Section 2 Installing the motor

After installing the sprocket to the rear wheel and placing the rear wheel on the bike, Attach the chain tensioner to the left side of the bike on the rear upper frame rail as shown.

Don‘t tighten the tension wheel yet. That will be tightened after the chain is installed.

Take out the 2 long screws, 2 flat bar with nuts and one black thick bar and assemble the long screw to the flat bar as shown, tighten it with the nut to lock it in place.

Unscrew the nut from the bicycle at the rear wheel axle, place the flat bar onto the axle then replace the nut as shown.

Be sure that the flat bar is in front of the bolt on the derailleur or the engine will not sit securely on the mount.

Remove the master link from the chain and slide it over the sprocket behind the small chain.

Master Link

Let the chain hang down to the wheel sprocket it should line up straight.

Wrap the chain around the wheel sprocket and replace the master link.

If the sprocket is straight and the chain length is good you may choose not to use the chain tensioner.

Adjust the tensioner wheel to remove slack in the chain and tighten in place.

If you need to slide the motor to the left or right to line up the sprockets loosen these two bolts and

If you need to adjust the chain tension on the small chain, slightly loosen the bolts on the drive housing.

Then raise or lower the T-bolt under the Motor.

GENERAL SAFETY PRECAUTIONS

1. Obey all traffic regulations.

2. Do not operate bike without the chain guard installed.

3. Always wear a helmet and eye protection when riding.

4. Do not wear loose fitting pants or skirt when riding, as loose fabric can catch in the drive chain and cause an accident.

5. Remember that you are riding a small, motorized vehicle and other traffic may not be able to see you. Wear bright colors on your shirt and helmet.

6. Never ride at night without proper headlight, taillight, and reflectors. Be sure to wear reflective clothing when riding at night.

7. Never ride on pedestrian throughways or sidewalks, especially with the engine running.

8. Never operate your MOTOcycle in an unsafe manner.

9. Wear riding gloves to prevent injury to hands during an accident.

10.Check local and state laws before riding your MOTOcycle on the street. 11.WARNING“ ALWAYS WEAR A HELMET WHILE RIDING!!

PREPARATION

1. Engine oil level

CAUTION!

Running the engine with insufficient oil can cause serious engine damage. Be sure to check the engine on a level surface with the engine stopped.

a.

Place the engine with the fuel tank side downward and horizontally on a level surface.

b.

Remove the oil filler cap and check the oil level: it should reach the top of the oil filler neck.

c.

If the oil is low fill to top of the oil filler neck with the recommended oil.

Every 10 hours check the oil level and replenish the oil up to the top of the filler neck if the engine is operated for more than 10 hours continuously.

Use a high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacture‘s requirement for service classification SG. SF. Motor oils classified SG, SF will show this designation on the container. SAE 10W-30 is recommended for general, all temperature use.

CAUTION!!

Using non-detergent oil or 2 stroke engine oil shorten the engine‘s life.

2. Air cleaner CAUTION!! Never run the engine without the air cleaner.

Rapid engine wear will result.

Check cleaner for dirt or obstruction of element.

3. Fuel

Use automotive gasoline (unleaded or lowleaded is preferred to minimize combustion chamber deposits).

Never use an oil / gasoline mixture or dirty gasoline. Avoid getting dirt, dust or water in the fuel tank.

WARNING!!

Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Don‘t smoke or allow flames or sparks in the area where the engine is refueled or where the engine is stored.

Don‘t overfill the tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely.

Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

Avoid repeated or prolonged contact with skin or breathing vapor.

KEEP OUT OF REACH OF CHILDREN.

Fuel tank capacity: 0.9 1 (0.238 US gal)

GASOLINE CONTAINING ALCOHOL

If you decide to use a gasoline containing alcohol (gasohol), be sure it‘s octane rating is high. There are two types of —gasohol“, one containing alcohol, and the other containing methanol. Don‘t use gasoline containing methanol (methyl or wood alcohol that does not also contain co-solvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has co-solvents and corrosion inhibitors.

CAUTION!

• Fuel system damage or engine problems resulting from the use of fuels that contain alcohol is not covered under the warranty. We can‘t endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete.

• Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol. If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a gasoline that you know does not contain alcohol, switch to a gasoline that you know does not contain alcohol.

4. Retightening bolts and nuts: Check for loose bolts and nuts. Tighten the bolts and nuts properly and securely, if necessary.

V. STARTING THE ENGINE

1. Turn the engine switch to ON position (on the equipment side).

2. Move the choke lever to the OFF position

CAUTION! Don‘t use the choke if the engine is warm or the air temperature is high.

1. Press the priming pump several times until a fuel flow in the fuel return tube is visually noticed.

2. Pull the starter grip lightly until resistance is felt, then pull briskly.

CAUTION! If not pulled briskly, sparks may fail to jump across the spark plug electrodes, resulting in failure to start the engine.

• High altitude operation

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor, and readjusting the idle needle screw. If you always operate the engine at altitudes higher than 1,860m (6000 feet) above sea level, have your authorized dealer perform these carburetor modifications.

Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 305m (1000 feet) increase in altitude. The affect of altitude on horsepower will be greater than this if no carburetor modification is made.

CAUTION!

Operation of the engine at an altitude lower than the carburetor is jetting for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture.

VI. OPERATION

1. Gradually move the choke lever to the ON position. Warm up the engine until it runs smoothly.

2. Position the throttle control lever for the desired speed (on the equipment side).

VII. STOPPING THE ENGINE

To stop the engine in an emergency, turn the engine switch to the OFF position (on the equipment side). Under normal conditions, use the following procedure.

1. Position the throttle lever fully to LOW (on the equipment side).

2. Turn the engine switch to the OFF position (on the equipment side).

VIII. MAINTENANCE

Periodic inspection and adjustment of the engine is essential if high lever performance is to be maintained. Regular maintenance will also ensure a long service life. The required service intervals and the kind of maintenance to be performed are described on the table below.

Maintenance Scedule

Service more frequently if used in a dirty area. These items should be serviced by an authorized dealer, unless the owner has the proper tools and mechanical proficiency.

WARNING!

• Shut off the engine before performance.

• To prevent accidental start-up, turn OFF the engine switch and disconnect the spark plug cap.

• The engine should be service by an authorized dealer unless the owner has proper tools and service data and feels he is mechanically qualified.

CAUTION! Use only genuine parts or their equipment. The use of replacement parts which are not equivalent quality may damage the engine.

1. Oil Change

Drain the oil while the engine is still warm to assure rapid and complete drain.

a.

Check the fuel filler cap is tightened.

b.

Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck.

c.

Refill with the recommended oil and check the oil lever.

Engine oil capacity: 0.101 (0.11 US qt. 0.09 Imp qt.)

Wash your hands with soap and water after handling used oil. CAUTION! Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Don‘t throw it in the trash or pour it on the ground.

2. Air cleaner service

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas.

WARNING! Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.

CAUTION! Never run the engine without the air cleaner. Rapid engine wear will result.

a.

Move the choke lever to the CLOSED (upward) position.

b.

Remove the air cleaner cover by unhooking the upper tab on the top of the air cleaner cover and its two lower tabs.

c.

Wash the element in a nonflammable or high flash point solvent and dry it thoroughly.

d.

Soak the element in clean engine oil and squeeze out the excess oil

e.

Reinstall the air cleaner element.

f.

Reinstall the air cleaner cover by inserting the lover tabs, then insert the upper tab.

3. Spark plug service

Recommended spark plug: C5HSB CR5HSB (NGK) CAUTION! Never use a spark plug of incorrect heat range.

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

a. Remove the spark plug cap and use the proper size spark plug wrench to remove the spark plug.

WARNING! If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

b.

Visually inspect the spark plug. Discard the spark plug if there is apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

c.

Measure the spark plug gap with a feeler gauge. Correct as necessary by bending the side electrode. The gap should be: 0.60~0.70mm (0.024~0.028 in).

d.

Check the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross- threading.

e.

After the spark plug is seated, tighten with a spark plug wrench to compress the washer.

C AUTION! When installing a new spark plug, tighten with ² turn after the spark plug seats to compress the washer. When reinstalling a used spark plug, tighten 1/8 to ³ turn after the spark plug seats to compress the washer.

CAUTION!

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may damage the engine.

4. Fuel filler service

WARNING! Gasoline is extremely flammable and is explosive under certain conditions. Don‘t smoke or allow flames or sparks in the area.

a.

Check the engine oil filler cap is tightened securely.

b.

Remove the fuel filler cap and drain the fuel into the container by inclining the engine toward the fuel filler neck.

c.

Pull out the fuel filter with the mechanic‘s wire from the fuel filler neck gently.

d.

Check the fuel filter for dirt. If the fuel filter is dirty, gently wash it with nonflammable or high flash point solvent. If the fuel filter is excessively dirty, replace it.

e.

Return the fuel filter into the fuel tank and the fuel filler cap securely.

5. Fuel tank cleaning WARNING! Gasoline is extremely flammable and is explosive under certain conditions. Don‘t smoke or allow flames or sparks in the area.

a.

Check the engine oil filler cap is tightened securely.

b.

Remove the fuel filler cap and drain the fuel into the container by inclining the engine toward the fuel filler neck.

c.

Pull out the fuel filter with the mechanic‘s wire from the fuel filler neck gently.

d.

Remove water and dirt from the fuel tank by rinsing the inside of the fuel tank with nonflammable or high flash point solvent.

e.

Return the fuel filter into the fuel tank and the fuel filler cap securely.

IX. TRANSPORTING AND STORAGE

WARNING! When transporting the engine, tighten the fuel filler cap to prevent fuel spillage. Fuel vapor of spilling fuel may ignite.

Before storing the unit for an extended period of time:

a.

Be sure the storage area is free of excessive humidity and dust.

b.

Drain the fuel…

WARNING! Gasoline is extremely flammable and is explosive under certain conditions. Don‘t smoke or allow flames or sparks in the area.

a.

Check the engine oil filler cap is tightened securely.

b.

Remove the fuel filler cap and drain the fuel into a container by inclining the engine toward the fuel filler neck.

c.

Press the priming pump several times until all fuel left in the fuel return tube is returned into the fuel tank.

d.

Tilt the engine toward the fuel filler neck again to drain the fuel left in the fuel tank into the container.

e.

Tighten the fuel filler cap securely after draining the fuel completely.

Accessory Kit Installation

Step 1.

Mounting the Headlight

The headlight bracket included in your kit is mountable on the front fork. You can mount it above or below the wheel line. Be sure to give yourself room for the spokes.

Shown here installed below the wheel line.

Step 2.

If you prefer an alternative to the front fork placement, you can easily make your own bracket out of a steel or aluminum bar purchased from your local hardware store.

Step 6.

Decide where on your bike you want the light installed.

You can easily install the headlight on the handlebars by bending your newly fashioned bracket around the bar, and drilling another hole that lines up with the hole drilled in step five.

Step 7.

If you prefer, you could bend the bracket into an —L“ shape and mount it to the front fork, above the wheel and behind the brake caliper.

The light installs easily and does not affect the braking of the bike.

Note: Most bicycle forks have a hole for a front brake caliper even if there is no brake caliper.

Step 12.