MINI–BIKE
Assembly Guidelines
Page 1: ...MINI BIKE Assembly Guidelines MINI BIKE Assembly Guidelines...
Page 2: ...mstances be liable for special or consequential damages such as but not limited to damage or loss of property or equipment loss of profits or revenue loss of capital cost of purchased or replacement g...
Page 3: ...a Chain Guard IT IS UNSAFE TO OPERATE A MINI BIKE WITHOUT A CHAIN GUARD DO NOT OPERATE WITHOUT A CHAIN GUARD COVERING BOTH SPROCKETS AND THE CHAIN Ask your engine provider to provide with an appropria...
Page 4: ...ch looks like this Use the Components Checklist while you unpack and assemble your Mini Bike It lists each component by two numbers Those in the Item column are used throughout this booklet to refer y...
Page 5: ...onnects the Fork to the Frame If you wish you may paint its head of the bolt but the threaded portion should be left unpainted Allow the paint to dry thoroughly before any assembly Quantity Descriptio...
Page 6: ...position both Wheel halves so that the half moon cuts on the inside rims form a circular opening around the valve stem of the innertube Secure the Wheel halves together using three of the 5 16 18 x 3...
Page 7: ...5 16 18 Locknuts IMPORTANT Follow the same wheel assembly and tire mounting and inflation procedures and precautions set forth in Step 3 above 5 MOUNT FRONT WHEEL NOTE The following procedure will re...
Page 8: ...the Rear Wheel and Brake Drum Sprocket assembly previously completed in Step 4 Partially insert the 10 Rear Axle Item 22 from the right side through the Frame s axle hanger tab NOTE In order to center...
Page 9: ...33 on each end of the Axle Tighten the Jamnuts until the Steel Bushings are snug and can t be rotated easily Place a 5 8 18 Locknut Item 31 onto each end of the Axle and hand tighten against the Jamn...
Page 10: ...ver on the left handlebar and rotate the Cable so that the barrel end fits into the slot in the brake adjuster housing Slide the Housing up over the cable until it fits into the opening in the Brake L...
Page 11: ...e Conduit Retainer and tightening the opposing Jamnut on the front When adjusted properly the brake should fully engage and lock a spinning rear wheel well before the depressed brake lever comes into...
Page 12: ...lock the clutch in place 16 ALIGN CLUTCH REAR SPROCKETS Lay a yardstick or other suitable straight edge along the rear wheel Sprocket with the end sticking forward far enough to touch the clutch sproc...
Page 13: ...all the way onto the Frame s right handlebar and then back it off by 1 2 NOTE Adjust the Twist Grip Throttle Control on the handle bar so that the attached Throttle Conduit and Cable connec tion poin...
Page 14: ...h two 1 4 x 7 32 Conduit Clips Item 14 Use another Conduit Clip to fasten the cable conduit onto the Frame at a point near or on the engine NOTE Make sure that the Conduit Cable will not come into con...
Page 15: ...resolved problems Re read each assembly step and inspect your assembly Check all fasteners bolts screws clips clamps etc to make sure they are secured installed tightened etc properly Check the steeri...
Page 16: ...IN GUARD At this time please review the following items the boxed NOTE in bold type near the top of the Components Check list the section entitled CHAIN GUARD on page 3 of this booklet and ABOUT THIS...
Page 17: ...e bolt end of the Foot Peg through the second clamp hole On the threaded end of the Foot Peg re install the Lockwasher and Jamnut you removed previously but do not tighten down yet Twist a 5 16 18 x 1...
Page 18: ...MINI BIKE ASSEMBLY GUIDELINES 18 BASIC MINI BIKE ASSEMBLY ILLUSTRATED Clutch not included Fender optional...
Page 19: ...MINI BIKE ASSEMBLY GUIDELINES 19 NOTES NOTES...
