2010+ Victory Cross Country / Cross Roads Installation Guide Nov 2014

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1 2010+ Victory Cross Country / Cross Roads Installation Guide Nov Industrial Drive Spearfish, SD Toll Free 888.3WHEELS w w w. l e h m a n t r i k e s. c o m

2 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! WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person (s) inspecting or servicing the vehicle. CAUTION Indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. 2

3 General 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. Verify that you have all components before assembly. Before installing your new Lehman kit, we recommend that your motorcycle be inspected and serviced by a qualified technician. Replace any worn or damaged parts before installing the trike kit. If the motorcycle has more than 12,000 miles, Lehman Trikes recommends installing a new drive belt during the trike conversion. CAUTION: This kit is not designed for use on lowered motorcycles. Interference between the tires and body may occur. Overall Width 57.75" Overall Length (w/ EZ Steer) 106" Wheel Base (w/ EZ Steer) 67" Curb Weight 1170 lb Rear Tire Size 205/70 15 Rear Wheel Size 15x7, 4x4.5, +35mm Offset Rear Tire Pressure 26 PSI Rear Suspension Double A Arm Independent Storage 5 Cubic feet 3

4 Disassembly NOTE: Refer to the Victory service manual for detailed instructions on removal of OEM parts. 1. Load motorcycle on lift and secure front wheel. 2. Place motorcycle on center stand or scissor style jack. 3. Disconnect negative battery cable. 4. Remove seat, save mounting hardware. 5. Remove side covers. NOTE: Save tour box mounting hardware 6. Disconnect wiring and Remove tour box. (if equipped) 7. Remove saddlebags (if equipped). 8. Remove saddlebag frames (if equipped). 9. Remove antenna and wiring. Plug is located behind front fairing (Can be removed during EZ Steer installation if applicable) 10. Remove mufflers and rear heat shields. 11. Remove rear wheel. 12. Disconnect rear brake line at caliper and remove caliper. 13. Remove rear fender. 14. Remove passenger floorboard assemblies, save hardware. NOTE: See. for steps Remove shock linkage from swingarm. 16. Remove swingarm pivot shaft and remove swingarm. Save pivot shaft and hardware. 17. Remove shock from motorcycle frame. NOTE: See Fig. 2. The Lehman differential is preassembled for shipping purposes. Swingarm, rear frame and top frame must be removed for belt installation. RH park brake cable must also be disconnected from the balance bar. Top Frame Fig. 2 Rear Frame Swingarm 4

5 ABS Pump Relocation ABS Models Only 1. Remove ABS Pump mounting hardware from frame. Do not remove front brake lines from pump. 2. Remove mounting bracket from pump. Remove grommets and spacers from bracket. 3. See. Remove entire rear brake line assembly from motorcycle. Disconnect line at master cylinder and ABS pump. Front brake line assembly ABS Pump 4. See Fig. 2. Install original grommets and spacers to new ABS pump bracket as shown. Fig. 2 Install grommets and spacers to Lehman ABS pump bracket 5

6 5. See Fig. 3. Install new bracket to ABS pump using original hardware. (1) ABS Bracket S See Fig. 4. Install banjo bolts, spacers and washers to block off rear brake line ports on pump. Torque banjo bolts to 16 ft-lbs. (2) Banjo Bolts CB6001 (4) Banjo Washers- CGC6002 (2) Spacer S Set pump assembly above frame until differential assembly is installed. 8. Apply ABS Disabled sticker over ABS light on instrument cluster. Fig. 3 Fig. 4 Block off ports for rear lines 6

7 Swingarm Installation 1. See. Apply grease to plastic bushings and press into swingarm. Insert steel sleeves in bushings. 2. See Fig. 2. Install swingarm to motorcycle and slide the pivot bolt though. Place two OEM washers on the RH side as shown below. 3. See Fig. 2. Reattach both floorboards supports with OEM hardware in lower holes. For the LH side, Torque the lower 8mm screw to 19 ft-lbs. For the RH side, attach the floor board and torque the lower 10MM screw to 35 ft-lbs. Place the OEM washers and nuts onto the pivot bolt. Hand tighten pivot hardware. Fig Item # Description Part # QTY 1 OEM Nut OEM 2 2 OEM Washer OEM 4 3 Sleeve S Bushing S Swingarm S OEM Pivot Shaft OEM 1 7

8 Top Frame Installation 1. See. Mount Top Frame to the motorcycle sub-frame using the hardware indicated below. Torque hardware to 19 ft-lbs evenly across all screws. (2) M8x35 Hex Bolt CB1622 (2) M8x40 Socket Head Bolt CB1975 (4) M8x45 CB1986 (8) M8 Lock Washers CW2168 (8) M8 Flat Washers CW2167 M8x40 SHCS w/ Flat and Lock Washer M8x45 SHCS w/ Flat and Lock Washer M8x35 Hex Bolt w/ Flat and Lock Washer 8

9 Differential Installation 1. See. Remove 3 of the 4 cross tubes as shown below. Front Leave front lower tube installed 2. Pass drive belt over differential assembly and position onto rear pulley. 3. Reinstall the cross tubes and spacers. Apply anti seize to all bolts and torque the 3/4 x 2-1/2 hex head screws to 150 ft-lbs. Torque the 1/2 x 2-1/4 hex head cap screw to 50 ft-lbs. 4. Guide differential under rear motorcycle frame while reinstalling belt past swingarm and onto front drive pulley. 5. See Fig. 2. Attach body mounts to top frame using the 3/8 x 1-1/4 hex head cap screws. Torque to 45 ft-lbs. Fig. 2 3/8 x 1-1/4 Hex Bolts w/ Flat Washers and Lock Nuts Top frame Body mount 9

10 Rear Frame and Swingarm 1. See. Position lower rear body frame inside of swing arm and install the 1/2 bolts through the mounting holes. (4) 1/2 x 3-1/2 Hex Head Bolts CB2178 (8) 1/2 Washers CN3060 Swingarm Rear Frame 2. See Fig. 2. Attach the adjuster plate to swingarm as shown with adjuster bolt in place. Torque adjuster plate mounting hardware to 45 ft-lbs. (2) 3/8 x 1-1/4 Hex Head Bolts CB2018 (2) 3/8 Flat Washers CW2180 (2) 3/8 Lock Nuts CN See Fig. 3. Leave approximately a 1/16 gap between the top of the stud and the face of the nut for both sides on swingarm pivot shaft. It is critical to have correct spacing. Torque pivot shaft nuts to 85 ft-lbs. 4. The floorboards need to be swapped with the opposite side such that the LH floorboard will be in the reversed position on the RH. Torque the replace RHS to 18 ft-lbs. Do not attach the floorboard onto the LHS. The park brake will need to be installed which is later in the instructions. 1/16 Gap Fig. 2 Aduster bolt Attach plate to Swingarm Fig. 3 10

11 Align and Tension Drive Belt 1. Set the belt tension and alignment by moving the independent drive train unit forward or rearward as necessary using the adjuster bolts. Belt tension can be measured by total vertical movement and should be approximately ¾ -1 with a new belt. Tip: Measure from the bracket to the face of the drive train on each side to get the alignment close. Then perform the next step. 2. To check the alignment, turn the sprocket by hand in the forward direction, noting whether the belt runs in the center of the pulley. If the pulley runs on the right side plate of the pulley, use the right hand adjuster bolts to move the right wheel rearward until the belt runs in the center. If the belt runs on the left side plate of the pulley, use the left adjuster bolts to move the left wheel rearward. Make small adjustments and recheck the alignment. 3. Once the belt is aligned, torque the four front 1/2" fasteners to 70 ft-lbs and double check belt alignment. If alignment is off, please repeat alignment process. Tighten all fasteners left loose for belt adjustment. Torque the four rear ½ fasteners to 70 ft-lbs. 4. Recheck belt tension and alignment after tightening the fasteners. 5. If belt is off to right or left go back to step 2. Belt Centered 11

12 Install Anti-Roll Bar 1. See. Install Anti-Roll Bar with the short side on the LH side of trike as shown below. Longer Side on RHS (10.80 Approximately) Shorter Side on LHS (10.42 Approximately) 2. See Fig. 2. Install hardware through anti-roll bar housing onto swingarm. Position the anti-roll bar on the frame so that the rod ends will be close to vertical when attached to the control arms. Torque hardware to 45 ft-lbs. (4) 3/8 x 1-1/4 Hex Head Bolts CB2018 (8) 3/8 Flat Washers CW2180 (4) 3/8 Lock Nuts CN

13 3. See. Attach rod-end to right control arm with the included hardware in the following order: 3/8 x2-1/4 bolt, washer, rod-end, washer, control arm, washer, and then nut. Torque to 45 ft-lbs. (2) 3/8 x 2-1/4 Hex Head Bolts CB2001 (6) 3/8 Thin Flat Washers CW2182 (2) 3/8 Lock Nuts CN Adjust left side rod-end until it aligns with the left control arm mounting hole. 5. Tighten jam nut on the left side rod end assembly. 6. Attach rod end to left control arm just as was done to right control arm. Torque to 45 ft-lbs. Brakes 1. See. Assemble the new brake lines and residual valve and install as shown using the following hardware. Route front of new brake line to master cylinder in original location. (1) Rear Brake Line, 29 - S (1) Front Brake Line, S (1) Residual Valve- GB1146 (2) Clamps S Residual Valve Front line/clamp Front line/clamp 2. See Fig. 2. Attach front brake line to master cylinder with brake light switch. (1) Brake Light Switch S (2) Banjo Washers GC6002 Fig. 2 Line OEM Master Cylinder Switch 13

14 3. Route new brake light switch wiring to original brake light switch connector on LH side of motorcycle and connect See Fig. 3. Attach brake block to bolt on swing arm using 1/4 locknut and washer. Torque to 11 ft-lbs. Connect both rear brake lines to t-block. (1) Brake Block S (1) 1/4 Flat Washer CW2005 (1) 1/4 Lock Nut CN See Fig. 4. Route the rear brake line around the LHS passenger floorboard as shown below. Attach the rear line to the brass block on swingarm. Torque banjo bolt to 16 ft-lbs. (1) Banjo Bolt CB6001 (2) Banjo Washers GC See Fig. 5. Verify new brake reservoir housing is assembled as shown. (1) Reservoir Bracket S (1) Reservoir Tank S (1) Cap S (1) Tank Mount S (2) M6 x 1 Flange Head Screws CB1905 (2) M6 Flange Lock Nut CN1902 Fig. 3 Fig. 4 Rear brake line Fig. 5 Tank Tank Mount Bracket 14

15 5. See Fig. 6. Install new reservoir assembly to original bracket on motorcycle. New bracket will mount to the inside of the existing bracket with star washer between the two brackets. (1) M6 x 1 Flange Head Screws CB1905 (1) M6 Flange Lock Nut CN1902 (1) Star Washer CW See Fig. 6. Install new rubber hose between reservoir and master cylinder. Secure with clamps on each end. (5 ) 5/16 Brake Hose CH2016 (2) Clamps- CC See Fig. 7. ABS Models Only- Finish mounting ABS pump to the top frame using the original hardware. Secure lines and wiring to frame. 7. Use the specified brake fluid in the owner s manual and bleed the rear brake system. Thoroughly bleed the system of any air using the upper bleeders and lower bleeders on rear brake caliper. OEM bracket Fig. 6 Fig. 7 Secure wiring to upper frame 15

16 Park Brake 1. See. Verify park brake cables are routed in front of rubber body mounts and secured to upper A-arms on both sides. 2. See Fig. 2. Verify cables are secured to balance bar as shown. Fig. 2 16

17 Exhaust Installation 1. See Fig s. 1 & 2. Install exhaust extensions onto OEM header pipes (longer extension is used on the LHS). Reuse the factory clamps plus additional clamp provide for RH side. Keep all the clamps slightly loose until the mufflers are installed. (1) Exhaust Clamp S (1) RH Exhaust Extension S (1) LH Exhaust Extension S Fig. 2 LH Side RH Side 2. See Fig. 3. Install muffler brackets to body mount frame with rubber isolators as shown. Tighten the nuts until a few threads of the bolts are visible. (1) RH Muffler Bracket S (1) RH Muffler Bracket S (6) Muffler Isolators S NOTE: See Fig. 3. Verify rear body mounts are installed before mounting mufflers. Fig. 3 Make sure rubber body mounts are installed before mounting mufflers. 17

18 3. See Fig. 4. Place mufflers over exhaust extensions with clamps in place. Attach mufflers to brackets using the original flange head bolts. Torque hardware to 20 ft-lbs. Fig Adjust the extensions and mufflers until the best fit is achieved. Make sure the mufflers are at the same angle relative to the body frame otherwise the gap around the muffler to the body may differ. Torque the OEM exhaust clamps to 35 ft-lbs. Fig See Fig. 5. Trim both heat shields. Cut RH heat shield shown shields behind rear clamp as shown. 6. See Fig. 6. Bend front tab on LH heat shield as shown. 7. Reinstall heat shields in original locations. Remove rear section from shield Fig. 6 Before After 18

19 Side Panel Modification 1. See Fig s 1 & 2. Trim both LH and RH side panels to fit around sway bar. Keep both panels loose on the Trike after cutting. Fig. 2 RH panel shown RH panel shown Grab Handle Installation 1. See Fig. 3. Mount grab handles to body using the following hardware. Install spacers between handles and body. (2) Grab Handle S (4) Grab Handle Spacer S (4) 5/16 x 1-1/4 Button Head Bolt CB1163 (4) 5/16 Fender Washer CW2109 (4) 5/16 Lock Washer CW2046 (4) Rubber Washer FG

20 Body Installation NOTE: The installation /alignment of the body is an important process to find the correct position of the body in relation to the wheels. The pre-drilled holes in the body are for shipping purposes. Re-drill the holes if necessary once the body is properly aligned. NOTE: Verify steps 1-4 are complete before installing body to trike. 1. See. Verify park brake cables are routed in front of rubber body mounts and secured to upper A-arms on both sides. 2. See Fig. 2. Verify cables are secured to balance as shown. 3. See Fig. 3. Verify all the rubber body mounts are in place before installing body. The three rear mounts should be loose. (7) Body Mounts S Verify wire harness and taillights are installed and secure. Taillights are mounted with the following hardware. (8) M4 x 8 Socket Head Screws CB1704 (8) #6 Stainless Flat Washers CW2086 (2) Taillights S (2) Taillight Grommets- GG0011 (1) Crossfire Wire Harness S Carefully position the body to the trike frame. Secure the body with the following hardware (original shipping hardware). Tighten hardware evenly to 20 ft-lbs. (7) 3/8 Fender Washers CW2180 (7) 3/8 Thin Locknuts CN3055 Fig. 2 Cables installed Fig. 3 20

21 5. See Fig. 4. Attach balance bar to front of body as shown using the following hardware. Bolt head, fender washer and rubber washer should be installed from inside the trunk with flat washers and lock nuts on the bracket side. (3) 1/4 x 1-1/4 Hex Head Bolts (3) 1/4 Fender Washers (3) 1/4 Flat Washers (3) Rubber Washers FG1002 (3) 1/4 Lock Nuts 6. See Fig. 5. Attach park brake bracket to LH passenger floorboard. Install bracket between OEM parts. (1) Park Brake Bracket- S See Fig. 6. Adjust park brake calipers as needed. Verify the hand lever is in the down position. On each caliper hand tighten the adjuster bolt until it contacts the pivot arm, then back off half a turn. Tighten the jam nut to lock the adjuster bolt in place. 8. Test the park brake operation and adjust the balance bar and calipers as needed. Verify that the wheels are able to rotate freely when the park brake is disengaged. 9. Install the boot over the hand lever. 10. Once final brake adjustments are made, install rear wheels and torque to 85 ft-lbs. Fig. 4 Fig. 5 Park brake bracket Fig. 6 Adjuster Bolt 21

22 Trunk Door 1. See. Install door seal to body as shown. Start seam in bottom center of trunk opening with lip on seal facing outward. (5 ) Door Seal CW Install door to hinges using the provided Phillips head screws. Adjust door as need and tighten all hinge hardware. 3. Wire license plate light to door matching the following wires. Place excess wiring inside door. (1) License Plate Light S Black wire (-) on door to Black wire on light Blue wire (+) on door to Red wire on light 4. See Fig. 2. Install license plate light to door. Screws are included with light assembly. 5. See Fig. 2. Install license plate to door using the following hardware. Install Spacers between rubber insert and license plate. (2) Rubber Inserts CN2103 (2) 1/4 Spacers S (2) x 1 Button Head Screws- CB2016 (2) #10 Flat Washers CW See Fig. 2. Install trunk lock to door. (1) Trunk Lock S See Fig. 3. Install badges to body below trunk door as shown. (1) Lehman Badge S (1) Crossfire Badge S (1) LLS Badge GB See Fig. 4. Install terminals and connector to wiring on inside of door and connect to main harness inside trunk. Match colors from door wiring to main harness. Secure harness to LH door hinge with cable ties as needed. (2) Female Terminal GH (1) Male Connector GH (5) 5 Cable Tie CT1014 Fig. 2 Plate Mounting Fig. 3 Fig. 4 Lock Light 22

23 Tour Box Installation Touring Models. 1. See. Install tour box mounting brackets to top frame as shown using the following hardware. Hand tighten hardware until box is mounted. (4) M8 x 25 Socket Head Bolts CB1989 (4) M8 Flat Washers CW2165 (4) M8 Lock Washers CW See Fig. 2. Install tour box to brackets using the original mounting hardware. Plug tour box wiring into main harness and secure wiring as needed with cable ties. 2. Tighten all tour box mounting hardware. 3. See Fig. 3. Plug trike body harness into main OEM harness. Verify wiring is routed on RH side of motorcycle frame. Secure harness to frame as needed with cable ties. 4. See Fig. 3. Route ground wire from harness module to RH gas tank mounting bolt as shown. 5. Route power wire under RH side of gas tank with OEM wiring. Continue down LH front frame rail and install to positive battery terminal. Secure power wire with cable ties as needed. 6. Install seat using original mounting hardware. 7. Install modified OEM side covers. Fig. 3 Tour Box brackets Fig. 2 Route power to battery under tank on LH side Place module in frame Connect to OEM harness Connect ground to tank 23

24 Hidden Antenna Installation Fairing models Note: Antenna may be installed during EZ-Steer installation if applicable. 1. See. Carefully remove outer headlight trim on fairing. 2. See Fig. 2. Remove headlight mounting hardware and carefully remove headlight from fairing. Unplug headlight connectors from backside of light. 3. See Fig. 3. Unplug OEM antenna connector located in upper LH side of fairing. Install hidden antenna to OEM connector. Clean inside of fairing were hidden antenna will mount. Remove protective tape from antenna and install on inside of fairing along the top. 4. Test radio operation and reinstall headlight and trim. Remove trim Fig. 2 Fig. 3 Install antenna along inside of fairing 24

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