Assembly Instructions

Instructions have been revised for the 2008 Hardknock Bobber.

Hardknock Assembly Instructions

Revision 6

Packing List:

Box #1:

Frame/engine assembly
Rear brake rod
Seat cover
Upturned pipe (optional)
Ape Hangar bars (optional)

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

Assembly:

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.
Hub attach point should be at the 6 o'clock position.

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*.

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 cablethrough 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. If it is necessary to adjust the throttle housing on the handlebar you must first loosen the housing set screw . Be aware that the two screws that hold the housing halves together are only to be snug tight and do not fixate the housing on the bar. If these screws are overtightened the threads may strip and this will not be covered under the warranty.

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*. Do not overtighten as this will fracture brass bushings. Check to see that the control horns rotate freely. Check to see that the control horns rotate freely. If not you may need to dress the brass bushings with a file to give free clearance.

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 left side switch to wires on handlebar.

Connect right side switch to wires on handlebar.

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.

DON'T FORGET THE 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.

Brake Bleeding Instructions (Click Here)

NEW VIDEO FOR ADDING SPEEDOMETER

ELECTRICAL SCHEMATIC (CLICK HERE)

WARRANTY CARD (CLICK HERE)