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Reverse bolt in puller tool; Secure tool in output gear; Hold tool with end wrench and ratchet bolt CW to
remove gear.
*Clutch Adjust Nut
2. Carburetor
Per instructions from the Dept. of EPA the idle and air fuel mixture screws have been epoxy sealed at the
factory to avoid end-user tampering. Depending on dusty riding conditions, clean air filter every 5 to 20
hours of operation by removing the filter cover to access the screen and element. Wash element with a
degreasing agent such as Simple Green™ or Purple Stuff™. Be sure element is completely dry before re-
assembly. IMPORTANT: If engine runs poorly clean tank shut off value filter.
#3. 3 pt. Spark Plug
Remove spark plug and inspect for excess carbon build up. Clean, re-gap to .0.036” of an inch if necessary.
Check plug after every 20 hours of operation. New spark plugs are available from your selling dealer. Be
careful using aftermarket spark plugs as heat range and threads differ greatly. An extra plug is included:
#4. Exhaust system
After 50 hours of operation check exhaust pipe for excessive oil and carbon build-up. If muffler is clogged
your dealer has replecements. Make sure attaching nuts are tight and no exhaust leaks are occurring. Be sure
to use supplied support strap to secure exhaust muffler to a solid anchor point on bike frame or engine.
A)
To remove inside catalytic exhaust insert loosen the retaining screw on end cap and remove.
B)
Pull cap and baffle out of pipe. Note: Some catalytic inserts are welded in and cannot be removed. If
you need a replacement muffler contact your dealer. 2010 models have an air shield welded on the
outside of muffler again per EPA rulings. This insures hot run so catalysis can clean the exhaust.
C)
Clean with degreaser, rinse and dry. Re-assemble: File muffler attach flange to have smooth flat surface.
D)
Always use a new exhasut gasket and good idea to use double nuts on muffler attach studs;
*NOTE:
Excessive periods of low speed operation, idling or leaving fuel petcock in the “on” position during
shut down periods may cause the muffler to become clogged with unburned fuel.
#5. Standard Bike 1/2x1/8” Chain is included in kit. HD 415 is available from dealers.
Every time bike is ridden check the tension of the drive chain by:
A)
Rolling to bicycle forward to remove slack from the bottom of the chain.
B)
Find the center and push downward on the top of chain while measuring the deflection.
C)
Tighten chain if deflection is more than ½ inch.
#6. Head Bolts
Tighten all fasteners after each five hours of operation. Most important to check
Cylinder head bolts : Tighten in a X pattern to 10 ft/lb using a torque wrench. A two piece cylinder and
head design engine requires head bolts be kept tight. Important: Check head bolts before each and every
long ride, vibration can cause them to loosen and blow a head gasket. Caution: Do not over torque or head
bolts may break off. ( Twisted or broken head bolts due to over tightening is not covered by warranty. )
#7. Right side gears:
Remove cover plate and keep small amount of heavy grease on gear train.
Do not over grease as leaks will occur and also may adversely affect clutch operation. Regular
greasing if required will help reduce gear wear and keep gear train quiet.
