-
tension to master cylinder with new extension
screws. Do not over tighten extension
screws.
Note: Verify all brake lines and hardware are
tight before bleeding system.
6. Add brake fluid (refer to OEM reservoir cap for
brake fluid requirements) to brake system and
work brakes to fill lines.
7. Remove rubber caps on bleeder valves. Install
clear brake bleeder hose over bleeder valve on
caliper.
8. Pump brake pedal to build hydraulic pressure.
9. While holding the brake pedal, open bleeder
valve to release pressure and remove air from
system. Repeat bleeding on both calipers until
fluid is solid without bubbles in bleeder hose.
10. Tighten bleeder valves and check for leaks.
11. Install master cylinder reservoir cap with new
screws. Do not over tighten cap screws.
Park Brake Assembly
1. See Fig. 4. Install park brake cable to caliper
brackets. Secure cable to bracket with cir-clip
provided on cables.
BRAKE SYSTEMS CONTINUED
20
Fig. 4
Attach cable
Secure to bracket
Fig. 3
Supplied cover screws
Extension screws (2008+ pack)