Harley-Davidson H4808, H0638 User Manual

Owner's Manual

with Assembly Instructions

For Models H0638 and H4808

Harley-Davidson is a registered trademark and the motorcycle sound is a trademark of H-D Michigan, Inc. used under license.

In an effort to provide the best products possible, we periodically make

product modifications. Actual product may not be identical to item pictured here.

Please read this manual and save it with your original sales receipt.

Tools needed for assembly: Phillips Screwdriver, Hammer, Safety Scissors, Slotted Screwdriver

and Adjustable Wrench (no tools included).

Use only with a Power Wheels®12 Volt Rechargeable Battery

and a Power Wheels®12 Volt Charger (both included).

Sound Box requires three “AA” (LR6) alkaline batteries (batteries not included) for operation.

Table of Contents

Important Information

A Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

C Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

D Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

E Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

F Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

G Label Decoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

H Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

I Battery Care and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

J Caring For Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

K Rules For Safe Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

L How to Operate Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

M FCC Note (United States Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

N Statement of Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

O Problems and Solutions Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

•Your new vehicle requires adult assembly. Please set aside at least 90 minutes for assembly.

•You must charge your battery for 18 - 30 hours before you use your vehicle for the first time.We recommend that you start charging your battery before beginning assembly. Please see Battery Charging beginning on page 9 for detailed instructions.

• Read this manual carefully for important safety information and operating instructions before using your vehicle. Keep this manual for future reference as it contains important information.

• This vehicle is designed for use on: grass, asphalt and other hard surfaces; on generally level terrain; and by children 3 years of age and older.

• Make sure children know and follow these rules for safe driving and riding:

- always sit on the seat.

- always wear shoes.

- only 1 (one) rider at a time.

• Please note that the front wheel of the vehicle can lift slightly off the ground during use, especially if the vehicle is driven forward in high speed from a stopped position. This is a normal occurrence and is not cause for alarm. The vehicle will not tip. The rear wheel is designed to act as a stabilizer by restricting front wheel lift, preventing the vehicle from tipping. To prevent front wheel lift, teach your child to start the vehicle in low speed and shift to high speed only when already moving forward.

• Use this vehicle ONLY outdoors. Most interior flooring can be damaged by riding this vehicle indoors. Fisher-Price

will not be responsible for damage to

floor if the vehicle is used indoors.

•For safety reasons, your vehicle has been pre-set so that it will operate at low speed. Note that the power boost button on the handlebar will not operate in the pre-set, low speed mode. You must connect the

high speed hook-up to allow operation of the vehicle at high speed when pressing the power boost button on the handlebar. Please see page 32

for detailed instructions.

•To prevent damaging the motors and gears, teach your child to stop the vehicle before switching direction. Do not tow anything behind the vehicle or overload it. Do not exceed the maximum weight capacity of 65 lb (29.5 kg).

• If you have any questions about your Power Wheels

vehicle, please call our toll-free service lines at 1-800-348-0751 from 8 AM to 6 PM (EST) Monday through Friday. Trained customer service representatives are available to take your call in English or French. Habla Español? Si usted tiene alguna pregunta ó necesita asistencia llame gratis 1-800-348-0755 para los Estados Unidos. Tenemos representantes que hablan español para atender su llamada.

•For your convenience, Power Wheels®maintains an independently owned and operated Authorized Service Center Network with more than 400 authorized service centers nationwide. The authorized service centers will repair or replace parts under warranty at no extra charge, and can perform non-warranty repairs for a minimal charge. To find the authorized service center nearest to you, visit us on-line at www.powerwheels.com or call 1-800-348-0751.

• If you would like to register your vehicle, please visit us on-line at www.powerwheels.com.

CAUTION

• In the unassembled state, this package contains small parts. Adult assembly is required.

• Use the charger in dry locations only.

WARNING

• Prevent Injuries and Deaths

• Direct Adult Supervision Required

• Keep Children Within Safe Riding Areas. These areas must be:

- away from swimming pools and other bodies of water to prevent drownings

- generally level to prevent tipovers

- away from steps, steep inclines, cars, roads and alleys.

RIDING HAZARD

WARNING

• Battery can fall out and injure a child if vehicle tips over. Always use battery clamp.

• PREVENT FIRE

- Never modify the electrical system. Alterations could cause a fire resulting in serious injury and could also ruin the electrical system.

- Use of the wrong type battery or charger could cause a fire or explosion resulting in serious injury.

- Use of Power Wheels

components in products other than Power Wheels®vehicles

could cause overheating, fire or explosion.

• The battery must be handled by adults only. The battery is heavy and contains sulfuric acid (electrolyte). Dropping the battery could result in serious injury.

•Never allow children to charge the battery. Battery charging must be done by adults only. A child could be injured by the electricity involved in charging the battery.

• Read the safety instructions on the battery.

• Examine the battery, charger and their connectors for excessive wear or damage each time you charge the battery. If damage or excessive wear is detected, do not use the charger or the battery until you have replaced the worn or damaged part.

• HOT motors. Handle carefully.

Warnings and Cautions

ELECTRICAL HAZARD

Steering Bushing - 2

Steering Stop

Parts

Wheel - 2

• If you experience a problem with this product, or are missing a part, please call us at 1-800-348-0751, rather than return this product to the store.

• Please identify all parts before assembly and save all packaging material until assembly is complete to ensure that no parts are discarded.

•Metal parts have been coated with a lubricant to protect them during shipment. Wipe all metal parts with a paper towel to remove any excess lubricant.

Vehicle Body

Fender

Left Footboard

Vehicle Frame

Horn

Air Cleaner Cover

Primary Cover

Exhaust Pipe Set

Parts

Tachometer Housing

Sound Box

Tachometer Cover

Front Fork Cover

Tank

Seat

Front Fork

Headlight Lens

Headlight Housing

Right - Outer Half

Left - Outer Half

Right - Inner Half

Left - Inner Half

Handgrip - 2

Parts

Right Shock SetLeft Shock Set

InnerOuter

Inner Outer

Left

Handlebar

Right

Handlebar

Left Strut

Signal Housing - 2

Right Strut

Signal Lens - 2

Wheel Axle - 2

Fork Axle

Wire Cover

Battery Clamp

Handlebar Harness

Right Mirror

Mirror Lens - 2

Mirror Clamp

Left Mirror

12 Volt Battery

Not Shown: Label Sheet

12-VOLT

CHARGER

12 Volt Charger

Axle Bushing - 2

Parts

All Shown Actual Size

.354 (Small Diameter) Cap Nut - 2

.354"

.437 (Large Diameter) Cap Nut - 4

For your convenience we’ve included extra fasteners!

Note: Tighten and loosen all screws with a Phillips screwdriver. Do not over-tighten the screws.

#8-32 Acorn Nut – 4

#8 x 3/4" Screw – 63

#8-32 x 3/4" Screw – 2

#8-32 x 15/8" Screw – 2

.437"

#8 x 1/2" Screw – 4

Short Hex Bushing - 2

Long Hex Bushing - 2

T M

Parts Diagram

1. Vehicle Frame

2. Vehicle Body

3. Seat

4. Wheel - 2

5. Tank

6. Left Footboard

7. Exhaust - Inner Half - 2

8. Exhaust - Outer Half - 2

9. 12 Volt Battery

10. Axle Bushing - 2

11. Short Hex Bushing - 2

12. Wheel Axle - 2

13. Air Cleaner

14. Steering Bushing - 2 15 Headlight Lens

16. Headlight Housing

17. Left Handlebar

18. Right Handlebar

19. Front Fork

20. Handgrip - 2

21. Long Hex Bushing- 2

22. Steering Stop

23. Fork Axle

24. Front Fork Cover

25. Fender

26. Tachometer Housing

27. Tachometer Cover

28. 12 Volt Charger

29. .354 Cap Nut - 2

30. .437 Cap Nut - 4

31. Battery Clamp

32. Left Strut

33. Handlebar Harness

34. Signal Housing - 2

35. Signal Lens - 2

36. Right Mirror

37. Wire Cover

38. Horn

39. Right Inner Shock

40. Right Outer Shock

41. Left Inner Shock

42. Left Outer Shock

43. Sound Box

44. Primary Cover

45. Mirror Clamp

46. Left Mirror

47. Mirror Lens - 2

Not Shown

#8 x

/4" Screw - 63 #8 x 1/2" Screw - 4 #8-32 x 3/4" Screw - 2 #8-32 x 15/8" Screw - 2 #8-32 Acorn Nut - 4 Label Sheet - 2

Note: Some parts shown are assembled

on both sides of the vehicle.

12-VOLT

CHARGER

Battery Charging

Important Notes

•Your new battery must be charged for at least 18 hours before you use it in your vehicle for the first time.

•We recommend that you start charging your battery before beginning assembly of your new vehicle.

•The battery must be upright while charging.

• The charger is not a toy.

• Do not short circuit the battery.

•You do not need to remove the battery from your vehicle to recharge it.

• Before charging the battery, examine the battery case for cracks and other damage which may cause sulfuric acid (electrolyte) to leak during the charging process. If damage is detected, do not charge the battery or use it in your vehicle. Battery acid is very corrosive and can cause severe damage to surfaces it contacts.

• Do not charge the battery on a surface (such as kitchen counter tops) which could be damaged by the acid contained inside the battery. Take precautions to protect the surface on which you charge your battery.

• If your battery is old and will not accept a charge, do not leave it in your vehicle. Always remove a dead battery from the vehicle.

• Use only a Power Wheels®12 volt charger (120 VAC 60 Hz 28W with an output of 12 VDC 1200mA) to charge your Power Wheels®12 volt battery.

• When replacing the 12 volt battery, use only a Power Wheels®12 volt battery.

About Thermal Fuses

Yo ur Power Wheels 12 volt battery is equipped with a built-in thermal fuse. The thermal fuse is a self-resetting safety device which automatically “trips” and shuts down operation of the vehicle if the vehicle is overloaded or the driving conditions too severe. Once a fuse has “tripped”, it will automatically reset itself after approximately 25 seconds and allow the vehicle to resume normal operations. To avoid repeated automatic shutdowns, do not overload the vehicle by exceeding the 65 lbs. maximum weight capacity or by towing anything behind the vehicle. Avoid severe driving conditions, such as driving up slopes or running into fixed objects, which can cause the wheels to stop spinning while power is still being supplied to the motors and make sure your child stops the vehicle before switching speeds or direction.

If a thermal fuse in a battery continually trips under normal driving conditions, please contact your local Power Wheels®Authorized Service Center. For the location of the Authorized Service Center nearest to you, please visit us on-line at www.powerwheels.com, or call 1-800-348-0751.

CAUTION

Use the charger in dry locations only.

WARNING

• Battery can fall out and injure a child if vehicle tips over. Always use battery clamp.

• PREVENT FIRE

- Never modify the electrical system. Alterations could cause a fire resulting in serious injury and could also ruin the electrical system.

- Use of the wrong type battery or charger could cause a fire or explosion resulting in serious injury.

- Use of Power Wheels

components in

products other than Power Wheels

vehicles could cause overheating, fire or explosion.

• The battery must be handled by adults only. The battery is heavy and contains sulfuric acid (electrolyte). Dropping the battery could result in serious injury.

•Never allow children to charge the battery. Battery charging must be done by adults only. A child could be injured by the electricity involved in charging the battery.

• Read the safety instructions on the battery.

ELECTRICAL HAZARD

Battery Charging

T M

• Plug the charger connector into the battery .

• Plug the charger into a standard 120 volt wall outlet . Note: If power flow to the wall outlet is controlled by a

switch, make sure the switch is “ON”.

•Before first-time use, charge the battery for at least 18

hours. Never charge the battery longer than 30 hours.

• Recharge the battery for at least 14 hours after each

use of your vehicle. Do not charge the battery longer than 30 hours.

• Once the battery is charged, pull firmly on the charger

connector to disconnect it from the battery. Unplug the charger from the wall outlet. The battery is now ready to be installed in your vehicle. Please see the Battery Installation section on page 29 for detailed instructions on installing your battery. If your battery is already installed in your vehicle, simply plug the motor harness connector into the battery and replace the seat.

• Remove the two screws holding the battery clamp to the vehicle body.

• Remove the battery clamp. Set the battery clamp and screws aside. Do not throw out the battery clamp or screws.You will use them when installing your battery (see page 29).

• Remove the battery from the battery compartment.

• Remove and discard any cardboard in the battery compartment which may have been added for shipping purposes.

Battery

Charger Connector

Battery

Clamp

Assembly

Children can be harmed by small parts,

sharp edges and sharp points in the

vehicle’s unassembled state, or by

electrical items. Care should be taken in

unpacking and assembly of the vehicle.

Children should not handle parts,

including the battery, or help in

assembly of the vehicle.

WARNING

• Lift to remove the vehicle body from the vehicle frame.

Vehicle

Frame

Vehicle

Body

• Fit motor harness connector up through the large rectangular opening in the vehicle body .

• Fit the high speed hook-up connector through the square opening near the front of the vehicle body .

•Position the vehicle body on top of the vehicle frame .

Square

Opening

Motor

Harness

Connector

Vehicle Frame

Vehicle

Body

Large

Rectangular

Opening

High Speed

Hook-Up

•Insert six #8 x 3/

4" screws through the vehicle body and

into the vehicle frame. Make sure the holes in the vehicle body and frame are aligned. Tighten the screws.

Vehicle Frame

Vehicle Body

Front View

Assembly

• Fit the motor harness between the vehicle body tabs.

Motor

Harness

Ta b

Top View

• Fit the tabs on the left footboard into the slots in the left side of the vehicle frame. Make sure both tabs are in

the slots.

Hint: You may need to squeeze the left footboard in order to align the tabs with the slots.

•Insert two #8 x 3/4" screws into the left footboard, as shown. Tighten the screws.

Left

Footboard

Ta b

Slots

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• The right footboard was inserted in the vehicle frame at the factory. Make sure the right footboard is in place.

•Insert two #8 x 3/4

" screws into the right footboard,

as shown. Tighten the screws.

Right

Footboard

• Separate the exhaust pipe set pieces. Note the R (right side) and L (left side) markings on the inside of each piece.

• Fit the inner half of the right exhaust pipe (R) over the stabilizer wheel on the right side of the vehicle. Make sure the peg on the inner exhaust pipe fits into the hole in the vehicle body.

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Stabilizer

Wheel

Vehicle

Body Hole

Right Exhaust

Pipe - Inner Half

Peg

Right Side View

Left Side View

+ 27 hidden pages