>Hardknock Assembly Instructions

Revision 4

 

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*.

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 rotorside of the wheel. Tighten axle nut*.

Place spring and ball bearing  inside kickstand and attach to frame.
Place fiber/metal washer on exhaust port and bolt exhaust to engine head. Place rubber fender washer between exhaust mounting tang and frame and attach bolt.

Install kick starter pedal on splined shaft. Tighten both clamp bolt and set screw*.

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. If needed the triple clamps can be loosened to rotate the fork tube to align the caliper bracket with the rotor. 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 and the triple 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.

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*. Check to see that the control horns rotate freely.  If not you may need to dress the end of the frame tubes with a file.

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 inside faux oil tank which can be accessed by removing the left side cover.

Apply pipe sealant and 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.