Lehman Crossbow 2011 Manual de usuario
Bracket Installation
HITCH & MUFFLER BRACKET INSTALLATION
1. See Fig. 1. Install (1) hitch bracket to frame as
shown using (8) bolts. Hand tighten bolts only.
• (1) Hitch Bracket (S001128)
• (8) Bolt (CB1972)
2. See Fig. 2. Install (1) body / exhaust bracket to LS
frame as shown using (2) bolts. Hand tighten
bolts only.
• (1) LS Body / Exhaust Bracket (S001534)
• (2) Bolt (CB1972)
3. Install (1) body / exhaust bracket to RS frame us-
ing (2) bolts. Hand tighten bolts only.
• (1) RS Body / Exhaust Bracket (S001535)
• (2) Bolt (CB1972)
Fig. 1
Fig. 2
2
Bracket Installation
RELAY/SIDE COVER BRACKET INSTALLATION
1. See Fig. 1. Install OEM relays to park brake
bracket as shown using plastic pushpins.
• (2) Relay (OEM)
• (2) Plastic Pushpin (S001430)
2. See Fig. 2. Install (1) Grommet to (1) Right Side
Cover Bracket as shown.
• (1) Grommet (S001427)
• (1) Right Side Cover Bracket (S001389)
3. See Fig. 2. Install (1) Right Side Cover Bracket as
shown using (2) Bolts. Tighten using 13mm
socket.
• (1) Right Side Cover Bracket (S001389)
• (2) Bolt (CB1972)
Fig. 1
Relay
Fig. 1
Mounting Bracket
Pushpin
3
Bracket Installation
BRACKET INSTALLATION
1. See Fig. 1. Install (1) Upper Body Mount Bracket
to right side of frame as shown using (1) Bolt.
Hand tighten only at this point.
• (1) Upper Body Mount Bracket (S001442)
• (1) Bolt (CB1972)
2. See Fig. 2. Install (1) Latch Assembly Alignment
Fixture to (1) RS Latch Bracket using (2) Bolts.
Tighten using 10mm socket.
• (1) RS Latch Assembly (Fixture)
• (1) RS Latch Bracket (S001377)
• (2) Bolt (CB1907)
3. See Fig. 2. Install Latch Assembly and Bracket to
frame as shown using (2) Bolts. Tighten using
13mm socket.
• (2) Bolt (CB1972)
4. See Fig. 3. Install (1) Grommet to (1) Left Side
Cover Bracket as shown.
• (1) Grommet (S001427)
• (1) Left Side Cover Bracket (S001389)
5. See Fig. 3. Install (1) Left Side Cover Bracket to
the left side of the frame as shown using (2) Bolts.
Tighten using 13mm socket.
• (1) Left Side Cover Bracket (S001387)
• (2) Bolt (CB1972)
NOTE: See Fig. 7. Ensure proper orientation of
module as shown REVERSE MODELS ONLY.
Fig. 1
Fig. 2
Latch Assembly
Bracket
S001442
Module
Fig. 3
4
Bracket Installation
6. See Fig. 4. Install (1) Upper Body Mount Bracket
to left side of frame as shown using (1) Bolt.
Hand tighten only at this point.
• (1) Upper Body Mount Bracket (S001442)
• (1) Bolt (CB1972)
7. See Fig. 5. Install (1) Latch Assembly Alignment
Fixture to (1) LS Latch Bracket using (2) Bolts.
Tighten using 10mm socket (Fig. 40-9).
• (1) LS Latch Assembly (OEM)
• (1) LS Latch Bracket (S001376)
• (2) Bolt (CB1907)
8. See Fig. 5. Install Latch Assembly and Bracket to
frame as shown using (2) Bolts. Tighten using
13mm socket.
• (2) Bolt (CB1972)
Fig. 4
Fig. 5
Latch Assembly
Bracket
S001442
5
Bracket Installation
FRONT BODY MOUNT BRACKET INSTALLATION
1. See Fig. 1. Install (1) Front Body Mount to LS
Rollover Brace as shown with (1) spacer using (2)
Bolts. Tighten using 13mm socket with loctite
243.
• (1) Front Body Mount (S001132)
• (1) Spacer (S001517)
• (2) Bolt (CB1975)
• (2) Nut (CN1908)
2. See Fig. 2. Install (1) Front Body Mount to RS
Rollover Brace as shown with (1) spacer using (2)
Bolts. Tighten using 13mm socket with loctite
243.
• (1) Front Body Mount (S001132)
• (1) Spacer (S001517)
• (2) Bolt (CB1975)
• (2) Nut (CN1908)
3. Torque and mark body mount bolts to 22 ft. lbs
using 13mm socket.
Fig. 1
Fig. 2
PART # PART DESCRIPTION TORQUE
CB1982 FRONT BODY MOUNT BOLTS 22 FT LBS
6
Bracket Installation
TAILLIGHT INSTALLATION
1. Remove Left and Right side Latch Assembly
Alignment Fixtures using 10mm socket.
2. See Fig. 1. Re-install modified tail section as
shown using (4) take off bolts with loctite 243.
Tighten top bolts using 13mm socket and bottom
bolts using 10mm socket.
• (4) Bolt (take out)
3. Torque and mark upper tail section bolts to 22
ft. lbs using 13mm socket.
4. Torque and mark lower tail section bolts to 8
ft. lbs using 10mm socket.
5. See Fig. 2. Re-install taillight assemblies to tail
section as shown. Tighten using 4mm allen head
socket.
• (2) Taillight Assembly (OEM)
• (5) Bolt (take out)
NOTE: Run taillight wire harness in tail section
track.
6. Connect license plate light wire harness.
7. See Fig. 2. Install (2) U-Nuts to modified tail sec-
tion as shown.
• (2) U-Nut (CN3302)
8. See Fig. 3. Install a 1” piece of 3M Double Sided
Tape to the left and right grab handle covers as
shown.
Fig. 1
Fig. 2
PART # PART DESCRIPTION TORQUE
TAKE OFF UPPER TAIL SECTION BOLTS (2) 22 FT LBS
TAKE OFF LOWER TAIL SECTION BOLTS (2) 8 FT LBS
Fig. 3
U-Nut U-Nut
7
Bracket Installation
Bracket Installation
REAR FRAME
1. Torque and mark frame bolts to 22 ft. lbs using
13mm socket as indicated
Fig. 1
Fig. 2
PART # PART DESCRIPTION TORQUE
CB1972 FRAME BOLTS 22 FT LBS
Leave Loose
Leave Loose
8
Bracket Installation
Operation 40 - Bracket Installation
EXHAUST INSTALLATION
1. See Fig. 1. Install (1) left side exhaust pipe as
shown using (1) exhaust clamp.
• (1) Left Side Exhaust Pipe (S001166)
• (1) Exhaust Clamp (Take-Off)
2. See Fig. 2. Install (1) polaris exhaust bracket to
transmission using (1) bolt (CB1906) in upper lo-
cation and (1) bolt (CB1928) with loctite 243.
Tighten using 4mm allen head socket and
15mm socket.
• (1) Polaris Exhaust Bracket (S001547)
• (1) Bolt (CB1906)
• (1) Bolt (CB1928)
3. Torque and mark upper exhaust bracket bolt
to 10 ft. lbs using 15mm socket.
4. Torque and mark lower exhaust bracket bolt to
35 ft. lbs using 15mm socket.
5. See Fig. 3. Install (1) right side exhaust pipe as
shown using (1) exhaust clamp.
• (1) Right Side Exhaust Pipe ( S001167)
• (1) Exhaust Clamp (S001412)
6. Re-install side covers with (1) push pin.
• (1) Push Pin (OEM take off)
• (1) Non Reverse Models Side Cover Set
(OEM)
OR
• (1) Reverse Models Side Cover Set
(Supplied with Reverse Kit) See modifica-
tion process on following page.
Fig. 1
Fig. 2
PART # PART DESCRIPTION TORQUE
CB1906 UPPER EXHAUST BRACKET BOLT (1) 10 FT LBS
CB1928 LOWER EXHAUST BRACKET BOLT (1) 35 FT LBS
Fig. 3
CB1906
CB1928
9
Side Cover Modification– Reverse Models
SIDE COVER MODIFICATION (REVERSE ONLY)
1. See Fig. 1. Using scribe lines on backside of side
covers, trim Left and Right side covers as shown
using air saw.
2. See Fig. 2. Install GT1800 weather seal to modi-
fied edges of side covers as shown.Use loctite
404 on inside edge of side covers to secure, being
careful not to get glue on outside edge of side
covers.
• Weather Seal (GT1800)
3. Install modified left and right side covers to trike.
Fig. 1
Fig. 2
Scribe Lines
10
Body Preparation, Installation, & Final Assembly
BODY PREPARATION
1. See Fig. 1. Drill out OEM latch assembly as
shown using 21/64” bit.
2. See Fig. 2. Install OEM latch assembly to OEM
latch bracket as shown using (2) take off bolts.
Tighten using 10mm socket.
• (1) Latch Assembly (OEM)
• (1) Latch Bracket (OEM)
• (2) Bolt (take off)
3. See Fig. 3. Install (1) latch cable to OEM latch as
shown using (1) SIR Clip and (1) Hair Clip.
• (1) Cable Door Release (S001504)
• (1) SIR Clip (provided with cable)
• (1) Hair Clip (S001510)
4. See Fig. 4. Install (1) latch cable to OEM latch
release mechanism as shown using (1) SIR Clip.
• (1) Latch Release Mechanism (OEM)
• (1) SIR Clip (S001531)
NOTE: Left side latch release mechanisms pull
from the bottom, right side latch release mecha-
nisms pull from the top.
Fig. 1
Fig. 2
Drill Out
Fig. 3
SIR Clip (provided)
Hair Clip
Fig. 4
SIR Clip (S001531)
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