Step 10: Remove the 3 screws from Counter shaft side cover and also remove spark plug. Remove clip from master link of chain and then thread chain up and over counter shaft sprocket by rotating the sprocket using tool. Having the spark plug removed allows engine to be turned easily to thread chain. Tip..Since you have this cover off, Hold clutch arm and rotate cover and pull clutch arm out of cover and then grease it and rotate it back in.
Step 11: Put some molly grease on the shaft and in the hole.
Step 12: Cut chain to length and using master link put chain back together. Do NOT cut chain too short !! Install Idler pulley. Make sure you grease the plastic wheel metal shaft (not necessary with the new ball bearing type). Do not over tighten the chain. Install chain guard. Use some tin snips to cut cover at the rear if needed. Use a good zip tie at the rear and the extra long bolt for the counter shaft cover will hold the front.
Step 13: Install exhaust pipe. If you need to bend the pipe some so it will not hit the frame or bolts, clamp the pipe into wood blocks and bend. Do NOT bend exhaust mounted to engine. If you do..You will not bend the exhaust, you will break the motor!! Exhaust pipe is very strong. Much stronger than the 2 mounting studs on the motor.
Step 14:Mount the carburetor. Check the other screws including the brass fuel inlet screw for tightness..Typically they need some slight turning. Once the carb is on and tight…You are ready to connect the tank line to carb. Tip..Get and inline fuel filter. Even though the fuel petcock has a screen filter, it is porous and allows sediment through.. A high quality inline fuel filter with paper element is a super way to go and to keep fine particulate out of the carb and the engine running fantastic and like new. Well….Install is done..Mix your oil with the gas 16:1 for the first 500km (63mL per 1L) and then 20:1 (50mL/1L). See the notes below about setting up the carburettor. ..Fuel up the bike..And…go baby go !!!!! Enjoy!!! Ahh..do not get too excited..This is a new motor and you need to take it easy for the first 500 kilometres or so …O well..the price of owning a new engine…You have to break it in….But..That is fun too…Enjoy!!!!
Note: During Break in, keep drive chain snug.
During break in Keep the mix ratio at 16:1 for 500 kilometres and keep your speed down!!!
After break in, you can allow the chain a little slack. Also…Keep mix ratio at 20:1 and use a high quality Motorbike / Lawnmower Two Stroke oil.
Step 1: Remove carb cap and lay out all the parts.
Step 2: Place needle into centre of carb slide and then put flat washer with groove on top of needle making sure you have the groove lined up with the groove in the carb slide.
Step 3: Install cable to plastic grip first, then thread this end through the carb cap and through the spring.
Step 4: Compress spring and load cable into the end of the slide. Once you have it started, put the entire length of the cable into the slide, once you have done that, release the spring to the inside of the carb slide allowing the spring to push onto the flat washer and thus holding the needle down.
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