MINI-BIKE ASSEMBLY GUIDELINES
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10. MOUNT BRAKE LEVER
❍
Loosen both clamp screws on the Brake Lever (Item 6) and
install it onto the Frame’s left handlebar about 4" from the
end with the steel ball end of the Lever pointing left and
forward.
❍
Secure the Brake Lever into position by tightening the
mounting collar screws.
CAUTION
: Prior to any operation, be sure to adjust the
position of the Brake Lever so that it is readily available to
and easily accessed and operated by the intended rider.
11. INSTALL BRAKE CABLE
❍
Locate the Brake Cable & Conduit Assembly (Item 8) (64"
Cable, 60" Black Conduit Housing).
❍
Pull about 18" of the Brake Cable out of the Housing.
❍
Shorten the Housing by cutting 6" off the empty end.
❍
Seat the barrel end of the Brake Cable into the hole in the
Brake Lever 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 Lever.
❍
Route the Brake Cable and Housing down the Fork and left of
the Frame toward the brake, using three Conduit Clips (Item
14) to secure the Cable and Housing to the Fork and frame as
you go.
IMPORTANT:
Cable and Housing should be routed and
secured to the inner surfaces of the fork and frame. Avoid
sharp bends. Also, make sure that your routing allows the
fork to move freely from side to side without binding or
pinching.
12. SECURE BRAKE CABLE TO BRAKE
❍
Run one 5/16-24 Jamnut (Item 32) almost all the way onto
the threaded end of the 5/16-24 x 2" Straight Conduit
Retainer (Item 16).
❍
Insert the threaded end of the Conduit Retainer through the
hole in the upper tab on the Brake backing plate, from the
front, and secure it in place with the second 5/16-24 Jamnut
(Item 32).
