lehman Trikes TRAMP 2009 Service Information

2009 SERVICE INFORMATION

SERVICE PROCEDURES

PARTS/PRICE LIST

FLAT RATE TIMES

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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

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FOREWARD

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 procedures 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.

taken in the preparation of this manual, Lehman Trikes damages resulting from the use of the information contained herein. Lehman Trikes 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 holders. Printed in the United States of America.

provides this publication as is without warranty of any kind, either expressed or implied. While every precaution has been

is a registered trademark. All other brands and product names are trademarks or registered trademarks of their respective

assumes no responsibility for errors or omissions. Neither is any liability assumed for

reserves the right to revise and improve its products

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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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SAFETY INFORMATION

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, bystander or person (s) inspecting or servicing the vehicle.

Indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE provides key information by clarifying instructions.

WARNING

CAUTION

NOTE:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

IMPORTANT:

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R & R AXLE BEARING

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.

Axle flange retaining nuts

Remove and discard locking collar

Fig. 1

Fig. 2

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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 installing. 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. Possible axle seal failure and contamination of rear brake linings can occur. Check differential 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.

R & R AXLE SEAL

Axle flange retaining nuts

Axle seal

Fig. 1

Fig. 2

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R & R BODY

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 operator seat behind battery.

6. See Fig. 1. Remove footpads (See R&R Passenger 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 remaining body mount bolts from top chrome rail.

NOTE: Get help to support body while removing the last two bolts.

12. Carefully remove body and set safely aside.

REPLACEMENT CAUTION: Use caution when adding equipment 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.

Remove footpads

Remove front body mount bolts

Remove back (2) bolts

Fig. 1

Fig. 2

Fig. 3

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3. Insert (2) original fender washers saved from disassembly to inside frame rails (front location).

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 buttonhead 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.

R & R BODY CONTINUED

Attach front section first

Taper faces inward

Fig. 4

Front fender brace bolts

Fig. 5

Hook rear section into place

Fig. 6

body mount bushing

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9. Center body to motorcycle using a fram er’s square.

10. See Fig. 7. Obtain a height measurement for both sides, adjusting body until equal measurements are obtained on both sides.

11. See Fig. 8. Obtain a center-to-center measurement for both sides, adjusting body until equal measurements are obtained on both sides.

12. See Fig. 9. Obtain a front-to-back measurement for both sides, adjusting the body until equal measurements are obtained on both sides.

13. The body has been centered when all measurements are within 1/8” of each other.

R & R BODY CONTINUED

Obtain same measurement for both sides + or - 1/8”

Fig. 7

Fig. 8

Obtain same measurement for both sides + or - 1/8”

Fig. 9

Obtain same measurement for both sides + or - 1/8”

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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, making 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

Fig. 10

Front body mount bolt

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BRAKE BLEEDING

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 prevent 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 surf ace into brake bleeder hose.

Note: Maintain fluid level in reservoir to prevent more air from entering brake system.

12. Clos e ble eder sc re w 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 system.

15. F ill res erv oir with brake fluid to within 1/8” from top.

16. Install reservoir gasket and cover by handstarting screws.

Remove reservoir cover

Fig. 1

Fig. 2

Fill reservoir with DOT 4 brake fluid

Fig. 3

Bleeder screw

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R & R REAR BRAKE SHOES

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 reinstall chrome fork w ith 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. 1

White spring

Fig. 2

Chrome fork and spring

Fig. 3

Remove hold-down springs

Green spring

Red spring

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lehman Trikes TRAMP 2009 Service Information

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY INFORMATION

Axle seal

BRAKE BLEEDING