MFG supply Mini-Bike User manual

MINI–BIKE
Assembly Guidelines
MINI–BIKE
Assembly Guidelines

MINI-BIKE ASSEMBLY GUIDELINES
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WARRANTY INFORMATION
Products manufactured by Manufacturer bear the following limited warranty:
Manufacturer warrants that goods delivered will be of the kind and quality
described in the retailer’s order or contract and will be free of defects in workman-
ship or material. Should any failure to conform to this warranty appear within
thirty (30) days after the initial date of delivery, Manufacturer shall, upon
notification and substantiation that the goods have been stored, installed,
maintained and operated in accordance with Manufacturer’s recommendations and
standard industry practice, correct such defect by suitable repair or replacement
as its own expense.
This warranty is exclusive and is in lieu of any warranty of merchantibility,
fitness for a particular purpose or other warranty of quality, whether expressed
or implied except of title and against patent infringement. Correction of non-
conformities, in the manner and for the period of time provided above, shall
constitute fulfillment of all liabilities of the seller to the purchaser with respect to,
or arising out of the goods, whether based on contract, negligence, strict tort or
otherwise.
Limitation of Liability: Manufacturer shall not under any circumstances 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 goods, or claims of customers or purchaser for service
interruptions. The remedies of the purchaser set forth herein are exclusive, and the
liability of manufacturer with respect to any contract, or anything done in
connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, installation or use of any goods covered by or
furnished under this contract whether arising out of contract, negligence, strict
tort, or under warranty, or otherwise, shall not, except as expressly provided
herein, exceed the price of the goods upon which such liability is based. This is
the only warranty on any of Manufacturer’s products. NO other writing or
description shall be construed as a warranty.
Products manufactured by other than Manufacturer bear the following limited
warranty: Manufacturer warrants that the goods manufactured by others will
conform to the description herein stated. NO other warranty express or implied is
made. Any warranty of the manufacturer is hereby assigned and transferred to the
buyer. Furthermore, except for the manufacturer’s warranty, if any, the products
sold hereunder are sold AS IS. Manufacturer is not liable for any incidental or
consequential damages in connection with these products.

MINI-BIKE ASSEMBLY GUIDELINES
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IMPORTANT!
READ THIS PAGE BEFORE ANY ASSEMBLY
Mini-bikes must be operated in accordance with all applicable
laws and regulations and riders must comply with all require-
ments regarding head, eye and body protection. Please check
with appropriate government agencies before operating your
mini-bike. Prior to any operation, all riders must be properly
trained in, and fully knowledgeable of all mini-bike functions
and safe operation and procedure. Full compliance with this
with all information set forth in these guidelines is mandatory.
FAILURE TO FULLY COMPLY IS UNSAFE AND COULD
POSSIBLY RESULT IN SERIOUS INJURY OR DEATH.
CHAIN GUARD
WARNING: This kit does NOT contain 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 appropriate Chain Guard.
ASSEMBLY SAFETY
Assembly should be performed by knowledgeable individuals
using appropriate tools. Please consult with your retailer or a
Kart or Mini-Bike shop or your local, knowledgeable mechanic
if you experience problems with, or have questions about any
portion of the assembly process, individual or overall function
or operation whatsoever.
CAUTION! COMPRESSED AIR CAN BE DANGEROUS! Con-
tainment guards and eye protection should be used when
inflating tires. Assemble tires and wheels with care. Never force
a tire onto a wheel by prying against the wheel rim. A properly
assembled tire will seat itself onto the wheel rim with less than
15 pounds per square inch (psi) of air pressure.

MINI-BIKE ASSEMBLY GUIDELINES
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☛ABOUT THE CONTENTS
All of the components you need to assemble a mini-bike chassis
have been delivered to you in one cardboard carton. An engine,
engine mounting hardware, clutch and chain guard are not
included and must be obtained and installed before you
operate your mini-bike.
Folded into this booklet, is a single sheet entitled “Mini-Bike
Components Checklist” which 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 you to
individual components. The “Mfgr. No.” is listed to aid your retail
merchant should you have questions or require replacement
parts. The illustration on the last page of this booklet is provided
to help you locate components and to present a basic visual guide
to assembly. Use it with these written guidelines.
A few more matters before you begin assembly:
ASSEMBLY GUIDELINES
ASSEMBLY GUIDELINES

MINI-BIKE ASSEMBLY GUIDELINES
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☛UNPACK & ORGANIZE
As you unpack, identify, inventory and group the components
according to their function and assembly step. Hardware which is
referenced throughout the remainder of this booklet is packaged
in four (4) poly bags, marked as follows:
Now, on to the fun stuff . . . .
1.PAINT FORK & FRAME
❍Thoroughly clean the Fork (Item 18), and Frame (Item 19),
making sure to remove the rust proofing oil.
❍The 5/16-18 x 6" Bolt (Item 32) connects 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 Description Bag#
1
1
6
1
1
1
2
Wire Stop with Screw
Wire Swivel with Screw
Conduit Clips
Conduit Clamp
Straight Conduit Retainer
Spring
Jamnuts, 5/16-24
A
A
6
6
4
3
Bolts, 5/16-18 x 3”
Locknuts, 5/16-18
Steel Bushings, 5/8” ID x 1-1/4”
Conduit Clamp
B
B
3
1
1
2
4
4
Bolts, 1/4-20 x 5/8”
Bolt, 5/16-18 x 1”
Bolt, 5/16-18 x 2-1/2”, Full Thread
Locknuts, 5/16-18
Locknuts, 5/8-18
Jamnuts, 5/8-18
C
C
6
2
2
2
Clamp Halves
Bolts, 5/16-18 x 1”
Locknuts, 5/16-18
Lockwashers
D
D

MINI-BIKE ASSEMBLY GUIDELINES
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2. ATTACH FORK TO FRAME
❍Attach the Fork to the Frame using the 5/16-18 x 6" Bolt
(Item 29) and the 5/8-18 Locknut ( (Item 34) (which for
packing purposes only is installed onto the 5/16-18 x 6"
Bolt).
❍Tighten the Locknut until snug, and then back it off slightly
to allow the Fork to move freely back and forth.
3. ASSEMBLE FRONT WHEEL
❍Insert one Innertube (Item 4) into the Front (Sawtooth) Tire
(Item 3) so that it is snug and resting completely within the
tire. Inflate the Innertube with just enough air to remove the
folds from the tube (1 or 2 psi).
❍Mount the Front Tire onto a 5" Wheel set (Item 1), as follows:
❍Insert one Wheel half into each side of the Front Tire and
over the Innertube.
CAUTION: Do not pinch the tube between the wheel
halves.
❍Carefully 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" Bolts and three of the 5/16-18 Locknuts. For
now, tighten the Locknuts only finger tight. Do not inflate
the tire yet.
❍Insert the threaded 8" Front Axle (Item 21) into the wheel
assembly through the 5/8" bearings. Doing so aligns the
wheel halves.
❍Carefully tighten each nut in sequence. Torque down
each nut tightly, but do not over torque. If you have a
torque wrench, which is suggested, tighten each nut to 5
ft-lbs.
CAUTION: If you use a source of compressed air to inflate
the tires, use eye protection and a tire cage during
inflation. A simple bicycle tire hand-pump is sufficient to
provide adequate inflation.
❍Inflate the tire to 15 psi and make sure it is seated
properly on the wheel (tire bead flush with wheel rim and
the wheel halves showing no gap at the center line).

MINI-BIKE ASSEMBLY GUIDELINES
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WARNING! 15 PSI IS APPROACHING THE MAXIMUM FOR
THIS TIRE AND WHEEL COMBINATION. DO NOT INFLATE
TO THE RUNNING PRESSURE STATED ON THE TIRE.
4. ASSEMBLE REAR WHEEL INCLUDING BRAKE DRUM & SPROCKET
❍Assemble the remaining Innertube (Item 4), the Rear (Stud-
ded) Tire (Item 2) and the remaining Wheel set as described in
Step 3; but DO NOT PUT THE BOLTS IN YET.
❍Center the Brake Drum/72 tooth Sprocket assembly (Item
10), sprocket side out, onto the Rear Wheel. Align the bolt
holes in the Drum with those in the wheels.
❍Insert three 5/16-18 x 3" Bolts into the Brake Drum and
through the corresponding holes in the Rear Wheel.
❍Align the Rear Wheel halves using the 10" Rear Axle (Item 22)
and complete the Rear Wheel assembly by installing and
torquing down three 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 result in centering the Front
Wheel between the Fork legs.
❍Support the Frame on a work table or other flat work area so
that the Fork ends are least 12" above the work surface.
❍Partially insert the 8" Front Axle (Item 21) into a fork leg hole
from the outside.
❍Slip one 5/8" ID x 1" OD x 1-1/4" Steel Bushing (Item 24)
onto the end of the Axle between the Fork legs.
NOTE: One or both front Axle Bushings may need to be
trimmed for exact alignment and spacing of wheel.
❍Position the Front Wheel assembly between the Fork legs and
insert the end of the Front Axle through the Wheel Bearings.
❍Rotate/twist the Axle while pushing it through the Bearings,
until it just exits the second Bearing.
❍Place another Steel Bushing (Item 24) onto the Axle end now
peeking through the second Bearing.

MINI-BIKE ASSEMBLY GUIDELINES
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❍Insert the Axle through the hole of the second fork leg and
center it between both fork legs.
❍Place a 5/8-18 Jamnut (Item 33) onto each front Axle end.
Tighten each until snug. There should be no space between
the steel Bushings, Wheel Bearings and Fork legs.
❍Install a 5/8-18 Locknut (Item 34) onto each front Axle end.
Hand-tighten each Locknut against each Jamnut.
❍Holding a Locknut in place with one wrench, back its corre-
sponding Jamnut away from the wheel with a second wrench.
Then tighten the Jamnut against the Locknut.
❍Repeat this process on the other side of the wheel.
❍When completed properly, this procedure will allow the Wheel
to spin freely, without binding or drag against the Front
Wheel Bearings.
6. MOUNT REAR WHEEL & BRAKE
❍Begin Rear Wheel mounting with 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 and align the Rear Wheel assembly
onto the Frame, you are about to install Nylon Spacers and
Steel Bushings which may and in certain cases must be
trimmed.
❍Place a 5/8" ID x 1" OD x 1-1/4" Steel Bushing (Item 24) onto
the Axle end now inside of the Frame’s hanger tab.
❍Over the Bushing, install a 5/8" ID Nylon Spacer (Item 25).
❍With the Sprocket/Brake Drum side to the left, Place the Rear
Wheel assembly in between the Frame’s axle hanger tabs and
onto the leading end of the Axle.
❍Rotate/twist the Axle while pushing it through the Wheel
Bearings until it extends out about 1-1/2" beyond the
Sprocket side.
❍Install the remaining two Nylon Spacers (Item 25) onto the
leading end of the Axle.
NOTE: One of these Spacers MUST be shortened. A length of
3/8" or less is required of the second Spacer. The Spacers

MINI-BIKE ASSEMBLY GUIDELINES
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must allow the Brake Assembly to sit inside the drum without
bottoming so that the Drum rotates freely.
7. BEGIN BRAKE ASSEMBLY INSTALLATION
❍Place the 4-1/2" Brake Assembly (Item 9) onto the end of the
Rear Axle and into the Brake Drum so that it is flush against
the properly trimmed Nylon Spacers.
❍Position the Brake Assembly with the “long fingers” of its
anchor brackets pointing forward, i.e., horizontal to the
ground and pointing toward the front of the Mini-Bike, with
the Brake actuating arm pointing straight up.
8. COMPLETE REAR WHEEL & BRAKE ASSEMBLY INSTALLATION
❍Install a 5/8" x 1-1/4" Steel Bushing (Item 24) onto the end of
the Rear Axle (now extending out of the Brake Assembly).
❍Push the Axle through the Frame’s left axle tab and center the
Axle between the tabs.
❍Place a 5/8-18 Jamnut (Item 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 Jamnuts.
❍Holding one Locknut in place with one wrench, back the
corresponding Jamnut off of its present position with another
wrench (less than one full turn) until the Jamnut is tight
against the Locknut. Repeat this procedure on both ends of
the Axle.
9. ANCHOR BRAKE ASSEMBLY TO FRAME
❍You will now anchor the Brake Assembly onto the lower
horizontal frame tubing using two Clamp Halves (Item 23),
one 5/16-18 x 1" Bolt (Item 27) and the single 5/16-18 x 2-1/
2" Full Thread Bolt (Item 28).
❍The shorter 5/16-18 x 1" Bolt fastens the lower end of the
clamp. The longer 5/16-18 x 2-1/2" Full Thread Bolt fastens
the upper end of the clamp and fits into the slot between the
“long fingers” of the Brake Assembly’s backing plate.
❍Use two 5/16-18 Locknuts (Item 30) to secure each of the
bolts. This procedure prevents the Brake Assembly from
rotating.

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).

MINI-BIKE ASSEMBLY GUIDELINES
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❍Thread the Brake Cable through the Conduit Retainer until
the Housing has been inserted into the Retainer as far as it
will go without forcing it further.
❍Slide the 1/4" ID x 3" Spring (Item 17) over the end of the
Brake Cable and up to the retainer.
❍Insert the barrel of the Wire Swivel (Item 13 – small internally
threaded cylinder with a hole drilled through its diameter)
into the Brake actuating arm so that the hex head is on the
tire side of the arm.
❍Insert the end of the Brake Cable through the drilled hole in
the Wire Swivel and pull it snugly up against the Spring.
❍Insert one (small, silver-colored) Fillister head screw into the
hole in the diameter of the Wire Swivel and carefully but
snugly tighten to secure the cable in place.
13. ADJUST BRAKE
❍Adjust the Brake by loosening the Jamnut on the rear of the
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 contact with the handlebar.
❍Cut off excess Brake Cable which remains past the end of the
Wire Swivel.
NOTE: You may choose to leave a small length necessary for
ease of adjustment. Make certain, however, that excess cable
remaining will not interfere with any other vehicle operation
and will not come into contact with the rider.
14. MOUNT ENGINE
NOTE: Engine, engine mounting hardware, clutch and clutch
installation hardware are not provided and must be obtained.
Seek the recommendation of your dealer about a engine suitable
for your rider. Be sure to obtain all appropriate installation
hardware and take note of any special instructions and recom-
mendations regarding installation of your engine and clutch.
❍Place the Engine on the Frame’s engine mounting plate,
aligning the engine’s mounting holes with the slots in the
Frame’s mounting plate.

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.

MINI-BIKE ASSEMBLY GUIDELINES
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NOTE: The closed end of the spring clip should point in the
direction that the chain travels during operation.)
18. POSITION & SECURE ENGINE
❍Carefully slide the engine forward until the chain is snug. In
doing so, do not allow the engine to slip sideways as this will
ruin the sprocket alignment. (If the sprockets sneak out of
alignment, leave the engine in its forward, chain-snug posi-
tion, unlock the clutch and realign.)
❍After the engine is in its forward, chain-snug position and the
clutch and rear sprockets are aligned, torque down tightly the
Locknuts on all engine mounting bolts.
19. INSTALL DUMMY & TWIST GRIPS
❍Locate the components of the Throttle Kit (Item 11).
❍Twist the Dummy Grip onto the Frame’s left handle bar
(under the installed Brake Lever) as far as it will go.
❍Slide the Twist Grip/Throttle Control 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 point is to the front of the handlebar with the Throttle
Conduit and Cable pointing down and slightly forward.
20. SIZE THROTTLE CABLE AND CONDUIT
❍The 54" length of Throttle Cable housed inside the 50" length
of Throttle Cable Conduit must be sized so that they may be
properly routed from Twist Grip/Throttle Control to engine
throttle. However, accurate sizing calculations cannot be
made accurately without knowing how the Throttle Conduit
and Cable are routed and fastened, as described in Step 21,
“Install the Throttle Conduit & Cable,” and Step 22, “Fasten
Throttle Cable to Engine,” that follow, below.
❍Review Steps 21 and 22 below to familiarize yourself with how
the Throttle Conduit and Cable will be routed and fastened to
estimate sizing and cutting.
❍Complete your sizing calculations and cut down the Throttle
Conduit and Cable accordingly.

MINI-BIKE ASSEMBLY GUIDELINES
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NOTE: The Throttle Cable should be approximately 4" longer
than the Throttle Conduit.
21. INSTALL THROTTLE CONDUIT & CABLE
❍In routing the Throttle Conduit and Cable make sure there
are no sharp bends. Further, when the handlebars are turned
lock-to-lock, the Throttle Conduit should not bind or catch.
❍With the Twist Grip/Throttle Control positioned on the
handlebar so that the Throttle Conduit and Cable are pointing
down and slightly forward, tighten the Twist Grip’s mounting
collar screws to lock it into position.
❍Route the Throttle Conduit and Cable down through the fork
and then back to the left angled member of the frame just
below the Fork-to-Frame Bolt bushing.
❍Fasten the Throttle Conduit and Cable to the inner side of the
frame with 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
contact with any of the engine’s hot or moving parts or with
the rider.
22. FASTEN THROTTLE CABLE TO ENGINE THROTTLE
❍The Throttle Cable is fastened to the engine with the Wire
Stop with Screw (Item 12) where it engages the engine’s
throttle arm.
❍Properly installed, the throttle should operate smoothly, from
full-on to full-off. If this is not the case, or throttle operation
is restricted in anyway, check the cable routing/fastening and
the position of the Wire Stop.
23. INSTALL THE SEAT
❍On the bottom of the 12" Plush Mini-Bike Seat (Item 5), there
are three threaded inserts.
NOTE: You may have to trim away some of the seat cover
material to expose the inserts.
❍Place the Seat onto the Frame. Line up the threaded inserts
with the stamped holes in the 2 flat cross-bars of the Frame.

MINI-BIKE ASSEMBLY GUIDELINES
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❍Fasten the Seat to the Frame by inserting the three 1/4-20 x
5/8" bolts (Item 26) up through the Frame and into the
threaded inserts.
❍Your assembly is now almost, but not quite, complete and
should not be operated
However If you feel like it, and, provided you do so carefully—
mini-bike upright and stationery, engine off, brake fully
engaged—let the rider mount up!—(Optional, Not Required—If
you want to keep working, by all means, proceed.)
24. ASSEMBLY & OPERATIONS REVIEW
❍Time to review all assembly and check all operations. Then,
additional items need to be installed.
❍First review the section entitled on “ASSEMBLY SAFETY” at
the beginning of this booklet. Review your assembly and
determine whether you have unanswered questions or
unresolved 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 steering operation, making certain that full-range
of operation is available and un-hindered throughout the
entire range of steering operation—lock-to-lock.
❍Check both wheels making certain they are securely and
properly fastened to the Frame, but spin freely.
NOTE: No additional items or accessories should be added to
the mini-bike, nor worn or carried by any rider which would
in any manner hinder operation or interfere with moveable
parts of the mini-bike including the engine.
❍Check to see that the throttle operation is working properly
throughout its entire range of operation, including but not
limited to:
• dummy and throttle twist grip properly installed and
securely on the handlebars?
• full-range, smooth, un-hindered Twist Grip/Throttle
Control operation?

MINI-BIKE ASSEMBLY GUIDELINES
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•Throttle Conduit and Cable from Twist Grip to engine
throttle properly routed, fastened and fully operable and
compatible with other operations—e.g., steering and
braking?
•Upon release of Twist Grip, Throttle disengages com-
pletely?
❍Check for proper installation of the braking system. Test
braking operation. When braking is initiated by depressing
the brake lever, the brake lock the rear wheel well prior to a
point at which the depressed lever touches the handlebar or
grip.
❍Check for proper sprocket alignment and snug chain tension.
WARNING! AFTER YOUR ASSEMBLY IS COMPLETE AND
PRIOR TO ANY OPERATION, HAVE THE VEHICLE EXAM-
INED BY A QUALIFIED AND KNOWLEDGEABLE PROFES-
SIONAL TO ENSURE PROPER ASSEMBLY, OPERATION,
SAFETY AND COMPLIANCE WITH ALL APPLICABLE LAWS.
THE SAFETY OF THE RIDER DEPENDS ON IT.
25. INSTALL THE CHAIN 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 KIT’S CONTENTS” in the first
paragraph of page 4 of this booklet.
•One purpose of a Chain Guard is to prevent injury to
riders and/or bystanders as a result of the chain break-
ing and then flying up or out from the sprockets.
•A chain guard may, but is NOT guaranteed to prevent
items from becoming entangled in the chain or sprockets
during operation. Examples: scarves, baggy, loose or long
clothing, shoelaces, etc. Such entanglements could cause
serious injury, such as throwing a rider from the mini-
bike, choking, etc. Even with the required chain guard in
place, these and similar items should not be worn nor in
any manner brought into the area of any moving parts
during operation.
❍Procurement and installation of an appropriate chain guard,
fabricated to fit your engine-sprocket drive system and that
covers the chain and both sprockets is MANDATORY.

MINI-BIKE ASSEMBLY GUIDELINES
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26. INSTALL THE FOOT PEGS
❍Secure the pair of Folding Foot Pegs (Item 7) to the Frame
with four Clamp Halves (Item 23), two 5/16-18 x 1" Bolts,
(Item 27) and two 5/16-18 Locknuts (Item 30).
❍Beginning with either side, position a Clamp half onto the
outside of the lowest horizontal Frame member just in front of
the engine mounting plate.
❍Remove the pre-installed Lockwasher and Jamnut from one of
the Foot Pegs. In its “down” position, twist the bolt end of the
Foot Peg into the top hole of the positioned clamp half .
❍Position another Clamp half on the inside of the frame
member, aligning its top hole with that of the first half and
twist the 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" Bolt through the bottom holes of the
outside Clamp halves and install a 5/16-18 Locknut, but do
not tighten down yet.
❍Position the foot peg so that when folded down it is horizontal
with the ground and its foot pad is pointing straight up and
then tighten down the upper Jamnut and lower Locknut until
the clamp and Foot Peg are secure.
❍Repeat the same procedure with the second Foot Peg on the
opposite side of the Mini-Bike.
☛PRIOR TO OPERATION. . .
❍Read/follow the engine manufacturer’s instructions carefully.
❍Check the engine crankcase for proper engine oil levels and
the fuel line connections before adding fuel and starting the
engine.
❍Ride safe and have fun!

MINI-BIKE ASSEMBLY GUIDELINES
- 18 -
BASIC MINI-BIKE ASSEMBLY ILLUSTRATED
(Clutch – not included)
Fender – optional

MINI-BIKE ASSEMBLY GUIDELINES
- 19 -
– NOTES –
– NOTES –