MINI-BIKE ASSEMBLY GUIDELINES
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❍
Insert the engine mounting bolts down into the engine’s
mounting holes until they extend through the bottom of the
Frame’s mounting plate slots.
❍
Carefully slide the engine as far to the rear of the mounting
plate as possible and then place recommended washers and/
or Locknuts onto the bolts. At this time, hand-tighten only.
NOTE:
The engine must remain in this temporary pushed-to-
the-rear position until after you have installed the clutch and
the chain as described in Steps 15 & 16.
15. INSTALL CLUTCH
❍
Install the clutch onto the engine drive shaft, with the
clutch’s
sprocket facing in, toward the engine
. DO NOT INSTALL THE
CLUTCH WITH ITS SPROCKET FACING OUT AND AWAY
FROM THE ENGINE.
❍
Do not yet 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 sprocket.
❍
Adjust the clutch by sliding it on the engine drive shaft into a
position where it is aligned EXACTLY with the rear wheel
sprocket and then lock it into its aligned position.
17. INSTALL CHAIN
❍
Item 20 includes a length of #35 roller Chain and a Connect-
ing Link with side plate and spring clip. For the time being,
put the connecting link pieces safely aside.
❍
Wrap the chain around both sprockets forming a closed loop.
With a piece of chalk, mark the link where the chain must be
“broken.”
NOTE:
Cutting too long is better than too short — you can
always remove additional links.
❍
Using a chain-breaker, cut the Chain at the marked link.
❍
Once sized, reform the loop around both sprockets and
complete it by installing the connecting link.
