ASSEMBLY/PRE-RIDE INSPECTION INSTRUCTIONS

⚠️ WARNING

Never attempt to start this Mini Bike without reading and understanding the Owner's/Operator's manual. The Owner's/Operator's manual provides information on safety, parts, functions, pre-ride inspection, starting, and maintenance.

REMOVAL FROM CRATE

Ensure all parts are present before beginning assembly:

• Owner's/Operator's Manual
• Tool Kit
• Zip Ties
• Handle Bar Hardware: Clamps, M8 x 32 bolts
• Front Fender Assembly: Front Fender with light bracket, M8 x 15 Bolts
• Front Fork Assembly: Front Fork Suspension, M10 Steering Bolt, M10 Small Washers, M10 Lock Nut, M10 Large Washers
• Rear Fender Assembly: Rear Fender, M8 x 20 Bolts, M8 Nuts, 8mm Large Washers
• Front Wheel Assembly: Front wheel, M14 Axle Bolt, M14 Washers, M14 Lock Nut
• Light Assembly: Light, M8 x 50 Bolts, M8 Nuts, M8 Rubber Grommets

FRONT FORK INSTALLATION

Components required: M10 Steering Bolt, M10 Large Washers, M10 Small Washers, M10 Lock Nut.

1. Install front Fork Assembly by inserting the M10 steering bolt through the assembly in the following order: Large washer, Top bracket, Small Washer, Steering Neck, Small washer, Bottom bracket, Large Large Washer, Lock Nut.
2. Tighten the Lock nut.
3. Tighten fork bolts on both sides of the assembly. Torque for bolts: 15 Ft/Lbs.

FRONT FENDER INSTALLATION

Components required: M8 x 15 Bolts.

1. Attach front fender with the 2 M8 x 15mm bolts. Torque bolts: 15 ft/lbs.

REAR FENDER INSTALLATION

Components required: M8 x 20 Bolts, Large M8 Washers, M8 Nuts.

1. Attach Rear fender with M8 x 20 bolts, large M8 washers, and M8 nuts. Torque bolts: 15 ft/lbs.

HANDLEBAR ASSEMBLY

Components required: Clamps, M8 x 32 bolts (Handlebar Hardware).

1. Lift up handlebars and center them on the fork assembly.
2. CAUTION: While installing handlebars, ensure brake cables, throttle cable, and on/off switch wire are not kinked or pinched.
3. Attach handlebars using clamps and M8 x 32 Bolts. Torque bolts: 15 ft/lbs.

FRONT WHEEL INSTALLATION

Components required: M14 Axle Bolt (1ea), M14 Washers (2ea), M14 Lock Nut (1ea).

1. Orient the front tire so the arrow on the tire faces forward.
2. Insert the Axle bolt with the M14 washers between the forks and wheel on each side.
3. Install the M14 lock nut and tighten.

LIGHT INSTALLATION

Components required: M8 x 50 Bolts, M8 Nuts, M8 Rubber Grommets.

1. Install the front light onto the bracket using M8 X 50 bolts, M8 rubber grommets, and M8 nuts. The rubber grommets fit between the light and the light bracket. Torque bolts: 12ft/lbs.
2. Plug light wires into the wires from the engine assembly.

SECURE WIRES AND CABLES

1. Ensure the On/Off Switch wire, throttle cable, and brake cable are not kinked and have free movement when the handlebars are turned from left to right.
2. Secure wires and cables to the frame using the provided Zip ties.

⚠️ WARNING
ALWAYS CHECK THE THROTTLE CABLE BEFORE STARTING THE ENGINE. THE THROTTLE CABLE SHOULD HAVE FREE MOVEMENT AND SNAP BACK TO IDLE WHEN RELEASED.

OIL AND FUEL

Engine Oil

The mini bike is shipped without engine oil. Fill with SAE 10W-30 Motor Oil. Refer to the owner's manual for the correct amount and grade of engine oil.

Caution: Do not over or under fill with engine oil.

FUEL

Never use leaded gasoline in this product, as it could affect the engine's emissions and damage the engine. The Mini Bike requires clean unleaded regular gasoline with a minimum octane rating of 86 or higher. Fill with gasoline up to the bottom of the filler neck.

TIRE PRESSURE

Check tire pressure. Incorrect tire pressure can affect handling, rider comfort, steering, tire life, and traction. Always check the tire pressure before each ride.

Tire pressure: Front tires: 10psi, Rear tires: 10psi.

Chain Tension

Check the tension of the chain. The chain (1) tension should be 1/2 - 3/4 in. (15-20mm).

Chain tension (slack) adjustment

1. Loosen bolt (2) on the rear axle assembly.
2. Adjust chain tension by turning the tension nuts (3). Tension nuts are located on both sides of the mini bike. Turning clockwise will tighten the chain; counter-clockwise will loosen the chain.
3. Once the chain is at the correct tension, re-tighten axle bolt (2).
4. Re-check chain tension.

BRAKE ADJUSTMENT

Brakes

Brake Lever Adjustment

The front left brake lever (1) should have 2.0 - 4.0mm (0.08 - 0.16) of free play.

To adjust brake lever free play:

1. Loosen the jam nut (2) on the brake cable.
2. Turn the adjuster nut (3) until the correct amount of free-play is achieved.
3. Re-tighten jam nut (2).

Brake Adjustment

To adjust rear brakes, loosen the rear axle bolt (4). Locate the adjustment nut (5) on the rear brake drum assembly. Turn the adjusting nut (5) clockwise to increase braking, counter-clockwise to decrease braking.

THROTTLE ADJUSTMENT

Idle speed adjustment

The idle speed should be set at 1700 ± 150 RPMs. A service center can perform this adjustment, and a diagnostic tachometer is required.

To adjust the idle speed:

1. Locate the idle adjustment screw (1) on the carburetor.
2. Allow the engine to warm up for approximately 10 minutes.
3. With the engine running, turn the idle adjustment screw in or out at small increments until the correct idle is achieved.

Throttle Cable adjustment

It is important that the throttle grip has a certain amount of free play. The hand grip throttle free play (2) should be .078 - .24 in (2-6 mm).

To adjust freeplay:

1. Loosen jam nut (3).
2. Turn adjusting nut (4) to the proper setting.
3. Once the throttle grip has the proper freeplay, re-tighten the jam nut (3).

PRE-RIDE INSPECTION

Inspecting and checking the condition of the Mini Bike before each ride is important. Following the pre-ride check list will help ensure there are no problems which could result in injury or becoming stranded. Make sure the Mini Bike is in good operating condition before each ride.

⚠️ WARNING
Failing to inspect and maintain the Mini Bike could be hazardous. Not following the pre-ride inspection procedures could result in losing control of the Mini Bike, leading to an accident or damage to the Mini Bike. Always perform a pre-ride inspection before each ride.

⚠️ WARNING
Performing maintenance and checks while the engine is running could be hazardous. You could be severely injured by moving parts or hot surfaces. Never perform maintenance or check procedures while the engine is running, with the exception of checking the engine stop switch or throttle.

STARTING ENGINE

To start the engine

1. Place the fuel valve (1) to the “ON” (right) position.
2. If the engine is cold, place the choke lever (2) to the “ON” (left) position.
3. Place the ON/OFF switch (3), located on the handlebars, to the (on) position.
4. Pull the starter recoil cord to start the engine.
5. Once the engine has warmed up for a few minutes, place the choke lever (2) back to the “OFF” (right) position.

⚠️ WARNING
Starting or running the Mini Bike in an enclosed area such as a garage or shed where there is no ventilation is hazardous. Inhaling exhaust fumes from the Mini Bike can cause severe injury or death. Never start or run the Mini Bike in an enclosed environment where there is no ventilation. Always start and run outdoors.