Gl1500 LI1062 Mar14, 03 PARK BRAKE 25. Honda Goldwing GL1500 GTL - 14 Mar. 03 Lehman Trikes Inc. - 3-Instruction Part # LI1062 ... Honda Goldwing GL1500 GTL ...

GTL

Installation Instructions

Will fit all Goldwing GL1500 modelsFrom 1988 to 2000

Honda Goldwing GL1500 GTL - 14 Mar. 03

Lehman Trikes Inc. - 2 - Instruction Part # LI1062

Table of Contents

SECTION PAGE

A. INTRODUCTION/GENERAL INFORMATION 3B. UNPACKING YOUR KIT 4C. PREPARING THE MOTORCYCLE 5D. INSTALLING THE LEHMAN SWINGARM 7E. MODIFYING THE DRIVE SHAFT 11F. INSTALLING THE DIFFERENTIAL 12G. INSTALLING THE SUSPENSION 14H. INSTALLING THE LEHMAN FRAME 14I. MODIFYING THE MUFFLERS AND INSTALLING EXHAUST SYSTEM 17J. CONNECTING THE BRAKE LINE 18K. ADJUSTING AND BLEEDING BRAKES 18L. ADJUSTING THE STEERING STEM 19M. INSTALLING THE GTL BODY AND WIRING 20N. INSTALLING THE REAR FRAME AND TRAVEL TRUNK 24O. REPLACEMENT PARTS 25

SUPPLEMENTS

OPTIONAL PARK BRAKE25



A. INTRODUCTION/GENERAL INFORMATION

Statements in these instructions preceded by the words WARNING, CAUTION, orNOTE and printed in bold face are very important.

** WARNING **Indicates a strong possibility of severe personal injury or loss of life if instructionsare not followed.

** CAUTION **Indicates a possibility of personal injury or equipment damage if instructions arenot followed.

** NOTE **Gives helpful information to make a step or procedure easier or clearer.

Throughout these instructions "Front" or "Forward" refer to the front of the bike. Thefront of any component 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.

Most of the procedures covered are straightforward and can be performed by anyonereasonably handy with tools. A few steps will require special skills. These should only bedone by qualified personnel.

These instructions do not include information, specifications, or procedures relating tothe motorcycle itself. For this information refer to the factory service manual, or a manualfrom one of the specialty publishers.

The information in these instructions is provided to Lehman Trike dealers, andpurchasers of Lehman Trike kits. It is proprietary to Lehman Trikes, Inc. and providedsolely for the use of kit purchasers or dealers. Any unauthorized duplication or distributionis a violation of international copyright law.



B. UNPACKING YOUR KIT

The crate contains the following:1. The body.2. The differential with brakes and wheels mounted. THE DIFFERENTIAL IS SHIPPED DRY.3. Boxed swingarm.4. Shock rod.5. Lehman frame.6. Hardware box containing smaller parts and bolt bags 7. Box containing optional shock absorbers.8. Warranty Book.9. Owners Manual.10. Packing/parts list

The contents of the crate can be more easily removed by removing one side of the boxafter the top is off. One side is held on with 9 screws. Three screws are located near thebottom, and 3 on each end.

** NOTE **IF YOUR KIT IS INCOMPLETE OR DAMAGED, PLEASE CONTACT LEHMANTRIKES. ASK FOR THE CRATING DEPARTMENT.



C. PREPARING THE MOTORCYCLE

1. Place the motorcycle on the center stand.2. Remove the right rear side cover and disconnect the battery.3. Remove the seat (4 socket head bolts)4. Remove the passenger floorboards. Disconnect the adjuster cables at the floorboard

(if equipped). Remove the bracket covers, passenger footrests, and holder covers.5. Remove the trunk lower cover (4 screws). Disconnect the wiring connectors. Remove

the trunk (4 bolts). Disconnect saddlebag latch cables in the bags.6. Remove the tool kit and mounts from the left saddlebag.7. Remove the left rear side cover and both front side covers.8. Remove any bumpers or accessory rails around the bags. Remove the saddlebag

lower covers.9. Remove the tail lights (3 nuts inside the bags)10. Remove the saddlebags. Take out the rubber grommets for the side covers.11. Remove the license plate bracket and rear fender.12. Remove the rear saddlebag guards.13. Loosen the clamps and take out the mounting bolts to remove the mufflers. Take the

metal inserts and rubber bushings out of the saddlebag supports.14. Disconnect the rear light harness (taillights, brake lights etc). Disconnect the modules

on the inner fender at the connectors.15. Remove the helmet holders and license plate light.16. Disconnect the airline at the right shock. Unplug the air system connectors.17. Take out two 10mm bolts and remove the Honda rear frame with inner fender and

compressor included.18. Remove the compressor and plastic inner fender from the rear frame. Strip the inner

fender of compressor and control modules.19. Remove the rear shock absorbers.20. Remove the union bolt at the rear calliper. Take out the bolts and free the rigid section

of line from the swingarm. Block the fitting to prevent fluid loss.21. Drain the final drive; remove the axle, calliper and rear wheel assembly.22. Remove 4 nuts and disengage the final drive. Take the drive shaft out of the rear

coupling.23. Remove the battery and the battery box to access the reverse resistor assembly and

remove it.24. Pull the rubber joint cover off the transmission. Loosen the lock nuts and back out the

socket head pins to remove the swingarm. 25. Take the reverse and auto cruise units from their mounting tabs and remove the front

inner fender. 26. Carefully using a chisel, remove the reverse resistor mounting bracket from the

exhaust chamber heat shield.



27. Remove the side stand. Tape the switch securely in the 'up' position (continuitybetween green/white and green wires), and secure it to the lower frame with a nylontie.

28. Mark the rear frame and cut off the saddlebag mounts and compressor mount. Grindor file your cuts smooth and touch up the paint.



D. INSTALLING THE LEHMAN SWINGARM

1. Stick a straight rod through the swingarm pivot on the motorcycle frame. Use a spiritlevel on the rod between the frame rails on the bike and shim under the center standuntil level. Locate a place on the frame under the seat to use as a reference point thatis the same as the (level reading) at the swingarm pivot. Place shims between theframe and the level if needed to match it to the pivot reading.

2. Install the rubber drive shaft cover on the front of the swingarm.3. Start the Lehman swingarm pins into the motorcycle frame. Use anti-seize compound

or a light film of grease on the threads and on the end of the bearings.4. Install the Lehman swingarm and use Snap On A26 Drag Link Socket or similar to

tighten the pins. Center the swingarm in the motorcycle frame. Make sure the pins arefully seated in the bearings.

5. Move the swingarm up and down several times to make sure it is free. Check theclearance to the sides and tighten the pivot bolts so there is no lateral play in the ballbearings.

** CAUTION ** CARE MUST BE TAKEN NOT TO OVER TIGHTEN THE PIVOT BOLTS. THE

FRAME MAY BE DISTORTED AND STRESSED. TIGHTEN THE BOLTSENOUGH TO SEAT THEM IN THE BEARINGS, THEN ADJUST TO ELIMINATESIDE PLAY.

7. Remove the rubber grommets (2 on

each side) from the frame above theswingarm pivot bolts. Clean the paintfrom the motorcycle frame around theswingarm pins. Clean an area largeenough for the frame support washers tocontact bare metal.

8. Loosely install the frame supportwashers, cups and lock nuts. The bevelon the washer is next to the lower frametube. Check the clearance between thewasher and the frame.



9. It will vary (usually more at the bottom). There must be at least 0.002" and nomore than 0.030" clearance all aroundthe washer when the lock nut pushes thecup against the washer. If there is noclearance, use a thin shim between thesmall end of the cup and the frame. Machine, file, or lap the small end of thecup if the clearance is too great.

10. In some cases the Gold Wing frame is not flat enough to achieve the minimumclearance of 0.002" to the support washer without exceeding the maximum of 0.030"somewhere else around the washer. In these situations the adhesive will not bridgethe wider clearance and still provide a strong bond.

11. It is essential that minimum/maximum clearances are achieved with the supportwasher wedged out flat against the cup. The washers may be hand fitted as follows.

12. Mark the washer at 12:00 o'clock with the chamfered edge located over the lowerframe tube.

13. Install the cup and use the Honda nut to hold the cup against the washer.14. Wedge the washer away from the frame so it is flat against the cup.15. Measure and record the

clearance to the frame at 12, 3,6, and 9 o'clock.

16. Remove the nut, cup, and washer. Machine, file orcarefully grind the washer onthe frame side to achieve thesame clearance all around.

** NOTE **

IF THE CLEARANCE IS AS FOLLOWS: TAKE OFF

12 O'CLOCK 0.010" 0.060" AT 12 O'CLOCK3 O'CLOCK 0.030" 0.030" AT 3 O'CLOCK6 O'CLOCK 0.060" NONE AT 6 O’CLOCK9 O’CLOCK 0.030" 0.030 AT 9 O'CLOCK17. If the clearance exceeds 0.030”, machine, file or lap the small end of the cup to

achieve clearance between 0.002” and 0.030” all the way around the washer.



18. When the clearance is within limits, use LOCTITE 330 adhesive to bond the washer tothe motorcycle frame. Apply the adhesive and install the washer, cup and lock nut.

19. Use small screwdrivers or similar aswedges to hold the washer away from theframe against the cup.

20. Let the adhesive cure 24 hours with thewedges in place as you continue theconversion.

21. When the adhesive is cured, remove thewedges and check again for full contact. Remove the cups. Identify them so they goback on the same side.



22. Machine, file or lap 0.002" to 0.005”from the small end of the cups toachieve proper crush.

23. Use LOCTITE 242 Thread Locker onthe lock nuts. Hold the pivot bolts while tightening the lock nuts to 150 foot pounds (useHonda Pivot Lock Nut Wrench 07908-469001.) The torque on this wrench is multipliedso torque value from the 3/8 square is 135 foot pounds.)

24. Touch up any areas around the washers where the paint was taken off. The cup andwasher must also be painted to prevent rust.

25. Install the rubber grommets back in the frame.

If MIG welding equipment and qualified personnel are available, the washers may bewelded to the Gold Wing frame.

** WARNING **WHEN WELDING IN THE SWINGARM AREA, REMEMBER THAT THE FUEL TANKON THE GOLDWING IS BELOW THE RIDER SEAT. ENSURE THAT THE BATTERY

IS DISCONNECTED.

** CAUTION **THE MATERIAL IN THE MOTORCYCLE FRAME IS VERY THIN IN THIS AREA ANDCAN BE EASILY BURNED THROUGH. MIG WELDING IS RECOMMENDED FOR

LOWEST HEAT AND BEST CONTROL.

1. Make sure the frame is free of paint and clean.2. Wedge the washer against the cup.3. Weld about five 3/4" beads, evenly spaced around the washer. We do not recommend

welding all around the washer.



E. MODIFYING THE DRIVE SHAFT 1. Remove the c-clip, ring, and spring from the motorcycle driveshaft. Install onto the

driveshaft supplied with the conversion kit. 2. Assemble the universal joint into the rear yoke. The grease fitting should face towards

the driveshaft. 3. Push the yoke onto the splined end of the driveshaft without the spring. 4. Grease all of the internal splines on the Honda motorcycle yoke. Install onto the drive

shaft, ensuring that the centers of the universal joints are aligned in phase as close as ispossible. (Centers may not exactly line up). Do not grease splines on rear of shaft orsplined rear yoke.

5. Check that there is approximately 15-3/8” between the universal joint centers when theHonda yoke is resting against the spring.

6. Install the drive shaft into the swingarm tunnel and onto the motorcycle transmissionshaft.

** CAUTION **THE SPRING ON THE DRIVE SHAFT MUST HOLD THE FRONT JOINT FULLYONTO THE TRANSMISSION SHAFT.


Lehman Trikes Inc. - 1 2 - Instruction Part # LI1062

F. INSTALLING THE DIFFERENTIAL

1. Support the Lehman differential under the rear of the motorcycle.2. Move the differential forward until the plates on the differential contact the plates on the

swingarm. Loosely install the eight cap screws, washers, and nuts. If park brake is tobe installed, bolt up bracket at this time.

3. Use a spirit level across the frame in the seat area to check that the bike is still level. Shim under the center stand to level. Use a plumb line from the hole in the tab on therear frame cross tube and measure to a straight edge off the axle flanges. Center thedifferential and tighten the eight cap screws. Level diff side to side as much aspossible with the play in the bolt holes.

4. Raise the differential to provide clearance over the shield on the exhaust chamber sothat the drive shaft may be installed.

** NOTE **

A SINGLE WRAP OF MASKING TAPE ON THE SPRING AND THE JOINT WILLHOLD IT IN PLACE DURING INSTALLATION. THE TRANSMISSION SHAFT WILLNOT TURN IF THE BIKE IS IN GEAR AND THE DRIVE SHAFT CAN BE TURNED TOENGAGE THE SPLINE. COMPRESSING THE SPRING TO POSITION THE REARJOINT ON THE DIFFERENTIAL WILL DISLODGE THE TAPE.



5. Working from the rear, install the drive shaft into the tunnel and onto the transmissionshaft.

** CAUTION ** THE SPRING ON THE DRIVE SHAFT MUST HOLD THE FRONT JOINT FULLYONTO THE TRANSMISSION SHAFT. THIS WILL ENSURE FULL ENGAGEMENT OFTHE SPLINE ON THE SHAFT INTO THE REAR OF THE FRONT JOINT AND KEEPTHE JOINT PROPERLY LOCATED IN LINE WITH THE PIVOT PINS. 6. Use 'U' bolts and lock nuts to connect the rear joint. ** CAUTION ** DO NOT OVER-TIGHTEN THE 'U' BOLTS. THE BEARING CUPS MAY BEDISTORTED, CAUSING PREMATURE JOINT FAILURE. 7. Grease the joint.8. Install the front rubber cover onto the transmission. 9. Fill the differential with 75W80 Hypoid Gear Oil. The correct level for theGL1500 is 1.25 litres (42 oz. USA).



G. INSTALLING THE SUSPENSION

1. Install the shock relocator brackets on the original shock studs. Use the original boltand washer.

2. Thread a 10mm x 1.25 x 50 bolt from the inside of the rear frame ears through the earsand then through the relocator brackets. Install the solenoid bracket on the right handbolt before threading it through the frame ear. The bottom edge with slot and hole istoward the center of the bike.

3. Mark the shock rod to locate the milled flats. Slide the shock rod through the relocatorbrackets. Center the shock rod and lock it in place by tightening the set bolts onto theflats. Tighten the jam nuts.

4. Use the washers supplied with the shocks and attach the shocks to the shock rod. Theair fittings point to the rear. Use 3/8 flat washer and lock nut to secure the shocks.

5. Use thin and thick washers as necessary to align the shocks and fill the spacebetween the differential shock tabs and the shock rubber. The shocks should bevertical plus or minus 1/16". The washers should just contact the rubber and not pinchit against the eye. Slide the hollow shock pins through the tabs, washers and shocks. Use 2-3/8 x 2 1/2 bolts, 4 flat washers and 2 lock nuts to hold the pins in the tabs. Install the bolts from the outside of the differential with the nuts to the inside for frameclearance. The shock rod can be moved slightly or the top washers moved to correctshock alignment.

6. If one shock is slightly longer, connect it first, and jack the rear end to connect the other.7. Use the instructions supplied with the shocks to connect the airlines.

H. INSTALLING THE LEHMAN FRAME



1. Install the rubber grommets from the saddlebags in the side cover brackets. Thesebrackets attach to the lower forward bolt for the Lehman frame.

2. Position the Lehman frame and use 4- M8 x 1.25 x 25 bolts to attach it to the rear lugson the motorcycle frame. Leave the bolts a little loose for now.

3. Place the GTL body on the frame. 4. Align the body with the motorcycle side covers. Adjust the height at the rear of the

frame for an even joint between the body and the side covers. Tighten the M8 x 1.25 x25 bolts and remove the body.

5. Attach the frame straps to the 10mm bolts at the back of the motorcycle frame. Checkthe rear frame to be level to the bike. One side is usually high. Clamp the strap to thetab on this (high) side and drill a 21/64 or 11/32 hole through the tab. Use 5/16 x 1 1/4bolt, 2 flat washers, and lock nut.



6. Loosen the M8 x 1.25 x 25 bolts and raise the low side to level the frame to the bike. Clamp, drill and bolt this frame strap. Tighten the M8 frame mounting bolts.

7. Attach a cross frame strap to the BACK of the tab on left shock relocator bracket. Thisstrap angles down to the right and attaches to the FRONT of the tab on the Lehmanframe.

8. Attach the other cross frame strap to the FRONT of the tab on right shock relocatorbracket. This strap angles down to the left and attaches to the FRONT of the tab on theLehman frame.

9. Drill 3/8 holes through the cross frame straps and use 3/8 x 1 1/4 bolts, and lock nuts toattach the cross straps.

10. The cross straps barely touch where they cross. Do not attempt to drill and bolt at theintersection.



I. MODIFYING THE MUFFLERS AND INSTALLING EXHAUSTSYSTEM

1. Fit the mufflers and mark the top where there will be interference with the differentialand swingarm.

2. Use a solid rod approx. 1 1/4” and a hammer to make clearance for the muffler as inthe diagram. Ensure the mufflers remain straight when mounted.

3. Check the fit and clearance and make any other necessary adjustments.4. Install the rubber muffler mount bushings and metal inserts in the muffler brackets.5. Attach the brackets to the mufflers with the original bolts. The brackets attach to the

outside of the frame with two thread cutting bolts. Position the mufflers level, pre-drillthe frame, and install the thread cutting bolts.

6. Tighten the clamps at the exhaust chamber.



J. CONNECTING THE BRAKE LINE 1. Spread the mounting clip on the front of the solid brake line, turn it over and squeeze it

back on. 2. Route the brake line along the swingarm. Use the tapping bolts and 1/4 flat washers to

attach the existing clips to the holes drilled in the swingarm. Make sure the brake linewill clear the bottom of the fuel tank as the swingarm travels.

3. Use a Honda OEM union bolt and sealing washers to attach the existing brake line tothe metric brass fitting block.

** WARNING **

KEEP THE LINE AND HOSE AS CLOSE TO THE SWINGARM AS POSSIBLE TOAVOID CONTACT WITH THE LEHMAN FRAME UNDER FULL SUSPENSION

TRAVEL.

K. ADJUSTING AND BLEEDING BRAKES 1. Install the brake drums and adjust the rear brakes. The brakes are adjusted manually

through the slot in the inside lower portion of the backing plate. Secure the drum to theaxle with some washers and two lug nuts. Set the brakes up until there is a definitedrag but the drums will still turn by hand.

2. Bleed the rear brake system with the bleed screws at the wheel cylinders. Bleed theleft front calliper as well.

** WARNING **THIS BRAKE SYSTEM WILL NOT SELF ADJUST. THE BRAKES SHOULD BEADJUSTED AT EVERY SERVICE OR WHENEVER THE PEDAL TRAVEL HASINCREASED.



L. ADJUSTING THE STEERING STEM

** WARNING **IMPROPER ADJUSTMENT OF THE STEERING STEM MAY CAUSE HANDLEBAROSCILLATION. STEERING HEAD BEARINGS MUST BE IN GOOD CONDITION,REGARDLESS OF MILEAGE. IF THERE HAS BEEN COLLISION DAMAGE, CHECKTHE STEERING HEAD FOR CRACKS, DEFORMATION AND MISALIGNMENT.

1. Remove the ignition switch cover and left and right top inner covers.2. Remove the handlebar clamps and lay the bars back on the tank.3. Remove the upper stem nut, loosen the pinch bolts and remove the top bridge.4. INCREASE the steering stem adjustment to 30 ft-lb.

** NOTE ** THE HONDA SPECIFICATION IS 14 FT-LB.

5. Install the top bridge, handlebars, inner covers, and ignition switch cover.



M. INSTALLING THE GTL BODY AND WIRING

**WARNING**To meet DOT and MOT requirements one of the following must be installed on all Lehman Trikes

(stock grab handles, stock grab strap or Lehman supplied grab handles). Product liability will notbe available for dealers not installing passenger grab handles. Please contact Lehman Trikes if

you require replacement grab handles.

** NOTE **WE RECOMMEND THAT YOU FIT THE GTL BODY (STEPS 9 TO 17) PRIOR TO

PAINTING.1. Identify the wires to the tail/brake lights on the original wiring harness. Plug extension

harnesses into the originals.2. Remove the inner panels at the back of each wheel well (5 screws)3. Feed the extension harnesses into the light pockets through the drilled hole in the

bottom of the pocket. You will have to remove the plug off the harness first.4. Install the taillights from inside the fender. Put the flat end into the recess at the side of

the inner trunk and rock the curved end into the cavity. Position the light in the bodyopening.

5. Reinstall the plug on the harness and connect the electrical plugs. Neatly coil theexcess harness under the tour pack and fasten away from any heat sources or movingparts that could cause damage to the harness. Fasten harnesses to the tabs attachedto the side of the trunk to keep them from getting damaged.

6. Align the inner panel over the studs on the light. Install the original nuts and 5 screwsand solder in the license plate light wires where most convenient in the harness.

7. Connect the wires in the trunk on the right side to the wires in the trunk door. Connectthe wires off of the license light to the wires in the trunk door. Solder and insulate theconnections and install the light with 2 screws. With the fibreglass body it does notmatter which way you connect the wires.

8. Position the holder covers and passenger footrests and start the bolts into the bikeframe.

9. Mark and cut out the top lip of the holder cover to clear the frame cup. Trim off thebosses on the inside front to clear the cup and frame support washer.

10. Temporarily install the holder covers and passenger footrests. 11. Place the body on the frame.12. Install the rear side covers. Snap the rear tabs into the grommets on the Lehman

brackets.13. Check the fit at the joint of the body and the side covers. The wheel openings should

be fairly uniform around the tires. Keep the measurements from the front of the fenderto the center of the tire tread within 1/4". The front edge of the body may be trimmed tomove it forward inside the covers. The rear edge of the side cover may be trimmed ifmore adjustment is required.

14. A carpenter framing square or 2 foot straight edge can be used to measure from thetires out to the top of the wheel openings. Shift the body from side to side to get equal



measurements on both sides with in 1/8". The side cover brackets may beformed/shimmed to maintain a good fit with the body.

15. Check that passenger footrests clear the body. Adjustable boards must clear thebody through the adjustment range. Adjust body position slightly to correct anyinterference.

16. Working from below drill 1/4" holes through the slots in the body mount tabs. Removethe muffler mounting bolts, loosen the clamps and rock the mufflers out of the way forthe front holes. Use 1/4 x 1 1/2 bolts, fender washers (inside), flat washers, and locknuts.

17. Use the #10 wire supplied to extend the 4 wires to the reverse resistor. Crimp ANDsolder the connections and use double shrink tube to insulate the connections.

18. Install the battery box.19. Remove the screws holding the metal back to the reverse resistor. Cut the bent part

off. Use the back as a template to drill from the outside and top of the trunk to locatethe resistor. Use the 5mm screws supplied to attach the resistor to the recess underthe tour pack and seat.

20. Use the pop rivets supplied to mount the reverse and auto cruise modules to the samearea, one on each side of the reverse resister.

21. Mount the compressor on the bracket on the left shock relocator bracket.



22. Mount the air distributor solenoid assembly on the bracket on the right side. Use a 15"nylon tie to attach the solenoid assembly to the bracket.





N. INSTALLING THE REAR FRAME AND TRAVEL TRUNK

1. Loosen the upper rear M8 x 1.25 X 25 bolts holding the Lehman frame to the lugs onthe bike frame enough to slide the slots on the lower arms of the Honda rear frameonto the bolts.

2. Back out the M10 x 50 bolts in the rear frame ears to install the modified travel trunkframe. Slide the trunk frame between the motorcycle frame and the shock relocatorbrackets. The front tubes of the frame go outside the plates on the Lehman frame. The slots fit over the M8 x 1.25 x 25 bolts. Turn the M10 X 50 bolts back in andloosely install the nuts. The rack will be adjusted to position the trunk, so protect thetop of the body with a clean shop towel and lower the rack as far as possible.

3. Connect the extended wires from the taillights to the original harness if not yet done.4. The wiring harness for the trunk lights and other modules plug back into their original

plugs.5. The modules and harness use the original tabs on the frame.6. Use nylon ties to secure the wiring.7. Install the travel trunk with the original 6mm bolts. Feed one of the original saddlebags

latch cables through the hole in the Lehman trunk.8. Connect the trunk wiring.9. Clip the trunk lower cover into place.10. Work through the wheel openings to tighten the M8 x 1.25 x 25 bolts. Tighten the M10

x 50 bolts to secure the top. Use LOCTITE 242 thread locker on the 10mm nuts.11. Drill and bolt the fender braces to the flat plate on the Lehman frame. Position the

braces to support the fender about 4" from its lower edge.12. Install the screws in the trunk lower cover.13. Connect the original saddlebag cable to the latch in the Lehman trunk. Use a cable

stopper from the saddlebags.14. Connect any wires, antenna leads, and the passenger footboard adjuster cables.15. Install the seat and passenger grips.16. Install the wheels and torque the nuts to 85 foot pounds. Set the rear tire pressure to

20 psi.17. Install the wheel center caps.18. Install the toolbox in the front right of the Lehman trunk. Use the bolts supplied and

original brackets removed from the saddlebag.19. Install the battery.



O. Replacement Parts

Description Lehman Number Vendor Part Number Vendor

Brake Shoes GB1118 474RP RaybestosLeft Brake Adjuster Kit GB1110 2592 EISRight Brake Adjuster Kit GB1112 2593 EISBrake Spring Kit GB1124 7157 EISWheel Cylinders GB1122 EW34958 TRU-TECH12" brake line GB1132 AS312 Papco30" brake line GB1135 AS330 Papco40" brake line GB1136 AS340 PapcoDifferential Cover Gasket (octagon housing) GG0650 RDS 13073 Fel ProDifferential Cover Gasket (square housing) GG0650-0 RDS 55323 Fel ProAxle Bearing GB1001 RW207 CCRA BCAAxle Flange Gaskets GG0600 n/a AGSPark Brake Cable GB1114 370100 ABSCOBrake Drum GB1120 857 ITTAxle Stud CS1001 560-186 PapcoBrake Shoe Retainer GB1119 D7TZ2028B FordPinion Seal GS1056 8181 NA NationalAxle Seal (25 spline shaft drive) GS1052 3214 NationalAxle Seal (23 spline shaft drive) GS1050 3199 NationalPark Brake Handle GB1100-0 30011810 ChevroletFLH Debris Guard LS1018 300026 LehmanSportster Debris Guard LS1017 n/a LehmanDebris Guard Bracket LB1181 n/a LehmanSpeedi Sleeve - all shaft drive GS1058 99181 National



SUPPLEMENT

OPTIONAL PARKING BRAKE

1. Remove the wheels and brake drums.2. Identify the levers (stamped left & right).3. Install the levers in the rear shoe of each brake. Install the spreaders and springs

supplied. The narrow slot and the forward spring go to the forward shoe. 4. Cut the springs supplied with the cables to 6".5. Run the inner cables through the holes in the backing plates. Connect the cable ends

to the levers. Slip the springs over the inner cables.6. Mount the bracket to the forward 2 swingarm bolts on the right side. 7. Attach the handle bracket to the slots. The bracket can be moved forward or back by

using different holes.8. Attach the lever to the handle bracket with the bolts supplied. Put the nuts on top to

provide clearance for the cables and pull mechanism.9. Route the left hand cable across the bike above the Lehman frame, down and under

the right axle and to the left hole in the handle bracket. Cut the outer sheath to lengthand use the end and clip supplied to secure the lever end. Attach the sheath to theside of the Lehman trunk to ensure it will not rub the tire.

10. Route the right hand cable sheath up, around the axle and forward to the right handhole in the handle bracket. Cut the outer sheath to length and use the end and clipssupplied to secure the lever end. Use a couple of nylon ties to hold the two sheathstogether and away from the tire.



11. Check that the cables will not be pinched as the suspension moves.12. Use the equalizer and cable ends to connect the cables to the threaded adjustment

rod.

** NOTE ** TAKE UP THE SLACK IN THE CABLES BEFORE TIGHTENING THE ENDS TO

ENSURE A GOOD ADJUSTMENT RANGE WITH THE THREADED ROD. 13. Cut the inner cables about an inch long. Cover the cut ends with some shrink tubing to

keep them neat.

Gl1500 LI1062 Mar14, 03 PARK BRAKE 25. Honda Goldwing GL1500 GTL - 14 Mar. 03 Lehman Trikes Inc. - 3-Instruction Part # LI1062 ... Honda Goldwing GL1500 GTL ...

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