AMERICAN IRONHORSE Classic SX User Manual Download | Manualshive

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B R A K E S Y S T E M S

52

4-7

DET

AILED MAINTENANCE PROCEDURES

BRAKE SYSTEMS ARE ONE OF THE MOST IMPORTANT SAFETY SYSTEMS ON YOUR AMERICAN IRONHORSE
VEHICLE. TROUBLESHOOTING, REPAIR OR SERVICING OF BRAKE SYSTEMS SHOULD ONLY BE DONE BY
TRAINED, EXPERIENCED, PROFESSIONAL MECHANICS. IMPROPERLY INSTALLED, ADJUSTED OR SERVICED
BRAKES CAN LEAD TO EXTREME BODILY HARM.

Brake system pads and discs should be checked at recommended inspections and maintenance

intervals. At the same intervals, brake system fluid level should be checked to ensure appropriate levels are
maintained. Use only hydraulic brake fluids approved by U.S. Department of Transportation, D.O.T #5 such
as that listed in “AMERICAN IRONHORSE Consumable Table.”

BRAKE PADS AND DISCS SHOULD BE INSPECTED FOR WEAR AT LEAST EVERY 2,000 MILES. UNDER
CITY DRIVING, STOP AND GO CONDITIONS OR WITH CONTINUOUS OPERATION IN HILLY TERRAIN, MORE
FREQUENT INSPECTIONS EVERY 500 TO 1,000 MILES SHOULD BE MADE.

Visual inspection of brake pads can be done without removing any parts. If the thickness of the brake

pad friction material (not including the brake pad metal backing plate) is not at least 1/16 of an inch
minimum, immediately replace the brake pad pair. Always replace brake pads in pairs.

OPERATING BRAKE SYSTEMS WITH BRAKE PAD FRICTION MATERIAL THICKNESS (NOT INCLUDING THE
BRAKE PAD METAL BACKING PLATE) OF LESS THAN 1/16" IS VERY DANGEROUS AND CAN LEAD TO BRAKE
FAILURE, COMPONENT DAMAGE OR INADEQUACY OF BRAKING RESULTING IN SEVERE BODILY HARM.

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Summary of Contents for Classic SX

Page 1: ...o advise you of safety issues please read this manual in its entirety before riding your AMERICAN IRONHORSE Motorcycle This manual provides operating safety and maintenance information on the AMERICAN IRONHORSE Classic SX Outlaw SY Slammer SZ Texas Choppers TX Tejas SJ Ranger SG Legend SC and Thunder SW Following the recommended inspection and maintenance procedures will ensure that your AMERICAN ...

Page 2: ... Trans Serial No ________________________________ Ignition Key No _________________________________ Dealer Name____________________________________ Number ________________________________________ Address ________________________________________ _______________________________________________ Phone Number __________________________________ FAX Number ____________________________________ ...

Page 3: ...NE THAT COULD POSSIBLY LEAD TO PERSONAL BODILY INJURY TO THE RIDER PASSENGERS OR OTHERS WARNING BOLD PRINT IN CAPITAL LETTERS INDICATES THAT THE SUBJECT IS ONE THAT COULD POSSIBLY LEAD TO DAMAGE TO THE MOTORCYCLE CAUTION Italic print indicates other important matters This manual covers all models of AMERICAN IRONHORSE motorcycles with standard and optional equipment Consult your local AMERICAN IRO...

Page 4: ...ch and Gear Shifting 22 2 6 Braking Systems 28 2 7 Turn Signal Indicators 29 2 8 Control Panel Indicator Lights 30 2 9 Control Panel Speedometer Odometer 31 2 10 Headlight Switch High Beam Activation 32 2 11 Horn Switch 32 2 12 Kick Stand 33 2 13 Rear Side View Mirrors 34 2 14 Securing Your Motorcycle 35 2 15 Vehicle Gas Caps 36 2 16 Shock Absorbers 37 2 17 Vehicle Loading Accessories 37 Recommend...

Page 5: ...rcuit Breakers 62 4 17 Vehicle Lights 63 4 18 Hydraulic Tappets 64 4 19 Motorcycle Lubrication 65 Mechanical Specifications 5 1 AMERICAN IRONHORSE Consumable Table 66 5 2 Torque Specifications 68 Important Notices 6 1 Reporting of Safety Defects 70 6 2 Noise Emission Warranty 70 6 3 Tampering 71 6 4 Limited Warranty on Emission Control System 73 I Coverage II Limitations III Limited Liability 6 5 ...

Page 6: ...ngs and caution information Find a professionally trained experienced mechanic with whom you can develop confidence and who can come to know your vehicle s operation over time Ensure that all the recommended inspection and maintenance procedures in this manual are strictly followed within the prescribed time intervals Stay acutely aware of road and ambient conditions Motorcycles with only two whee...

Page 7: ...ehicle operator on the road with little or no bodily protection in the event of an accident Always operate under the premise that the other guy will act in a way that will increase the risk of you becoming involved in an accident Remember as a motorcyclist you are often not seen by other vehicle operators Take particular care of motorists making turns into your oncoming traffic lanes Always operat...

Page 8: ...ocking at the rotor with a rotor lock and locking and removing the ignition key This will help prevent unauthorized use or theft When your vehicle will not be in use close the fuel supply valve to prevent accidental gasoline spillage For California vehicles with Evaporative Emission Systems failure to do so could cause serious damage to your engine when gasoline leaks into crankcase oil Pay partic...

Page 9: ... 5 42 35 31 5 31 5 37 36 35 Overall Height 47 5 45 5 49 51 5 46 5 48 48 51 Ground Clearance 4 75 4 75 4 75 5 25 4 75 4 75 5 25 5 5 Seat Height 25 5 25 5 25 5 25 5 24 75 25 25 26 5 25 5 B Weight pounds Texas Slammer Thunder Outlaw Legend Classic Tejas Ranger Choppers Weight 610 610 610 610 610 580 590 610 GVWR 1200 1100 1200 1200 1100 1200 1100 1200 GAWR Front 490 450 490 490 450 490 450 490 GAWR R...

Page 10: ...voir w Filter 98 ounces Front Forks each All Models 12 ounces D Engine Specifications 107 cubic inch 113 cubic inch Number of Cylinders 2 2 Design 4 cycle V twin 4 cycle V twin Compression Ratio 9 6 1 10 1 1 Bore 4 0 4 0 Stroke 4 1 4 4 1 2 Volume Displacement Cubic Inches 107 113 Cubic Centimeters 1753 1852 E Transmission Specifications Number of Forward Speeds 5 speed 6 speed optional Type Consta...

Page 11: ...smission 34 Rear Wheel 70 tooth standard Driving Gear Ratios standard 1st Gear 2 94 1 00 2nd Gear 2 21 1 00 3rd Gear 1 60 1 00 4th Gear 1 23 1 00 5th Gear 1 00 1 00 6th Gear optional 1 00 0 86 G Electrical Specifications Battery 12 volt negative ground Spark Plug Champion Type RN12YC Gap 0 040 inches Size Thread 14 mm ...

Page 12: ...E TIRES WITH CAST DISC OR BILLET WHEELS IN ADDITION PROTECTIVE RUBBER RIM LINERS MUST ALWAYS BE EMPLOYED WITH WIRE SPOKE WHEELS NEVER SWAP FRONT AND REAR TIRES THEY ARE NOT INTERCHANGEABLE AND CAN LEAD TO VEHICLE INSTABILITY IN USE NEVER EXCEED MAXIMUM INFLATION PRESSURE AS INDICATED ON TIRE SIDEWALL NEVER INSTALL A NEW WHEEL TIRE ASSEMBLY WITHOUT PROPER BALANCING Front Tire Size 130 70 VB 18 tire...

Page 13: ...AMERICAN IRONHORSE VEHICLE SPECIFICATIONS 13 1 2 I Brake Specifications Rotor Diameter Calipers Pistons Front All Models 11 5 1 4 or AIH equivalent Rear All Models 11 5 1 4 or AIH equivalent ...

Page 14: ...NG ALWAYS FILL TANK SLOWLY AND LEAVE THE TANK NECK SPOUT VOID AS FUEL EXPANDS WITH AMBIENT AND OPERATING TEMPERATURE INCREASES ALWAYS ENSURE THAT GAS TANK CAP IS SECURELY TIGHTENED AFTER REFUELING TAKING SPECIAL CARE NOT TO CROSS THREAD Note that the gas caps are a left and right thread and cannot be interchanged Only the right cap is vented WARNING GASOLINE WITH FUEL ADDITIVES MAY CAUSE DAMAGE TO...

Page 15: ...ne break in period Improper engine break in may void your AMERICAN IRONHORSE limited warranty First 500 Miles Do not overrev the engine during break in period Never rev the engine in neutral gear Avoid running engine in 4th or 5th gear at very low rpm Never hold engine speed constant for long periods of time vary the speed frequently Avoid jackrabbit starts or racing from a standstill with engine ...

Page 16: ...AN IRONHORSE WITH THE HEADLIGHT ON TO IMPROVE YOUR VISIBILITY TO OTHERS FOR IMPROVED SAFETY The ignition switch Fig 1 Letter B has two operative positions as wired from the factory The off lock mode is located approximately at the 12 o clock position The switch mechanism is activated by inserting the key into the ignition key slot and turning the switch mechanism straight up and down and parallel ...

Page 17: ...justment Screw Fig 2 Letter B is provided to increase or decrease gripping pressure required to activate throttle control Unscrew the Engine Throttle Tension Adjustment Screw such that the throttle control returns to the idle position when operator s hand is removed This is the normal operating tension for the throttle control grip The Engine Throttle Tension Adjustment Screw may be screwed in fro...

Page 18: ... for normal warm engine operation This temporary adjustment to fuel to air mixture ratio is accomplished by adjusting the fuel air mixture lever CHOKE or enrichener See Section 2 4 Starting Procedures As the CHOKE or enrichener is engaged engine speed will increase as a richer fuel mixture is delivered to the engine During normal operation the CHOKE should always be in the OFF fully depressed posi...

Page 19: ...S S carburetor Fig 5 Turn fuel petcock located on bottom of left tank to ON position Twist throttle control grip counterclockwise toward operator two times and return grip to engine idle position Pull up enrichener lever Letter C to its maximum extended position Lever is located just above and to the rear of the S S air cleaner cover Start engine Twist throttle speed control grip as required to ke...

Page 20: ...p as required to keep engine running After engine has run for a period long enough to warm up usually no longer than 3 minutes depress the choke knob inward to the OFF position NOTE If choke is left on while throttle is actuated the spark plugs will foul and cause motor to perform poorly To fix fouled plugs remove and replace C FOR WARMER WEATHER above 45 F AND COOL ENGINE for both carburetor type...

Page 21: ...trol grip to the full ON full counterclockwise position Start engine Do not feather the throttle while attempting to start the engine Leave throttle in the wide open position to offset the effects of flooding Immediately upon starting return throttle position to idle BEFORE ATTEMPTING TO START THE ENGINE ALWAYS ENSURE THAT THE TRANSMISSION IS SET TO THE NEUTRAL POSITION THE GREEN DASH INDICATOR SH...

Page 22: ...AY RESULT IN SEVERE DAMAGE TO THE VEHICLE AND LOSS OF CONTROL OF THE VEHICLE DUE TO REAR WHEEL TRACTION LOSS The clutch engage disengage mechanism is controlled by the clutch hand lever on the left side handlebar of the vehicle Fig 4 Letter A Squeezing the lever in toward the grip disengages the clutch mechanism Releasing the clutch lever engages the clutch mechanism The clutch mechanism is the me...

Page 23: ... DAMAGE EXCESSIVE WEAR AND BODILY INJURY DUE TO LOSS OF VEHICLE CONTROL The gear shifter lever is located on the lower left side of the vehicle Fig 5 Letter A It is operated with the left foot To change gears the gear shifter lever must be raised all the way up with the top of the left foot to increase the gear number desired and must be lowered all the way down with the bottom of the left foot to...

Page 24: ... 5th Gear 6th Gear 65 103 RECOMMENDED DECELERATION SPEED From To M P H KM Hr 6th Gear 5th Gear 50 79 5th Gear 4th Gear 40 63 4th Gear 3rd Gear 30 48 3rd Gear 2nd Gear 20 32 2nd Gear 1st Gear 10 16 After each gear shift the gear shift lever must be allowed to return to its rest position before it can be actuated again for another gear change This is accomplished by merely removing left foot pressur...

Page 25: ...ECHANISM SKIPPING GEARS WHILE THE VEHICLE IS IN MOTION OVER STRESSES THE VEHICLE AND CAN LEAD TO DAMAGE SKIPPING GEARS WHILE THE VEHICLE IS IN MOTION AND DECREASING GEAR NUMBERS ALSO OVER STRESSES THE VEHICLE AS WELL AS DRAMATICALLY INCREASES THE POSSIBILITY OF LOSS OF VEHICLE CONTROL DUE TO SLIPPAGE OF REAR WHEEL When at a standstill with the engine off and wanting to shift gears it may be necess...

Page 26: ...r in neutral position physically seated and straddling the vehicle 2 Squeeze clutch lever Fig 4 Letter A to the fully disengaged position with left hand 3 With the left foot push the gear shifter foot lever Fig 5 Letter A down as far as it will go and release it to return to its rest position You should now be in first 1st gear 4 Slowly release the clutch lever Fig 4 Letter A in your left hand to ...

Page 27: ...r or sixth 6th gear as desired Use Gear Shifting Speed Table as a guide as to when to shift to the next highest gear To downshift shift from a higher to a lower gear follow the similar procedure of disengaging clutch only reducing engine throttle by about one half to ensure engaging to a lower gear does not cause the rear wheel to lose traction depressing the foot shifter lever to its full down po...

Page 28: ...ver located on the right handlebar Fig 2 Letter E The rear brake is operated by depressing the rear brake pedal on the lower right hand side of the vehicle Fig 7 Letter A BRAKES ARE BEST USED WHEN EQUALLY BALANCED BETWEEN BOTH FRONT AND REAR BRAKE FOR BRAKING AND STOPPING NEVER APPLY BRAKES SO STRONGLY THAT FRONT OR BACK WHEELS LOCK UP THIS WILL CAUSE LOSS OF OPERATOR CONTROL AND MAY RESULT IN PER...

Page 29: ...perates both the front and rear left side turn signal lights The right side turn signal switch Fig 2 Letter F operates both the front and rear right side turn signal lights Depressing either turn signal switch will begin the corresponding side turn indicator lights blinking on and off Always ensure that turn signal lamps are operating Replace burned out lamps only with replacements as listed in AM...

Page 30: ...ine is experiencing low oil pressure When initially starting the vehicle this indicator light should momentarily go on for one or two seconds before the engine is experiencing adequate oil lubrication This condition should last only one or two seconds Sometimes especially when a vehicle s idle speed is set very low this light may flash on as the vehicle idles IF THE RED LOW OIL PRESSURE LIGHT REMA...

Page 31: ... D Speedometer Your vehicle s speedometer provides a continuous reading either digital or analog of the vehicle s forward speed NEVER EXCEED THE POSTED SPEED LIMIT ALWAYS LOWER SPEED BELOW THE POSTED SPEED LIMIT WHEN CONDITIONS WARRANT Odometer Your vehicle s odometer indicates total miles traveled by the vehicle since leaving the factory WARNING NEVER ALTER OR TAMPER WITH VEHICLE S ODOMETER READI...

Page 32: ...ey to be turned an additional position to activate lights Fig 1 Letter B To turn on high beams push the headlight switch to HI position To turn headlights down to normal intensity push switch back to the LO position The vehicle s horn can be momentarily activated by depressing the horn switch on the left side handlebar controls Fig 4 Letter D Removing pressure from the switch will discontinue horn...

Page 33: ...TTED THROUGH THE KICKSTAND MECHANISM TO THE SUPPORTING SURFACE FAILURE TO DO SO COULD RESULT IN THE VEHICLE FALLING OVER AND CAUSING VEHICLE DAMAGE AND POSSIBLE PERSONAL INJURY ENSURE THAT THE KICKSTAND IS IN THE FULLY FORWARD LOCKED POSITION BEFORE APPLYING THE WEIGHT OF THE VEHICLE IF THIS IS NOT DONE ANY SUBSEQUENT MOTION OR MOVEMENT OF THE VEHICLE MAY RESULT IN RETRACTION OF THE KICKSTAND AND ...

Page 34: ...great care must be exercised when making judgments as to how far back items actually are in your rear view mirror OBJECTS VIEWED IN YOUR REAR VIEW MIRRORS ARE CLOSER THAN THEY APPEAR TAKE CARE WHEN JUDGING DISTANCES THROUGH USE OF REAR VIEWING MIRRORS Using rear viewing mirrors is an excellent habit to develop Always check the positioning of your mirrors before starting off on a ride Always use Ov...

Page 35: ... this includes locking and removing the key from the ignition Padlocking the brake rotor mechanism with a heavy duty rotor lock is another method of securing your AMERICAN IRONHORSE Fig 6 Letter A WHEN THE ROTOR LOCK IS IN PLACE VEHICLE CANNOT ROLL NEVER ATTEMPT TO RIDE A VEHICLE WITH A ROTOR MECHANISM INSTALLED THIS MAY RESULT IN SERIOUS PERSONAL INJURY ...

Page 36: ...ise To secure right side tank gas cap turn the cap clockwise WHEN REFUELING ALWAYS REMOVE GAS TANK CAPS SLOWLY PRESSURE BUILD UP IN FUEL TANKS CAN CAUSE GASOLINE FLUID AND MIST TO CONTACT PERSON REFUELING ALWAYS FILL TANK SLOWLY AND LEAVE THE TANK NECK SPOUT VOID AS FUEL EXPANDS WITH AMBIENT AND OPERATING TEMPERATURE INCREASES ALWAYS ENSURE THAT GAS TANK CAP IS SECURELY TIGHT AFTER REFUELING TAKIN...

Page 37: ...E Ranger Series is equipped with two external shock absorbers Fig 3 4 These shock absorbers can be adjusted for rebound and dampening settings Your AMERICAN IRONHORSE was custom designed to operate with an operator and optionally with one passenger riding directly behind the operator in an appropriate companion seat The addition of accessories additional weight loads etc have not been taken into c...

Page 38: ...g off or changing fluids and replacement of worn parts and assemblies is the only way to ensure continuous safe operation of your AMERICAN IRONHORSE motorcycle Strictly following recommended procedures cannot be overemphasized General procedures of maintenance Insuring a safe well operating AMERICAN IRONHORSE motorcycle requires a partnership between rider and a competent formally trained professi...

Page 39: ...chains for proper tension and integrity 4 Check operation of brakes brake fluid levels brake hydraulic lines and fittings for leaks or damage and brake pads and discs for excessive and or uneven wear 5 Check system lamps for proper operation headlight taillight brake light and front and rear directional lights 6 Check major operating systems for proper function throttle controls steering and brake...

Page 40: ...S FORMALLY TRAINED EXPERIENCED AND PROFESSIONALLY QUALIFIED TO PERFORM THESE IMPORTANT PROCEDURES THE FIRST RECOMMENDED COMPLETE PROFESSIONAL INSPECTION AND MAINTENANCE MUST BE PERFORMED AT 500 MILES SUBSEQUENT PROFESSIONAL INSPECTION AND MAINTENANCE PROCEDURES MUST BE PERFORMED AT LEAST EVERY 2500 MILES THEREAFTER CONSEQUENTLY A COMPLETE PROFESSIONAL INSPECTION AND MAINTENANCE MUST BE PERFORMED A...

Page 41: ...ect clean or replace tappet oil screen B Electrical Systems Check integrity of battery connections Check that all lights are functioning properly headlight front and rear turn signal lights brake light s and taillight Check all electrical switches and assemblies for proper operation C Drive Train Systems Check rear belt for proper tension condition of teeth and general integrity of belt if applica...

Page 42: ...eck speedometer cable and connections Check integrity and interconnections on throttle control cables Lubricate cables as necessary to avoid corrosion Check ignition timing E Braking Systems Check brake fluid level and general condition of fluid replace or replenish as indicated by inspection Check brake pads and discs for wear life and abnormal or uneven patterns of wear Replace in sets as indica...

Page 43: ... G Suspension System Replace front end fork oil at 10 000 mile intervals beginning with odometer reading of 10 000 miles Check adjust front fork neck bearings Check fork bearings Check adjust rear fork pivot nut Check condition of shock absorbers H Other Checks Check engine mounts special attention to top mount Check integrity of vapor containment system and interconnections on California models o...

Page 44: ...RY RECOMMENDED INTERVAL MAINTENANCE A COMPETENT PROFESSIONALLY TRAINED AND EXPERIENCED MOTORCYCLE MECHANIC SHOULD ROAD TEST THE MOTORCYCLE TO ENSURE THAT ALL VEHICLE SYSTEMS ARE IN GOOD SAFE OPERATING CONDITION WARNING NEVER USE A PRESSURE WASHER ON YOUR MOTORCYCLE AS IT MAY RESULT IN FAILURE DAMAGE OF ELECTRICAL SYSTEM OR COMPONENTS ...

Page 45: ...nded that engine oil be changed more frequently Under normal operating conditions slight water vapor in the crankcase is expelled through the breather port However operation in extremely cold ambient conditions or riding in short runs may not allow the engine oil to heat up to the point of passing water vapor thereby retaining it in the crankcase Such occurrences may block oil flow in the lines an...

Page 46: ...l Achieving this condition will vary according to ambient temperatures When the engine oil has reached the appropriate temperature turn off the engine and remove the oil cap If level indicates addition of oil is required do so using S A E 20W50 oil Oil is added through the fill spout opening Fig 8 Letter C Never check the oil level or a cold motorcycle WARNING ALWAYS USE THE APPROPRIATE FILLING DE...

Page 47: ...Fig 3 Letter B Clean oil filter mounting plate surface to remove any foreign material old gasket remnants etc Apply a thin film of oil to the cleaned oil filter mounting plate Apply a similar thin film of oil to a new oil filter gasket Screw the new filter with gasket onto oil filter mounting plate Fill oil tank with appropriate amount of oil listed in 1 2 Section C Fluid Capacities Type listed in...

Page 48: ...r level is read with dipstick touching first thread of case Transmissions are easy to overfill and very messy when overfilled Remove and read the indicated transmission fluid level on the transmission fluid dipstick Fig 9 Letter A If indicated add transmission fluid type recommended in AMERICAN IRONHORSE Consumable Table in this manual through the transmission fluid dipstick port Prior to draining...

Page 49: ... DRAIN PLUG ABOUT 6 TO 8 POUNDS IS ADEQUATE ENSURE THAT NO FOREIGN MATERIAL DUST DEBRIS ETC ARE INTRODUCED INTO THE TRANSMISSION DURING DRAINING AND REFILLING OF RESERVOIR ENSURE THAT TRANSMISSION FLUID DOES NOT SPILL OVER ONTO TIRES BRAKES OR REAR WHEEL AS THIS COULD IMPAIR SAFE OPERATION OF THE VEHICLE AND CAUSE BODILY HARM ...

Page 50: ...two pulleys The play or deflection on the bottom strand should be 1 2 Soft tail type motorcycles should note that the belt gets looser as the suspension compresses This is proper and should be expected The belt should be adjusted with ride height consideration Rubber mounted engine motorcycles have a suspension system with the opposite characteristics The belt will get tighter as the suspension is...

Page 51: ...l cable except in motorcycles fitted with hydraulic clutches such as the Slammer and Signature Series The clutch control cable must be oiled adjusted and tested for proper operation at recommended inspection and maintenance periods Improperly adjusted clutch cable or worn clutch plates can cause clutch slippage under load conditions or can cause hesitation before engaging upon lever release These ...

Page 52: ...sportation D O T 5 such as that listed in AMERICAN IRONHORSE Consumable Table BRAKE PADS AND DISCS SHOULD BE INSPECTED FOR WEAR AT LEAST EVERY 2 000 MILES UNDER CITY DRIVING STOP AND GO CONDITIONS OR WITH CONTINUOUS OPERATION IN HILLY TERRAIN MORE FREQUENT INSPECTIONS EVERY 500 TO 1 000 MILES SHOULD BE MADE Visual inspection of brake pads can be done without removing any parts If the thickness of ...

Page 53: ...IRE TREAD WEAR RESULTING IN UNSTABLE VEHICLE OPERATION UNDERINFLATION OF TIRES CAN RESULT IN TIRE SLIPPAGE OR TIRE FAILURE THESE AND SIMILAR RESULTS OF IMPROPER TIRE INFLATION CAN RESULT IN SEVERE BODILY HARM Always follow recommended inflation pressures of tire manufacturer For AMERICAN IRONHORSE original equipment tires the following inflation pressure should be maintained measured when tire is ...

Page 54: ...See AMERICAN IRONHORSE Consumable Table for replacement tire information Selection of an improper replacement tire could cause unstable vehicle operation Always have a trained professional service replace your vehicle s tires Special procedures and tools are required to properly and safely install maintain and replace tires tubes and wheels Operating your vehicle with excessively or unevenly worn ...

Page 55: ...quent intervals all bearings should be repacked at 10 000 mile intervals or once annually whichever comes first Indications of roughness of operation or excessive play in bearings should be heeded by initiation of bearing replacement or repacking Repacking procedures should always include use of the proper lubrication medium and replacement of spent seals with new ones If shock absorbers malfuncti...

Page 56: ...is 040 An appropriate spark plug feeler gauge should be used Never remove spark plug wires from plugs by pulling on wires Always grasp the molded rubber spark plug cap for removal of wires Spark plugs should be tightened down to about 100 inch pounds to ensure proper continuous operation Your AMERICAN IRONHORSE is equipped with one of the most advanced electronic ignition systems presently availab...

Page 57: ...CKED AT EACH RECOMMENDED INSPECTION AND MAINTENANCE INTERVAL IF EXCESSIVE PLAY EXISTS IN FRONT OR REAR OF VEHICLE WHEN OPERATING THIS COULD INDICATE AN OUT OF ALIGNMENT CONDITION THAT COULD LEAD TO A LOSS OF VEHICLE STABILITY AND OR CONTROL SUCH SITUATIONS COULD LEAD TO SEVERE BODILY INJURY ADJUSTMENTS TO VEHICLE ALIGNMENT SHOULD ONLY BE DONE BY A PROFESSIONALLY TRAINED MOTORCYCLE MECHANIC ...

Page 58: ...NG EYES SKIN CLOTHING OR OTHER ITEMS IN CONTACT WITH BATTERY ACID SUCH CONTACT COULD CAUSE SEVERE INJURY OR DAMAGE EMERGENCY PROCEDURE IF CONTACT IS INADVERTENTLY MADE SWALLOWED DRINK LARGE QUANTITIES OF WATER THEN MILK OF MAGNESIA OR VEGETABLE OIL IMMEDIATELY SEEK MEDICAL ATTENTION CONTACT WITH EYES OR SKIN FLUSH AFFECTED SURFACES CONTINUOUSLY WITH WATER CONTINUE FOR THREE TO FIVE MINUTES IMMEDIA...

Page 59: ...y be permanently damaged and be unable to ever properly hold a charge and function properly again A similar situation can occur if the internal battery plates remain uncovered by electrolyte for extended periods If long term storage is required it is recommended that the battery be in a fully charged condition removed from the vehicle and stored in a cool dry place The battery should be recharged ...

Page 60: ...ES A VERY DANGEROUS SITUATION Battery should be charged according to one of the two following charge rates For a 1 amp hour battery charger charge for 10 hours or until charger shows fully charged for a partially discharged battery For a 10 amp hour battery charger charge for 1 hour or until charger shows fully charged for a partially discharged battery DO NOT ALLOW SMOKING SPARKS OR OPEN FLAMES I...

Page 61: ... safe ground on the uncharged vehicle Step 5 Start the disabled motorcycle Step 6 Quickly but safely remove the cables in the reverse order that they were applied namely a sequence of steps 4 then 3 then 2 then 1 THE RECOMMENDED SAFE GROUND ON THE DISCHARGED BATTERY S VEHICLE IS THE ENGINE CASE BOLT NEVER CONNECT THE OPPOSITE END OF THE NEGATIVE CABLE TO THE DISCHARGED BATTERY S NEGATIVE TERMINAL ...

Page 62: ... adjustments of the voltage regulator are required after leaving the factory The vehicle s alternator should be diagnosed by a professionally trained motorcycle mechanic Vehicle electrical problems can be very difficult to diagnose and correct Consequently it is recommended that any such problems be dealt with by a professionally trained mechanic Circuit breakers are provided to protect your vehic...

Page 63: ...HER WATTAGE REPLACEMENT LAMPS BULBS THAN ORIGINAL EQUIPMENT CAN CAUSE ELECTRICAL SYSTEM PROBLEMS FINGERPRINTS OILS OR OTHER FOREIGN MATERIALS CAN DAMAGE HEAD LAMPS ALWAYS USE CLEAN GLOVES CLOTH OR SIMILAR PRECAUTIONS TO PREVENT SUCH DAMAGE WHEN HANDLING HEADLAMPS USING LOWER WATTAGE REPLACEMENT LAMPS BULBS THAN ORIGINAL EQUIPMENT CAN RESULT IN IMPAIRED VISIBILITY BY OPERATOR OF OTHER VEHICLES RESU...

Page 64: ...he hydraulic tappets pump up or completely refill with oil If at any other point the valve mechanism becomes excessively or abnormally noisy it may indicate that one or several of the hydraulic units are not functioning correctly Always check oil supply first as normal oil circulation through engine is necessary for hydraulic units to function properly If there is oil in the tank there may be dirt...

Page 65: ...ransmission fluid See Section 4 4 4 The following levers and cables should be inspected and lubricated as needed at recommended inspection and maintenance intervals or sooner if systems operation indicate Clutch control cable and lever throttle control cable and speedometer cable Front brake hand lever 5 Lubricate mechanical kickstand with white lithium grease or anti seize Do not over lubricate a...

Page 66: ...on RN12YC Battery Yuasa YTX20L BS Tucker Rocky 58 1318 Brake Pads Kevlar Hi Tech FA 216 3 Air Filters Mikuni or S S Compatible K N S S Gasoline Filters Peak Flo Golan 60 312C Tire Front ME880 130 70 18 Drag Specialties SW SX 18 ME880 80 90 21 Drag Specialties SC SG SJ SX 21 SY SZ TX Tire Rear ME880 200 50 18 Drag Specialties SC SW SX 18 SX 21 ME880 240 40 18 Drag Specialties SJ SY SZ TX ME880 180 ...

Page 67: ...e 17 2089 B Coils Crane Dual Fire Drag Specialties DS 325486 Oil Filter Chrome Drag Specialties DS 275 126 Bulbs Headlight Halogen 5 3 4 Headwinds 8 9501 7 Headwinds 8 9701 Front Signal Rear Signal Single Filament 1156 Drag Specialties DS 282090 PK Rear Brake Dual Filament 1157 Drag Specialties DS 282090 PK Speedometer Single Filament GE53 Drag Specialties DS 243877 Indicator Amber Painless Wiring...

Page 68: ...5 Ft Lbs Inner Primary Bolts 18 22 Ft Lbs Jack Shaft Bolt 36 Inch Lbs Outer Primary Bolt 8 10 Ft Lbs Motor Mount to Engine 35 Ft Lbs Bracket to Motor Mount 35 Ft Lbs Bracket to Frame 35 Ft Lbs Fork Stem Nut 80 Ft Lbs check fallaway and re adjust as needed Triple Tree Pinch Bolts 25 Ft Lbs Front Axle 55 Ft Lbs Rear Axle 65 Ft Lbs Axle Pinch Bolts 8 10 Ft Lbs Spark Plugs 100 Inch Lbs ...

Page 69: ...ssion Side Cover 8 10 Ft Lbs Case Bolts 20 Ft Lbs Head Bolts 8 18 Ft Lbs 90 turn Pinion Gear Nut 45 Ft Lbs Rocker Box 5 16 20 Ft Lbs 1 4 10 Ft Lbs Rocker Box Cover Screws 10 Ft Lbs Alternator Stator Screws 30 40 Inch Lbs Cam Cover 8 10 Ft Lbs Lifter Blocks 8 10 Ft Lbs Oil Pump 8 10 Ft Lbs Relief Valve Plug 8 10 Ft Lbs Tappet Screening Plug 8 10 Ft Lbs Check Valve Plug 8 10 Ft Lbs ...

Page 70: ... cannot become involved in individual problems between you your dealer or AMERICAN IRONHORSE To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the hotline AMERICAN IRONHORSE warrants t...

Page 71: ...r element of design has been removed or rendered inoperative by any person Among these acts presumed to constitute tampering are the acts listed below 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gasses 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or part...

Page 72: ...use neglect or improper maintenance of your motorcycle Your emission control system may include parts such as the carburetor or fuel injection system the ignition system catalytic converter and engine computer Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists American IronHorse Motorcycle Company will repair your motorcycle at no...

Page 73: ...s in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use depending on the engine displacement of 12 000 kilometers 7 456 miles if the motorcycle s engine displacement is less than 170 cubic centimeters of 18 000 kilometers 11 185 miles if th...

Page 74: ...oints condensers spark plugs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts In the State of California only Emission Control System emergency repairs as ...

Page 75: ...e 4 repairs improperly performed or replacements improperly installed 5 use of replacement parts or accessories not conforming to AMERICAN IRONHORSE specifications which adversely effect performance and or 6 use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for required maintenance C Any motorcycle on which the odometer milea...

Page 76: ...EQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B No express emission control systems warranty is given by AMERICAN IRONHORSE except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control systems warranty terms stated in this warrant...

Page 77: ... that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However AMERICAN IRONHORSE is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins on the date the motorcycle is delivered to an ulti...

Page 78: ...s 2 INITIAL QUALIFICATION To qualify for the limited warranty the purchaser and the selling Dealer if sold through an authorized dealer must complete the Warranty Registration Form and return it to AMERICAN IRONHORSE within 5 days after delivery 3 TRANSFERENCE Any unexpired portion of this limited warranty may be transferred to a purchaser of said motorcycle upon the receipt of written authorizati...

Page 79: ...f original factory specifications or improper storage d Removal or tampering with vehicle odometer e Abusive use of vehicle by overreving due to missed gear change 5 LIMITATIONS This limited warranty does not apply to a Deterioration of paint chrome seats trim or other parts and accessories due to normal wear and tear b Parts and labor for any normal recommended maintenance items including but not...

Page 80: ...selling dealer and other authorized service providers must receive prior written approval from AMERICAN IRONHORSE Such warranty activities will be provided by authorized providers during normal business hours and scheduled by the provider consistent with existing workloads and parts availability IMPORTANT NOTICE AMERICAN IRONHORSE DEALERS ARE INDEPENDENTLY OWNED AND OPERATED AND AS SUCH AMERICAN I...

Page 81: ...E 2 F I G U R E 3 F I G U R E 4 F I G U R E 5 F I G U R E 6 F I G U R E 7 F I G U R E 8 F I G U R E 9 F I G U R E 10 F I G U R E 11 F I G U R E 12 F I G U R E 13 F I G U R E 14 F I G U R E 15 F I G U R E 16 F I G U R E 17 F I G U R E 18 ...

Page 82: ...FIGURE 1 82 Mikoad Onrighter Knob A B Ignition Switch ALL MODELS ...

Page 83: ...FIGURE 2 83 Hydraulic Clutch Reservoir A C Right Turn Signal Switch B Starter Switch D Ignition Kill Switch ALL MODELS ...

Page 84: ...FIGURE 3 84 Rear Shock Spring Adj A Rear Axle B D Rear Brake Caliper C Rear Shock Dam Adjuster RANGER SG ...

Page 85: ...FIGURE 4 85 S E C T I O N Transmission Gear Selector A B Ignition Switch ALL MODELS ...

Page 86: ...FIGURE 5 86 Negative Post of Battery A Engine Oil Tank Filler Tank B C Positive Post of Battery ALL MODELS ...

Page 87: ...FIGURE 6 87 Right Rear Brake Master Cylinder A ALL MODELS ...

Page 88: ...FIGURE 7 88 Petcock A ALL MODELS EXCEPT TEXAS CHOPPERS ...

Page 89: ...FIGURE 8 89 A Transmission Fill Plug ALL MODELS ...

Page 90: ...FIGURE 9 90 Transmission Fill Plug A ALL MODELS ...

Page 91: ...FIGURE 10 91 A Currently in Odometer Mode TEXAS CHOPPERS ...

Page 92: ...FIGURE 11 92 Starter Switch A Right Turn Signal B C On Off Switch ALL MODELS EXCEPT SLAMMER ...

Page 93: ...FIGURE 12 93 A S S Enricher Lever ALL MODELS EXCEPT CALIFORNIA ...

Page 94: ...FIGURE 13 94 Horn Switch A Left Turn Signal B C Headlight High Low Beam Switch ALL MODELS EXCEPT SLAMMER ...

Page 95: ...FIGURE 14 95 TEXAS CHOPPERS A Petcock ...

Page 96: ...FIGURE 15 96 SLAMMER ...

Page 97: ...FIGURE 16 97 Low Oil Pressure Indicator A Neutral Indicator B Speedometer Odometer C D High Beam Indicator D L and R Turn Indicator TEXAS CHOPPERS ...

Page 98: ...FIGURE 17 98 Neutral Indicator A High Beam Indicator B Left Turn Indicator C D Right Turn Indicator E Low Oil Pressure Indicator ALL MODELS ...

Page 99: ...FIGURE 18 99 High Low Beam Switch B Horn Switch A C Hydraulic Brake without reservoir D Left Turn Signal SLAMMER ...

Page 100: ...NTENANCE You are authorized to perform the applicable maintenance and lubrication services These services are to be performed at your regular rates and paid for by me the owner I also authorize you to road test this motorcycle for proper operation Owner s Signature VIN Date ______________ Mileage_____________ DEALER RECORD ...

Page 101: ...AINTENANCE You are authorized to perform the applicable maintenance and lubrication services These services are to be performed at your regular rates and paid for by me the owner I also authorize you to road test this motorcycle for proper operation Owner s Signature VIN Date ______________ Mileage_____________ DEALER RECORD ...

Page 102: ...AINTENANCE You are authorized to perform the applicable maintenance and lubrication services These services are to be performed at your regular rates and paid for by me the owner I also authorize you to road test this motorcycle for proper operation Owner s Signature VIN Date ______________ Mileage_____________ DEALER RECORD ...

Page 103: ...MAINTENANCE You are authorized to perform the applicable maintenance and lubrication services These services are to be performed at your regular rates and paid for by me the owner I also authorize you to road test this motorcycle for proper operation Owner s Signature VIN Date ______________ Mileage_____________ DEALER RECORD ...

Page 104: ... MAINTENANCE You are authorized to perform the applicable maintenance and lubrication services These services are to be performed at your regular rates and paid for by me the owner I also authorize you to road test this motorcycle for proper operation Owner s Signature VIN Date ______________ Mileage_____________ DEALER RECORD ...

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