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Harley-Davidson CLASSIC CHROME H4808 - page 1
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 ma y not be identical to item pictured h ...
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Harley-Davidson CLASSIC CHROME H4808 - page 2
2 Ta bl e of Contents Impor tant Inf ormation A Impor tant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 B Wa r nings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Harley-Davidson CLASSIC CHROME H4808 - page 3
3 CA UTION • In the unassembled state , this pac kage contains small par ts. Adult assembly is required. • Use the charger in dr y locations only . W ARNING • Prevent Injuries and Deaths • Direct Adult Super vision Required • K eep Children Within Saf e Riding Areas . These areas must be: - aw a y from swimming pools and other bodies of w ...
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Harley-Davidson CLASSIC CHROME H4808 - page 4
4 Steering Bushing - 2 Steering Stop Pa r t s C Wheel - 2 • If you e xper ience a problem with this product, or are missing a par t, please call us at 1-800-348-0751, r ather than return this product to the store. • Please identify all par ts before assemb ly and sa v e all packaging material until assemb ly is complete to ensure that no par ts ...
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Harley-Davidson CLASSIC CHROME H4808 - page 5
5 Exhaust Pipe Set Pa r t s T achometer Housing Sound Bo x T achometer Cov er F ront F ork Cov er T ank Seat F ront F ork Headlight Lens Headlight Housing Right - Outer Half Left - Outer Half Right - Inner Half Left - Inner Half ...
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Harley-Davidson CLASSIC CHROME H4808 - page 6
6 Handgrip - 2 Pa r t s Right Shock Set Left Shock Set Inner Outer Inner Outer Left Handlebar Right Handlebar Left Strut Signal Housing - 2 Right Strut Signal Lens - 2 Wheel Axle - 2 Fo rk Axle Wire Cov er Batter y Clamp Handlebar Har ness Right Mirror Mirror Lens - 2 Mirror Clamp Left Mirror ...
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Harley-Davidson CLASSIC CHROME H4808 - page 7
7 12 V olt Batter y Not Shown: Label Sheet 12-VOL T CHARGER 12 V olt Charger Pb Axle Bushing - 2 Pa r t s All Shown Actual Size .354 (Small Diameter) Cap Nut - 2 .354" .437 (Large Diameter) Cap Nut - 4 For your con venience we’ve inc luded extra fastener s! Note: Tighten and loosen all screws with a Phillips screwdriver . Do not over -tighte ...
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Harley-Davidson CLASSIC CHROME H4808 - page 8
8 T M Pa r ts Diagram D 1. V ehicle F rame 2. V ehicle Body 3. Seat 4. Wheel - 2 5. T ank 6. Left F ootboard 7. Exhaust - Inner Half - 2 8. Exhaust - Outer Half - 2 9. 12 V olt Batter y 10. Axle Bushing - 2 11. Shor t Hex Bushing - 2 12. Wheel Axle - 2 13. Air Cleaner 14. Steering Bushing - 2 15 Headlight Lens 16. Headlight Housing 17. Left Handleb ...
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Harley-Davidson CLASSIC CHROME H4808 - page 9
9 Battery Charging E Important Notes •Y our new battery must be c harged f or at least 18 hours bef ore y ou use it in y our vehicle f or the first time. •W e recommend that you start charging your batter y bef ore beginning assembly of y our ne w v ehicle. •T he batter y must be upright while charging. • The charger is not a to y . • Do ...
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Harley-Davidson CLASSIC CHROME H4808 - page 10
10 Battery Charging T M Pb • Plug the charger connector into the batter y . • Plug the charger into a standard 120 volt w all outlet . Note: If power flo w to the w all outlet is controlled by a s witch, mak e sure the s witch is “ON”. •B ef ore first-time use, charge the battery for at least 18 hours. Ne v er charge the battery longer th ...
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Harley-Davidson CLASSIC CHROME H4808 - page 11
11 Assembl y F Children can be har med b y small par ts, shar p edges and shar p points in the v ehicle’ s unassembled state , or b y electrical items. Care should be tak en in unpacking and assemb ly of the v ehicle. Children should not handle par ts, including the batter y , or help in assembly of the v ehicle. W ARNING T M • Lift to remov e ...
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Harley-Davidson CLASSIC CHROME H4808 - page 12
12 Assembl y T M • Fit the motor har ness between the v ehicle body tabs . Motor Har ness Ta b Ta b T op Vie w • Fit the tabs on the left f ootboard into the slots in the left side of the vehicle fr ame. Make sure both tabs are in the slots. Hint: Y ou may need to squeez e the left f ootboard in order to align the tabs with the slots. •I nser ...
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Harley-Davidson CLASSIC CHROME H4808 - page 13
13 Assembl y T M Right Exhaust Pipe - Outer Half • Fit the outer half of the right exhaust pipe ( R ) to the inner half of the right exhaust pipe . Hint: Use a long-shaft Phillips screwdriv er to complete this assembly step . • Align the holes in the inner half of the right exhaust pipe with the holes in the vehicle fr ame. •I nser t four #8 ...
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Harley-Davidson CLASSIC CHROME H4808 - page 14
Assembl y 15 Right Strut Tighten These Screws Rear F ender #8-32 x 1 5 / 8 " Machine Screw #8-32 x 3 / 4 " Machine Screw • First, inser t a #8-32 x 1 5 / 8 " machine screw through the hole in the side of the right str ut that is closest to the rear of the vehicle body , as shown . • Attach an #8-32 acorn nut to the end of the scr ...
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Harley-Davidson CLASSIC CHROME H4808 - page 15
15 Assembl y • Slide an axle bushing, flat side first , on the wheel axle . Axle Bushing Flat Side Wheel Axle Wheel Shor t Hex Bushing Shor t Hex Bushing • Fit a shor t hex b ushing, barrel side first, into the hole in each side of a wheel. • Separate the f ork axle from the two wheel axles. (The fo rk axle is shor ter than the wheels axles.) ...
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Harley-Davidson CLASSIC CHROME H4808 - page 16
16 Assembl y T M Steering Bushing V ehicle Fr ame Neck •P osition the v ehicle fr ame so that the front f aces you. • Fit a steering bushing underneath the neck of the v ehicle fr ame. •I nser t a #8 x 3 / 4 " screw into each end of the steering b ushing and tighten. Front Vie w 21 • Fit the headlight lens onto the headlight housing. ? ...
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Harley-Davidson CLASSIC CHROME H4808 - page 17
17 Assembl y Wire Cov er Switch Switch Pe g • Fit the wrapped por tion of the handlebar harness into the wire cov er . • Fit the tab on the wire cov er into the notch in the s witch to lock the tw o par ts together . Handlebar Harness 25 Right Handlebar • Locate the right handlebar . The r ight handlebar has an additional hole in the grip are ...
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Harley-Davidson CLASSIC CHROME H4808 - page 18
18 Assembl y •T ur n the front fork assembly around so the bac k is f acing you. • Slide the end of the wire cov er into the upper hole in the front f ork, as shown. • While making sure the handlebar harness plug remains inser ted through only the upper hole in the front f ork, slide the right handlebar down through the upper and lower holes ...
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Harley-Davidson CLASSIC CHROME H4808 - page 19
19 Assembl y • Fit the handlebar har ness plug up through the rectangular opening in the vehicle body . TM Handlebar Har ness Plug Rectangular Opening T M See Inset Handlebar Har ness Plug Rectangular Opening 35 • Align the screw holes in each handlebar with the scre w holes in the front f ork. • First, inser t two #8 x 3 / 4 " screws th ...
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Harley-Davidson CLASSIC CHROME H4808 - page 20
20 Assembl y .354 (Small Diameter) Cap Nut Fo rk Axle • Place a .354 (small diameter) cap nut on a flat surf ace , inside up . Fit the end of the f ork axle into the cap nut. •T ap the opposite end of the fork axle with a hammer to secure the cap nut on the axle. Pull on the cap nut to be sure it is securely assembled. .354" .354 Cap Nut 3 ...
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Harley-Davidson CLASSIC CHROME H4808 - page 21
21 •I nser t the handlebar har ness into the wire clip on the side of the v ehicle body . Assembl y T M Wire Clip Handlebar Har ness See Inset Wire Clip Handlebar Har ness 41 T M • Slide the f ork axle up through the bottom of the front fo r k, through the frame neck and steering stop , and out the top of the front f ork. • Fit a .354 (small ...
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Harley-Davidson CLASSIC CHROME H4808 - page 22
22 Assembl y T M •I nser t a #8 x 3 / 4 " screw through the hole in each side of the tank and tighten. Hint: To replace the batteries in the sound bo x, simply remov e the scre ws from the tank and remov e the tank from the vehicle fr ame. After replacing the batteries, be sure to replace the sound bo x, tank and screws . T ank V ehicle Fr a ...
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Harley-Davidson CLASSIC CHROME H4808 - page 23
23 • Slide the f ender onto the ends of the handlebars. Make sure the pegs on the f ender slide ov er the tabs on the front f ork. Handlebar F ront Fo r k T abs F ront Fo r k T abs Handlebar F ender Assembl y 48 T M • Fit the tachometer to the f ork cov er . •I nser t two #8 x 3 / 4 " screws into the tachometer and tighten. T achometer F ...
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Harley-Davidson CLASSIC CHROME H4808 - page 24
24 • Fit a long he x bushing, he x side first, into the hole in each side of the wheel. Long He x Bushing Long He x Bushing Wheel Assembl y 52 Long Hex Bushing He x Side • The shock sets ma y be held together by rubber bands to aid in assembly . After completing assembly step 50, remov e and thro w aw a y the rubber bands. • Fit the inner and ...
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Harley-Davidson CLASSIC CHROME H4808 - page 25
25 • Continue to slide the wheel axle through the long he x b ushing, wheel, long he x bushing and then the shock. • Fit a .437 (large diameter) cap nut on the end of the wheel axle. • Suppor t the opposite end of the wheel axle and tap the cap nut with a hammer to secure it on the end of the wheel axle. • Pull on the .437 cap nut to be sur ...
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Harley-Davidson CLASSIC CHROME H4808 - page 26
T M T M Assembl y • Fit the left mirror to the left handlebar . • Fit and hold the mirror clamp to the left mirror . •I nser t two #8 x 3 / 4 " screws through the left mirror and into the mirror clamp . Tighten the screws. •F it the primar y cover onto the left side of the v ehicle , as shown. •I nser t two #8 x 3 / 4 " screws t ...
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Harley-Davidson CLASSIC CHROME H4808 - page 27
27 Label Decoration G Proper label application will help to keep the labels looking their best! When applying labels, keep the following guidelines in mind: •W ash y our hands bef ore applying the labels. • Bef ore applying the labels, wipe the surf ace of the v ehicle with a clean, dry cloth to remov e any dust or oils . • Place the labels e ...
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Harley-Davidson CLASSIC CHROME H4808 - page 28
Label Decoration T M Left Side Right Side 28 5 4 31 8 24 22 23 25 30 10 18 21 ® ® ...
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Harley-Davidson CLASSIC CHROME H4808 - page 29
29 T M IMPORT ANT! Use only P o wer Wheels ® 12 v olt battery . Use of any other battery will damage your v ehicle. Make sure that you charge the battery for at least 18 hours using the enclosed P ower Wheels ® 12 v olt charger bef ore operating your vehic le f or the first time. Charge the batter y f or at least 14 hours after each use of the v ...
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Harley-Davidson CLASSIC CHROME H4808 - page 30
30 If a battery leak develops, av oid contact with the leaking acid and place the damaged batter y in a plastic bag. See inf ormation below for proper disposal. If acid comes in contact with skin or eyes, flush with cool water f or at least 15 min utes and call a ph ysician. If acid is internally ingested , giv e water , milk of magnesia or egg whi ...
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Harley-Davidson CLASSIC CHROME H4808 - page 31
31 Rules f or Saf e Driving K T each Saf ety Rules to Children While children can quickly de velop the skill necessar y to drive this v ehicle, it is important to remember that their judgment skills are still ve r y immature. Unsuper vised driving by children can lead to serious injur y . Bef ore children use this vehicle , an adult should carefull ...
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Harley-Davidson CLASSIC CHROME H4808 - page 32
32 Re v erse • Press the DRIVE b utton on the tank. • Press the f oot pedal. The vehicle drives f orw ard at a maximum of 2 1 / 2 mph. • Help your child pr actice steering to lear n how f ar and how quic kly to turn the handlebar when dr iving f orward in low speed. •Y our vehicle has a patented, electronic br aking system that automaticall ...
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Harley-Davidson CLASSIC CHROME H4808 - page 33
33 Po w er Boost Button • Press the power boost b utton to shift the v ehicle into high speed. The vehicle mov es f orw ard at a maximum of 5 mph. • Help your child pr actice steering to lear n how f ar and how quic kly to turn the handlebar when dr iving f orward in high speed. Ho w to Operate Y our V ehic le Bumper -to-Bumper* Limited W arran ...
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Harley-Davidson CLASSIC CHROME H4808 - page 34
34 Problem Possible Cause Solution V ehicle does not run Undercharged battery Charge the battery . A new battery should hav e been charged for at least 18 hours bef ore using the v ehicle f or the first time. After first-time use, recharge the battery for at least 14 hours after each use. Nev er charge the battery longer than 30 hours. Check all co ...
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Harley-Davidson CLASSIC CHROME H4808 - page 35
35 V ehicle was running but Loose wire or loose connectors Chec k all wires and connectors. Make sure the motor suddenly stopped harness connector is tightly plugged into the batter y , and that there are no loose wires around the motors. Tr ipped thermal fuse Each P ower Wheels ® 12 volt battery has a built-in thermal fuse. A thermal fuse may &qu ...
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Harley-Davidson CLASSIC CHROME H4808 - page 36
36 V ehicle runs sluggishly (cont.) Battery needs charging Be sure to charge the battery after each use. Battery is old and will not Even with proper care , a rechargeable battery does not accept full charge last f ore v er . A ver age battery life is 1 to 3 years depending on vehicle use and use conditions . Replace only with Po w er Wheels ® 12 ...
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Harley-Davidson CLASSIC CHROME H4808 - page 37
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Harley-Davidson CLASSIC CHROME H4808 - page 38
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Harley-Davidson CLASSIC CHROME H4808 - page 39
PRINTED IN MEXICO H0638a-0920 If y ou are missing par ts or need assistance, please call us toll-free: Po wer Wheels ® Consumer Relations 1-800-348-0751 8 AM - 6 PM EST , Monday thr ough Friday . Over 400 A uthorized Service Centers! Visit us on-line at www .powerwheels.com f or the location nearest y ou. Or contact your local, independentl y o wn ...
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