Kodiak Motorcycle Company AGGRESSOR Base, AGGRESSOR Custom, AVENGER Base, AVENGER Custom, ENFORCER SS Owner's Manual
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Owner’s Manual
KODIAK MOTORCYCLE
COMPANY
2905 HIGHWAY 30 EAST
#1 KODIAK INDUSTRIAL PARK
TYNER, KY
40486
606-364-2100 FACTORIES
775-307-3340 FAX
859-277-5644 CUSTOMER SERVICE
THE MODELS:
AGGRESSOR SERIES
BASE
CUSTOM
AVENGER
BASE
CUSTOM
ENFORCER
ENFORCER SS
ENFORCER SSXTREME
ENFORCER STS
Breaking in your KMC custom bike 2
FIRST 500 MILES:
FIRST 1000 MILES:
NEXT 1000 MILES:
WARNING: Do not overfill the gas tank, although your KMC custom has a 4.8gallon gas tank, we do not recommend filling past 3 gallons to stay well away
from over-filling. The overflow valve will vent any excess gas out.
It is important to follow this break-in procedure to ensure the quality of future
performance and durability of your custom bike.
The first 50 miles are especially critical; over-revving
your motorcycle can cause permanent damage to your
engine and void the warranty.
Do not exceed speeds of 60 mph.
Do not rev the engine harder than 3000 rpm in any gear.
Vary speeds.
Do not overheat or lug the engine.
Do not exceed speeds of 70 mph.
Vary your range of speeds.
Do not rev the engine harder than 3000 rpm in any gear.
NO drag racing, dyno runs, burn outs, trailer towing, etc.
Copyright 2002, Kodiak Motorcycle Company – www.kodiakmc.com
Maintaining your KMC custom bike 3
Regularly Check:
- that tires don’t have any bad wear or cuts.
- Drive-belt for proper tension.
- Brakes, Steering and Throttle.
- Brake fluid level.
- Hydraulic lines and fittings to make sure there aren’t leaks
- Brake pads and disks, make sure they’re not too worn.
- Cables, be sure they’re not frayed or coming loose.
- All the lights.
CAUTION: Your KMC bike should not ever be supported by placing props
under the brake system as damage could occur.
FLUID MAINTENANCE
Oil Filter: The oil filter should be changed every time the oil is changed.
Hydraulic Lifter Oil Filter Screen: The hydraulic lifter oil filter screen is
located in the crankcase above the oil pump.
Air Filter: Inspect the air filter after the first 500 miles and after that, every
2,500 miles. If it is dirty, discard and replace. Do not run the engine without an
air filter.
Fuel Tank Strainer: This is a screen, located on top of the supply valve inside
the fuel tank. It should be inspected and cleaned every 5,000 miles. First empty
the gas tank through the fuel supply line, then unscrew the fuel supply valve
from the tank. Clean and then reinstall the valve.
Engine Oil: Check the level after the engine has been ridden some so that the
oil is at operating temperature.
Changing the Engine Oil: Engine oil should be changed after the first 500
miles, and after that every 2,500 miles, or less if the bike is operated in cold
climates. Oil-changes should be done while the oil is at operating temperature.
- Position the bike standing straight up and level.
- Completely drain the engine oil tank before removing the engine oil filter.
- Remove the oil-filter, then clean the filter gasket contact surface on the
mounting plate. Apply a thin film of oil to the gasket contact surface.
Copyright 2002, Kodiak Motorcycle Company – www.kodiakmc.com
Maintaining your KMC custom bike 4
- When the oil tank has drained, clean the drain-plug and reinstall it.
- Remove the oil filter.
- Pour four ounces of clean oil into the filter.
- Put the new filter back on.
- With the oil tank drain plug in place, fill the oil tank to the proper level.
Checking the Transmission Fluid: Check the tranny oil while the engine is at
normal operating temperature. The bike should be position straight up and level.
Changing the Tansmissiom Fluid: The transmission fluid should be changed
after the first 500 miles, and every 5,000 miles or seasonal change after that,
whichever comes first.
- Position the bike straight up and level.
- Unscrew the drain plug and allow the fluid to drain.
- Remove any foreign material from the end of the plug.
- After the fluid has drained, reinstall the drain-plug.
- Remove the threaded filler-plug and fill with fluid.
SUSPENSION MAINTENANCE
Front Fork Oil: Drain the front fork oil every 10,000 miles ,or annually. If
there is insufficient oil in the fork, rebound action will not be as responsive.
Brake Fluid: Check the fluid level every 5,000 miles.
FRONT END MAINTENANCE
- Repack the front and rear wheel bearings at least every 10,000 miles, or
yearly if the bike is in storage. Replace seals and axle spacers if they seem to
show distortion or wear.
- Remove and lubricate the handlebar throttle control grip sleeve with fresh
graphite every 5,000 miles, once a year, or when it seems to need better
lubrication.
- Repack the steering head bearings with new grease at 10,000 mile intervals or
every 2 years, whichever comes first.
- Lubricate the side stand mechanism with anti-seize every 2,500 miles.
- Be sure to re-oil all control connections after washing the motorbike or
driving in wet weather.
- Tightness of the rear fork pivot shaft fastener should be checked after the
first 500 miles and every 5,000 miles thereafter.
Copyright 2002, Kodiak Motorcycle Company – www.kodiakmc.com
Maintaining your KMC custom bike 5
- Check the front forks for proper bearing adjustment after the first 500 miles,
and then after every next 5,000 miles. Bearings should be repacked at 10,000
mile intervals.
Checking Ride Height: With the bike unloaded, on the side stand, and the
shock fully extended, measure from the center point of the rear axle to a point
on the fender or body work directly above it. With the bike off the stand and the
rider in the sear, bounce on the suspension and let the bike settle. Measure from
the same two points. Subtract the second measurement from the first. The
difference should be between 1 and 1.5 inches. The amount of settle is a
function of wheel travel and should be between ¼ and 1/3 of total wheel travel.
If the difference is less than the maximum, reduce the spring preload (back the
nut off, turn it counter-clockwise). If the ride height is too low, the shock will
bottom out frequently, resulting in a bumpier ride. If the ride height is set too
high, the shock will “top out” more frequently and from smaller bumps, resulting
in a bumpier ride.
WHEELS AND TIRES
Wheel Inspection: Check wheels periodically for tightness of spokes, billet
wheels should be checked periodically for cracks or dents.
Tire Inspection: Check your tire pressure at least every week. If your tire is
under-inflated, you may experience bad handling, additionaly the tire may slip
off the rim, causing serious personal injury. If your tires are changed, the
replacements must be of the same type as those currently on the bike. IF the tire
strikes an object, such as a curb, at speed, internal damage may result, when
this happens, it’s a good idea to inspect the tire internally for damage.
CAUTION: Never put previously used, damaged, punctured or repaired tires
on your bike, once a tire has been damaged, it isn’t safe to use.
THE ENGINE
Hydraulic Liftes: Hydraulic lifters automatically adjust for engine expansion
and valve mechanism wear. For the first few minutes of starting an engine, the
valve mechanism will be noisier than usual until the hydraulic units refill with
oil. If the valves do not quiet down a few minutes after then engine has started,
valve mechanism becomes abnormally noisy, it’s an indication that one or more
of the hydraulic units may not be functioning properly. If a hydraulic unit
appears to have failed, verify that the oil tank is properly filled, and that the
Copyright 2002, Kodiak Motorcycle Company – www.kodiakmc.com
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