With the tires and frame prepped, the mini-bike assembly continues with the installation of the engine and related accessories. Important: Included below are the steps in this mechanical procedure as shown in the episode. These steps are general guidelines that are applicable to most mini-bike kits. With any particular kit, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that kit. Read and follow the manufacturer's directions and precautions that come with your kit and/or parts. Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools and air tools. Drive-Train Installation - The next step in the assembly is to attach the engine (figure A) to the mounting plates.
- The custom mounting assembly is required for the racing engine that we selected. One plate attaches to the frame of the bike, while a smaller one attaches to the first plate (figure B) and the engine.
- With the components of the mounting assembly bolted together, place the mounting plate onto the engine as shown (figure C).
- At the same time that the engine is fastened to the mounting plate, the brake-band bracket is attached to the mounting plate (figure D) and secured by two bolts.
- Check the mounting bolts for proper length as you install them, and tighten them down snugly as you attach the engine and the brake-band bracket to the mounting plate.
- The clutch assembly gets installed next. Check for proper orientation, as the clutch has a sprocket on one side and an Allen screw on the other (figure E). The clutch aligns onto the shaft by means of a kew-slot and is tightened down with the Allen screw.
- Align the key with the kew-way running down the shaft, and install the clutch onto the shaft with the sprocket toward the engine.
- With the clutch in place, install the brake-band around the clutch (figure F) and tighten it into place.
- The exhaust system can be installed next. It consists of a pipe, muffler, tail-pipe and an aluminum spacer that rests against the exhaust-port on the engine (figure G).
- Apply some high-temp sealant to the spacer (figure H) before installing it. Also apply sealant to the gasket that goes between the spacer and exhaust pipe.
- With the spacer and gasket in place, install the exhaust pipe and tighten it down with the two securing bolts (figure I).
- Attach the heat-shield to the muffler. It's held in place by two screws (figure J).
- Next, install the air filter (figure K). Ours had the fuel-lines already pre-installed onto it.
- Attach the other end of the fuel-line to the carburetor using a hose-clamp.
- To cut down on vibration, rubber bushings are installed underneath the engine (figure L).
- Bolts are installed from the bottom of the frame-mounting plate, through the bushings and engine-mounting plate. At this point, the nuts should be tightened down lightly. They will be tightened down fully later. Use the same procedure on both sides of the mounting plate (figure M).
- Once the engine is in position, the chain can be installed. The single length of chain is fed through the sprocket on the clutch, wrapped around the rear sprocket, then joined to form a loop using a master link (figure N). The master link consists of three pieces -- the link that extends through both ends of the chain, a washer and a clip that holds the link in place. Make certain that the clip is firmly seated over the washer.
- Now you can remove any excess slack in the chain by moving the engine forward (figure O).
- Once the slack in the chain is removed, tighten down the engine-mounting bolts.
In the segment that follows, assembly is completed and a kill-switch is added as a safety feature.
RESOURCES :
The Haynes Small Engine Repair Manual
ISBN: 1850106665
Author: Curt Choate, John H. Haynes
Haynes Publishing Group
Chilton's Small Engine Repair Up to 20 Hp
Model: 0801983258
Author: Kerry A. Freeman
Nichols Publishing
Go-Kart Racing Chassis Setup
Model: 0960506845
Author: Brian Martin
Martin Motorsports Pub. Co.
International Karting Industry Buyer's Guide
Model: 0966146743
Author: Darrell E. Sitarz
Kart Marketing Association of America
Gokartparts.com
gokartparts.com
Dorchester, WI 54425
Fax: 800-294-4144
Email: sales@mfgsupply.com
Website: www.gokartparts.com
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