| Mini-Bike Kit: Final Assembly and Safety Features |
From "Weekend Mechanic"
episode WKM-212 |
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The final steps in the mini-bike project include installing a kill-switch, connecting the engine accessories and finishing up the frame assembly. 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.
Steps:
- The kill-switch (figure A) is installed next the throttle control on the handlebar. With this switch, the engine can be shut down instantly.
- Two wires lead from the kill-switch (figure B). One wire is the ground, while the other leads to the engine. The ground wire is held in place by the same bolt that will hold the gas tank in place.
- Place the bolt through the ground-wire terminal, the bracket and through the hole in the frame (figure C), and tighten down the bolt.
- The other kill-switch wire attaches to the engine wire (figure D). Strip the end of the wire and crimp the two wires together using a butt-connector.
- Next, attach the second bracket that holds the fuel tank.
- The fuel-tank is attached to the two brackets by a couple of hose clamps (figure E). Avoid overtightening the hose-clamps as this could damage the fuel tank. Simply tighten them down until snug.
- Attached to the gas-tank is a fuel hose and fuel filter (figure F). Ensure that the filter is oriented correctly and connect it to the carburetor fuel-hose. (Most fuel filters have an arrow indicating the direction of fuel flow.) Situate the hoses so that they don't interfere with moving parts.
- Next, install the throttle assembly by sliding it onto the handlebar and tightening down the screws to secure it (figure G).
- The throttle cable feeds through a hole in the throttle linkage and is secured in place with a cable stop (figure H).
- Install the brake assembly on the other handlebar and tighten down the lever.
- Attach the other end of the brake cable by gently pushing it through the brake-band holder, and through a guide that slides into the other end of the brake band (figure I). Attach a cable-stop to the end of the cable and tighten it down.
- Tie down all cables with zip-ties so that they don't interfere with moving parts.
You're now ready to check all bolts and connections, mix your gas and oil (check your engine manual for the proper ratio), gas up your mini-bike and go for a ride. Be sure to check your kill-switch first to make sure that it's operational.
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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