1st question:
I'm trying very hard to follow the run-in instructions but something doesn't make much sense so I have a question. The manual says I shouldn't run more than 1/4 throttle, no more than 35 mph, and whatever I do I must not "lug" the motor. My question is this: If the purpose of the run-in is to run at relatively low rpm to wear in the parts without overheating, why the 35 mph limit? When I run 35 mph I'm running 4th gear at low rpm. At the same rpm in 5th I would be doing about 50 mph. So, why the speed limit if it would be the same rpm?
2nd question:
The manual also suggests re-torqueing the head at 500km. Is that intended for the iron classic only or the aluminum also? I know in my former Harley days, I needed to re-torque the heads on the old ironheads and Shovelheads but it was a big no-no for the aluminum Evo motors.
Rigderunner,
Your owner's manual gives run-in procedures specific to the AVL engine, and you're doing the right thing to pay it careful attention.
In the absence of a tach you have two guidelines: road speed as indicated by the speedometer and engine speed as gauged by the gear and by the ear.
If you feel that 35mph in 4th gear is too low for break-in (especially with the caveat about lugging the engine), then run at 35mph mostly in third gear. That is precisely what I did - and I do think that 35 in 4th is lugging the engine for the purpose of break-in. Mine has 3600 miles and I don't shift into 4th until 40mph (or just under) - and that is in no-way over-revving the engine. You're supposed to vary the throttle, so run it mostly in third with just occasional sprints in 4th - if you feel like you just have to upshift.
I don't have my owner's manual here at work, but if I recall you only do this for 200 miles or so.
The difference between the AVL and Classic can be highlighted by this example: when I went on a New Year's day ride with a Classic owner, his bike was in 5th while mine was still in 4th for better part of the ride. Had I shifted into 5th it would have been lugging the engine.
The torque specs are definitely for your AVL and definitely need attention. Is it 500kms or 500 miles? Either way, I believe the torque spec is 24 ft/lbs - which should NOT be exceeded. If you're interested, you can see my maintenance notes in the signature, from my own experience.
Matt