Hardknock Assembly
Instructions
Revision
3
Packing List:
Box
#1:
Frame/engine assembly
Rear brake rod
Box
#2:
Front wheel assembly
Rear wheel assembly
Rear brake hub
Rear wheel sprocket hub
Handlebar assembly with
front brake
Chain
Chain cover
Battery
Rear fender brace tube
assemblies
(L&R)
Box
#3:
Front fork assembly
Gas tank
Rear fender
Headlight
Tail light
Gas cap
Fuel line & petcock
Front axle (spacers & nut
included)
Left and right foot
control
Jockey shift (pushrod
installed)
Forward foot peg assembly
Rear view mirror
Brake return spring
Brake
light actuator
spring
Place frame assembly on stand
Install
rear fender using the two
attach bolts in the center of the frame. Install rear
fender brace tubes. Note
that the fork end of the brace tubes tubes attach to the frame. The
left
side
bracket has the tail light attachment.
Place chain on engine
drive
sprocket.
Place
the brake and sprocket hubs on
the rear wheel. Align the rear wheel assembly with rear axle plates on
frame.
Place chain on wheel sprocket. Put rear axle through chain adjuster on
frame,
axle spacers, and rear wheel assembly. Note: The longer axle spacer
goes on the
brake side. Ensure correct chain tension by using chain adjusters on
frame.
Tighten axle nut*.
Install
brake hub brace tube. Check
to make sure tire does not make contact with rear fender brace tube
bolts.
Install
chain guard on
engine.
Tighten upper triple
clamp on fork tubes. Triple clamp should be flush with the top of the fork tubes.
Loosen lower triple clamp and slide down fork.
Place flat washer on steering bolt.
Apply
high temperature bearing
grease to tapered steering bearings. Place one bearing on steering bolt
above the washer and install the second on the top race on frame
steering
tube. Slide steering
bolt up through steering
tube .
Hand
tighten threaded
washer on
large bolt under upper triple clamp. Slide upper triple clamp down over
steering bolt. Install and tighten large cap nut
on top
of upper triple clamp*. Tighten lower triple clamp* on fork tube.
Loosen springer clamp and
position midway between high and low travel. Retighten
clamp
onto fork tubes*.
Install
front wheel by placing front
axle through lower rockers and wheel spacers. The shorter spacer goes
on
the
rotor side of the wheel. Tighten axle nut*.
Secure headlight to
springer clamp*.
Connect headlight wire to plug on frame.
Install
handlebar risers on upper
triple clamp. Make sure that risers are aligned to fit the handlebar
before
tightening. Place handlebar on risers and
secure in place with riser caps*.
Remove plastic chock
between the
pads on the brake caliper. Slide caliper onto rotor and Attach
front
brake caliper to mounting bracket. If caliper bolt holes do not align
with the bracket holes, slide springer clamp up or down. This will
reposition the brake rotor and allow the caliper bolt holes to align.
Once the caliper is bolted to the bracket, lower the springer clamp on
the fork until the brake caliper is close but not touching the outer
edge of the rotor. Retighten springer clamp bolts*.
Unscrew the top of the
carburetor
and remove slide. Warning: The slide return spring is under tension and
may
exit the vehicle. To remove the slide place your pinky finger inside
the top of
the carb down to the slide. Hold side pressure on the slide and pull
up. Feed the throttle cable through the carb
top and
return spring. Secure the end of
the throttle cable to the slot on the slide. Place the slide into the
carb
making sure that the beveled edge of the slide is towards the air
filter. Hand tighten the top of the
carb.
. Secure
caliper onto brake
mount*.
Place
forward control horns onto
forward foot peg mount on frame. Note that the top of the control horn
is
convex. Slide threaded foot peg rod through
frame tube and place flat washers
against each control horn. Screw foot pegs onto threaded rod*.
Remove rod end from left
control
horn and thread onto jockey shift pushrod. Reinstall
rod end onto control horn. Slide jockey shift
onto gearshift spline on engine and tighten clamp bolt*.
Place
tail light on mounting bracket
on left rear fender mount tube and secure with bolt. Plug wires into
corresponding wires on frame.
Thread
petcock onto gas tank
fitting. Make sure that the lever is to the right side of the tank.
Place gas tank onto frame
and place
rubber washers under brackets. Install mounting
bolts. With the stainless steel
cover over the fuel line, push fuel line onto tank petcock and
carburetor. Thread
gas cap onto filler neck.
Remove adjustment nut,
barrel and
spring from rear brake rod. Make a slight bend 8” from the rear end and
4” from
the front on the rod. Reinstall spring. Put brake barrel through brake
arm on
wheel hub. Place rear brake rod through alignment bracket on frame and
brake
barrel. Thread adjustment nut onto brake rod.
Note that the brake arm should be
at the 7 O’clock position if properly
adjusted. If not, the brake arm can be
repositioned on the splined shaft.
Remove
rod end from right control
horn. Thread rod end onto brake rod. Reinstall rod
end onto control horn.
Install
brake rod return spring
between frame tang and hole drilled through brake rod.
Install
brake light actuator spring
to switch on the frame under the kick start pedal. Slide strait spring
end
through hole in brake rod end and bend back.
Install rear view mirror.
Connect red (positive)
and black (negative)
wires to battery. Secure battery with rubber blocks. replace battery
box
side cover and tighten leather straps. Note: electric start will not
function unless rear brake is depressed.
Check engine oil level. Use 20w50 motor oil.
Recheck tightness of all
bolts and nuts on bike. Be sure that the set screws on the side covers
of the electrical box are tight and have Loctite applied.
Inflate tires to 32 psi.
*Apply Loctite thread lock on threads.
