MFG supply Mini-Bike Bedienungsanleitung
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).
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