American Racer 215 Mini Bike, Owner'S Manual

Page 1: ...215 MINI BIKE OWNER GUIDE By GOKARTS USA ...

Page 2: ...RES 8 SPROCKET DRUM 9 BRAKE 10 REAR WHEEL 10 REAR AXLE 11 ENGINE 12 TORQUE CONVERTER 14 THROTTLE CONTROL stock carburetor 15 BRAKE LEVER 17 BRAKE CABLE 17 ADJUST BRAKE 18 KICKSTAND 18 OIL SERVICE 18 TEST RUN 19 Avoid run away bike 19 FEATURES 20 PERFORMANCE PARTS 21 Boost your Honda Titan or Predator up to 26hp 21 HIGH FLOW EXHAUST 21 STAGE 1 KIT 21 ...

Page 3: ... WARNING DEATH OR INJURY CAN OCCUR GOKARTS AND MINIBIKES CAN BE DANGEROUS TO OPERATE INJURY AND DEATH CAN RESULT FROM IMPROPER ASSEMBLY MAINTENANCE and or operation Customer assumes all risk associated with assembling maintaining building and operating any minibike or go kart kit Customer agrees to hold harmless go karts USA and its associates affiliates and parent companies Customer responsible f...

Page 4: ...sembly of kit For safety reasons as well as proper operation we strongly recommend that kits are assembled and or inspected by a qualified mechanic or persons with appropriate mechanical expertise prior to operation We cannot refund or exchange your kit if you cannot perform these functions or refuse to let a shop do it for you AMERICAN RACER MINI BIKE The American Racer 215 Mini Bike is sold full...

Page 5: ...020 Rear Wheel 8 w 2 Bearings L1065 3021 Rear Wheel Bearing L1065 3052 Rear Tire 480 400 x 8 L1065 3053 Rear Tube 480 400 x 8 L1065 3025 Rear 5 8 Axle L1065 3026 Rear 5 8 Nut for Axle L1065 3027 Rear Drum Sprocket 40 41 54T L1065 3028 5 Drum Brake Assy L1065 3030 5 Brake Anchor Spacer L1065 3054 Throttle Control Grips 1 L1065 3035 Throttle Cable L1065 3036 Throttle Wire Stop L1065 3037 Brake Lever...

Page 6: ...making sure to remove the rust proofing oil The 5 16 18 x 6 Bolt connects the Fork to the Frame If you wish you may paint the head of the bolt but the threaded portion should be left unpainted Allow the paint to dry thoroughly before any assembly ...

Page 7: ...into the Neck Fasten the nut at the bottom until snug and then back it off slightly to allow the fork to move freely back and forth Full Size for an Adult up to 6 5 Handlebars tilt forward for more room for your knees Large Foot Pegs 5 Degree Engine Mount Cut away for Torque Converter Heavy Duty Axle with Chain Adjust ...

Page 8: ...els for the holes Your holes will pop through the bumps on the outer side of the wheel Do not drill the 8021 wheel half Do not drill these holes on the front wheel Inflate the innertube a small amount for easier installation Insert the innertube into the tire Align both wheel halves into tire being careful not to pinch the innertube Bolt the wheel together Do this for both wheels See details below...

Page 9: ... 16 18 x 3 Bolts and three of the 5 16 18 Locknuts For now tighten the Locknuts only finger tight Do not inflate the tire yet Insert the threaded Axle into the wheel assembly through the 5 8 bearings Doing so aligns the wheel halves Carefully tighten each nut in sequence Torque down each nut tightly but do not over torque If you have a torque wrench which is suggested tighten each nut to 5 ft lbs ...

Page 10: ... using three additional bolts into the holes you previously drilled on the 8020 wheel half The bolts will go through from the inside of the wheel Fasten the nuts and tighten in a pattern to make sure the sprocket is centered and true Note The picture above shows the brake cable anchor used on the Little BadAss Mini Chopper The 215 has an integrated brake cable anchor and does not come with this an...

Page 11: ...e sprocket is installed correctly you should not see any wobble in the sprocket when the wheel spins REAR WHEEL Insert the chain adjuster as shown so the axle can go through Check to be sure the brake actuator arm is in optimum position You may need to loosen remove and re position the arm Hold the wheel in position and slide the rear axle bolt through Be sure the bearings are installed It may be ...

Page 12: ...hain adjusters needed shown installed on the outer portions of the axle below two extra unused chain adjusters are shown hanging loose on the axle Please disregard Brake Anchor Spacer with two bolts One bolt fastens to the frame the other only fastens to the brake plate ...

Page 13: ...fit but the stock gas cap is large making re fueling a bit difficult NOTE Engine engine mounting hardware clutch and clutch installation hardware are not provided and must be obtained Seek the recommendation of your engine manufacturer about an engine suitable for your rider Be sure to obtain all appropriate installation hardware and take note of any special instructions and recommendations regard...

Page 14: ...o the engine s mounting holes until they extend through the bottom of the Frame s mounting plate slots Carefully slide the engine as far to the rear of the mounting plate as possible and then place washers and or Locknuts onto the bolts At this time hand tighten only NOTE The engine must remain in this temporary pushed to the rear position until after you have installed the chain ...

Page 15: ...ion pdf There is a cut away on the motor plate for the Torque Converter The torque converter triples the climbing power and increases top end The bike can also support a Centrifugal Clutch You will need a chain tensioner and longer chain This is the preferred configuration for racers who need more precise speed control without the hesitation of a torque converter Shown with the stock cover Cast Al...

Page 16: ...t the cable from fraying You are going to thread the cable through the barrel connector at the carburetor If you fray the cable cut off a few of the frayed strands Install the throttle cable into the twist grip control so that the barrel end slips into the notch Install the Throttle Control onto the handlebar on the right when sitting on the bike Using a Philips screw driver gently tighten each sc...

Page 17: ...tighten the screw Be sure the cable is pulled through the barrel connector until snug You will likely have to re adjust this once you start and test the engine Re Install the air cleaner assembly Note The throttle mechanism will appear to not be operating when the engine is not running The engine must be running for the throttle to operate See more full information for throttle linkage here https ...

Page 18: ...hole in the Brake Lever on the left handlebar and rotate the Cable so that the barrel end fits into the slot in the brake adjuster housing Slide the Housing up over the cable until it fits into the opening in the Brake Lever Route the Brake Cable and Housing down the Fork and left of the Frame toward the brake using three Conduit Clips to secure the Cable and Housing to the Fork and frame as you g...

Page 19: ...ivel NOTE You may choose to leave a small length necessary for ease of adjustment Make certain however that excess cable remaining will not interfere with any other vehicle operation and will not come into contact with the rider KICKSTAND Measure cut to fit Install onto frame bracket OIL SERVICE Add just over a half of a quart 10W30 oil recommended Synthetic ok Check the dipstick You should see oi...

Page 20: ... person start One person to stand in front of the bike to hold it The other person to operate the pull start throttle control and kill switch As part of road test check and adjust the following Add Engine Oil Fuel Adjust Engine Idle Adjust Throttle Cable Adjust Throttle Control Adjust Brake Cable Adjust Chain Tension Set Tire pressure 12 15lbs These items must be checked BEFORE EVERY RIDE ...

Page 21: ...erter Front and Rear Fender Mounts Heavy Duty Rear Axle Mount Kickstand Mount Fork Assembly 8 Aluminum Wheels Premium Tires and Inner tubes 5 Heavy Duty LBA Drum Brake Integrated 40 41 54 Tooth Sprocket Chain Tension Adjusters Premium 40 41 Chain 6 5hp engine TC2 Torque Converter ...

Page 22: ...Power see the Mikuni Stage 1 Kit with Fatty or Mikuni Stage 1 Kit with Stinger This carb upgrade really wakes up the responsiveness of the engine and as an added bonus allows you to remove the stock throttle linkage mechanism and replace it with one simple throttle Cable connection Mikuni STAGE 1 INSTALL GUIDE CARB JETS Upgrading the Intake and Exhaust usually requires re jetting the Carburetor If...