Engine Kit Setup Instructions Part 1
Engine Kit Setup Instructions Part 2
Engine Kit Setup Instructions Part 3
Step 6: Move the existing bike controlls in along the handle bars. Measure 130mm along the top of the right side of the handlebar and drill a 5mm hole for the locating peg inside the throttle clamp. Lightly grease right side handle bar end. Slide throttle on all the way and then back it off a hair and then tighten it down evenly. Do not over torque the screws. If you get real ambitious, unload cable from carb slide and from throttle end and clean up the fiber plastic and lube the cable sheath and re assemble. One of the wires (does not matter which one) goes to earth (say under an engine mount) and the other connects to the white wire from the magneto. The other two wires from the magneto connect to the CDI. Black to Black and Blue to Blue. Some CDIs have a red wire. Connect it to the blue.
Step 7: Mount clutch lever.
Step 7 Complete: Here is what the clutch cable connection should look like at the motor. The small spring can be used over the inner cable as a return spring but it is not necessary to fit it. It makes the clutch a bit harder to use. Keep it in case the inner cable gets a bit stiff later on due to lack of lubrication.
Step 8: Screw in the fuel valve filter combo into the tank and then mount the tank. Tip. Wrap top frame tube with bar wrap where tank clamps are. Also. If you have cable runs on the top bar that are open cables, you may need to run them through cable sheath the length of the tank in order for them to work once tank is clamped over them.
Step 9: Mount your Coil. Tip. Use 2 high quality cable zip ties . Go up and over and around the coil and zip tie it to the frame. Loop one zip tie up and over and also through the holes that would normally have the screws going through them. This is a better method than using the screws that come with the kit. You will have a more solid mount and not break the coil. It is not hard the break the coil ears off using the screws…Wire Connections…Blue to Blue and Black To Black. Also.. Connect one wire from kill switch (colour does not matter) to white wire, the other goes to earth e.g. under the engine mount.. The White Wire is Generator and has a Max Output of .5 A 7.5V. Anything that draws more Current connected to the white wire will kill the motor.
Special Note: If your spark plug has its crown screwed on. Unscrew it and remove it so that you can put your Spark Plug Cap on. Failure to remove this Crown can damage or ruin the Spark Plug Cap.
Here is what the Idler Pulley looks like Installed. Notice the Wheel is at the most down position so as the chain gets slack, you simply move the wheel up to take out the slack.
Engine Kit Setup Instructions Part 1