YuanDong GT2A Manual Download Page 18 | Manualshive

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Failing to follow these instructions when installing a certified engine in a piece of non-road equipment

violates Federal Law 40CFR-1068.05 (b) and is subject to fines or other penalties as described in the Clean

Air Act of 1970.

Parts Reference:

When replacing the spark plug in an Angle Fire head it’s best to use a 3 point electrode spark plug P/N
Z4JC to ensure total combustion.

( Ask your selling dealer for it by part number. )

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Summary of Contents for GT2A

Page 1: ...nstallation Many do it yourself backyard mechanics will find this project rewarding A love of small engines is the only required catalyst for this project However installation is sometimes best done by a professional auto or motorcycle mechanic Frame size should be 28mm to 30mm dia with 70 degree included V angle For sufficient engine clearance select a bike with a seat tube length of at least 12 ...

Page 2: ...cept 6mm bolts or 1 4 US thread depending on your choice of bolt For the left hole use the furnished large down tube adapter to determine placement of the hole The measurements for the two right wholes are an estimate and may vary with individual installations Figure 3 Bend the bar as shown in figure 3 The front or left side must be bent up high enough to connect to the mounting holes on the front...

Page 3: ...cover Keep as low as possible Beach Cruiser bike frames work good as well as do the classic 70 degree Old time European style Note Front mount size is different with new 203 brg block engines versus old style 202 block engines Gen III engines all have 203 brg blocks and Gt5 Gt2B have 202 brg Blocks Master Link rd side in direction of pull Need clearance here ...

Page 4: ...e and mounts on axel hub on the left side of the rear wheel against the spokes dish side in The sprocket must fit over the hub in a perpendicular plane with the axle This insures that your rear chain sprocket spins true with the rear bike wheel NOTE On some older bike axle hubs like on coaster brake models it may be required to slightly enlarge the sprocket center hole to obtain a flush and concen...

Page 5: ...orrect length Special tools are required to remove and replace the master link when shortening the chain by removing links Ideally both your pedal drive chain and your engine drive chain should have the same tension A Remove left rear cover plate from engine This is the plate next to and under the clutch swing arm B MASTER LINK B Your engine may come with a standard bike chain or with a Heavy Duty...

Page 6: ...hing to engine and wheel axle struts Ignition Coil and Engine Kill Switch installation A Mount CD ignition coil on bike frame close enough to attach coil wire to spark plug Mount as far away from exhaust pipe as possible to avoid heat damage to semiconductors in CDI module B Attach CD ignition coil wires to same identical color coded wires coming from engine C Install Engine Kill Switch Wire on th...

Page 7: ...clutch plate out similar to a car clutch Releasing the handle bar lever engages the clutch and provides engine torque to the drive chain or to start the engine The friction of 15 pads on the clutch plate allows the engine to start and also transmits engine torque to the drive chain When the bike is in pedal mode the handle bar clutch lever is locked inward held by the push button In pedal mode the...

Page 8: ...8 GT5 and GT2A models with external CDI use this kill switch hook up ...

Page 9: ...ections and tape with black electrical tape The remaining white wire from the engine is not needed unless you want to run a small wattage 6V headlight but it s not recommended as it will rob engine ignition power requirements so is really best to tape this wire up securely or just snip it off at the engine exit plug To keep water out of the magneto box use a heat shrink tube over the wire sheathin...

Page 10: ... wires so as to fire the spark plug at the right time Engine firing timing is not adjustable Position of rotor is fixed to ensure correct timing If engine does not fire at start up check all bullet connections Check if kill switch has an unwanted ground Make sure magneto has a good ground and not insulated by varnish New style 4 hole magneto When installing new magneto sand off varnish from back s...

Page 11: ...h the long groove on the slide valve Cable comes hooked up to carb for trouble free installation Note component positions in pictures Needle clip is factory set in second slot The spring is placed inside the cylinder slide and is compressed when the throttle is twisted Be sure it is seated all the way inside the cylinder The spring then forces the throttle to return For this to work properly the t...

Page 12: ... break in period 1st gallon of fuel the ratio is 16 to 18 parts gasoline to 1 part oil After the break in period the ratio can increased to 25 parts gasoline to 1 part oil NOTE Synthetic 2 Stroke Oil can also be used to insure proper engine lubrication Consult your WD dealer for his recommendations for your country and area WARNING Remember safety first Wipe up any spilled fuel NEVER fuel a hot en...

Page 13: ...e primary 10T drive sprocket secure sprocket from moving and remove nut Screw in puller tool to the threads in sprocket internal ID Tighten puller tool securely Hold tool with end wrench while using ratchet on tool bolt to push on the output shaft which causes the sprocket to lift off the shaft To remove engine B5 gear Secure clutch gear and remove slot head nut Remove star washer ...

Page 14: ...d If you need a replacement muffler contact your dealer 2010 models have an air shield welded on the outside of muffler again per EPA rulings This insures hot run so catalysis can clean the exhaust C Clean with degreaser rinse and dry Re assemble File muffler attach flange to have smooth flat surface D Always use a new exhasut gasket and good idea to use double nuts on muffler attach studs NOTE Ex...

Page 15: ...r at the end of the choke cable All the way Up the choke is on All the way Down the choke is off Move progressively downward to off position during engine warm up period Engine Starting procedure for Lever Clutch Models 1 Pull the handlebar clutch lever inward to disengage the engine from the rear wheel 2 Pedal down hill if possible for first start 3 A mid frame or rear wheel bike stand is helpful...

Page 16: ...y inspection and only the defective part or parts will be replaced not the complete kit or engine Only the defective part or parts should be returned to the selling dealer for warranty replacement consideration Your dealer may require you to obtain his authorization first before returning defective parts Include description and picture of failure with as many details as possible Note Seized piston...

Page 17: ... dealer for the China GAS Model 2 HD axle kit Complete assembled Rear Wheels for 1 speed or Multi speed 26 bikes are available Pull 2 pins to pedal with no restriction and stick them back in to motor Ask your WD if he stocks HyBriPed If not ask him to order some from China GAS www hybriped com www chinabestexporter com ...

Page 18: ...tes Federal Law 40CFR 1068 05 b and is subject to fines or other penalties as described in the Clean Air Act of 1970 Parts Reference When replacing the spark plug in an Angle Fire head it s best to use a 3 point electrode spark plug P N Z4JC to ensure total combustion Ask your selling dealer for it by part number ...

Page 19: ...19 GT5 and GT2B GT2 SM GT5 SR ...

Page 20: ...20 CNS Carburetor p n C 32CNS66 EPA ...

Page 21: ...ce rust from occuring 4 Long Short expansion chamber racing exhaust Improved catalytic muffler for 2010 EPA requirements with twice the size of palladium insert plus an outside air shield Two psc STREET POO POO PIPE available in dealer service parts ...

Page 22: ...22 44T REAR WHEEL Drive Sprocket ...

Page 23: ...23 ...

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