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Manafacture: Harley-Davidson
File size: 2.4 mb
File name: H0638a-0920.pdf
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manual abstract
• While holding the two parts firmly together, insert two #8 x 3/4" screws into the switch and tighten. 17 Assembly Handgrip Handgrip Handlebars29 • Fit a handgrip on the end of each handlebar. Hint: If it is difficult to slide the handgrips onto the handlebars, moisten the inside of the handgrips with water. Plug Fork Cover •Position the front fork so that it is upright and facing you. •Insert the handlebar harness plug through the upper hole in the front fork. Do not insert the plug through the lower hole in the front fork. Handlebar Harness Upper Hole 30 DO NOT insert the plug through the lower hole in the front fork! Front View •Turn the front fork assembly around so the back is facing you. • Slide the end of the wire cover into the upper hole in the front fork, as shown. • While making sure the handlebar harness plug remains inserted through only the upper hole in the front fork, slide the right handlebar down through the upper and lower holes in the front fork. Front Fork Handlebar Harness Plug Right Handlebar Handlebar Harness 31 32 Back View Front Fork Assembly Upper Hole in Front Fork End of Wire Cover 18 19 Assembly • Fit the handlebar harness plug up through the rectangular opening in the vehicle body. TM Handlebar Harness Plug Rectangular Opening TM See Inset Handlebar Harness Plug Rectangular Opening 35 • Align the screw holes in each handlebar with the screw holes in the front fork. • First, insert two #8 x 3/ 4" screws through the lower holes in the front fork and into each lower hole in each handlebar and hand tighten. Do not tighten the screws completely. These screws will be tightened in step 55. • Next, insert two #8 x 3/ 4" screws through the upper holes in the front fork and into each upper hole in each handlebar and hand tighten. Do not tighten the screws completely. These screws will be tightened in step 55. Handlebars Handlebar Harness 34 • Turn the front fork around so the front is facing you. • Slide the left handlebar through the upper and lower holes in the front fork. Front Fork Left Handlebar 33 Front View Right Side View 20 Assembly .354 (Small Diameter) Cap Nut Fork Axle • Place a .354 (small diameter) cap nut on a flat surface, inside up. Fit the end of the fork axle into the cap nut. • Tap the opposite end of the fork axle with a hammer to secure the cap nut on the axle. Pull on the cap nut to be sure it is securely assembled. .354" .354 Cap Nut 39 TM Steering Stop Neck of Vehicle Body • First, fit the tab on the steering stop into the curved slot in the lower steering bushing . • Hold the steering stop in place. • Then, slide the handlebar assembly on the vehicle frame neck and over the steering stop . Handlebar Assembly 38 TM Tab Handlebar Harness • Fit the handlebar harness behind the tab in the vehicle frame neck. See Inset Tab Handlebar Harness 36 TM • Fit the remaining steering bushing onto the top of the vehicle frame neck. • Insert two #8 x 3/ 4" screws into each end of the steering bushing and tighten. Steering Bushing 37 Front View 21 • Insert the handlebar harness into the wire clip on the side of the vehicle body. Assembly TM Wire Clip Handlebar Harness See Inset Wire Clip Handlebar Harness 41 TM • Slide the fork axle up through the bottom of the front fork, through the frame neck and steering stop, and out the top of the front fork. • Fit a .354 (small diameter) cap nut on the end of the fork axle. • Support the fork axle and tap the cap nut with a hammer to secure it on the end of the fork axle. Hint: You may need the help of another adult to hold the fork axle in place while you secure the cap nut. • Pull on the .354 cap nut to be sure it is secure on the fork axle. .354 (Small Diameter) Cap Nut Fork Axle Front Fork Assembly .354" .354 Cap Nut 40 22 Assembly TM • Insert a #8 x 3/ 4" screw through the hole in each side of the tank and tighten. Hint: To replace the batteries in the sound box, simply remove the screws from the tank and remove the tank from the vehicle frame. After replacing the batteries, be sure to replace the sound box, tank and screws. Tank Vehicle Frame TM • Balance the sound box on the vehicle body. (The speaker should face down.) • Fit the tabs at the bottom of the tank under the front end of the vehicle body. • Lower the tank on the vehicle frame, making sure that the two small square openings in the tank fit over the buttons on the sound box. Sound Box Buttons Tabs Tank 43 44 • Loosen the screw in the sound box battery compartment door and open the battery compartment. • Insert three “AA” (LR6) alkaline batteries in the sound box. Hint: For longest battery life, use only alkaline batteries. • Close the battery compartment door and tighten the screw. Sound Box Battery Compartment Battery Compartment Door SHOWN ACTUAL SIZE 1.5V x 3 “AA” (LR6) Battery Safety Information Batteries may leak fluids that can cause chemical burn injury or ruin your product. To avoid battery leakage: • Do not mix old and new batteries or batteries of different ty...