DIY Network

Mini-Bike Kit: Tires and Frame From "Weekend Mechanic" episode WKM-212

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Bruce does some restoration work on the vintage mini-bike frame. Figure A Figure B Figure C Figure D Figure F Figure G Figure H Figure I Figure J Figure K Figure L Figure M

With the wheels installed in the new tires, work can continue with tires and restoration work on the frame.

Important: Included below are the steps in this mechanical procedure as shown in the episode. These steps are general guidelines that are applicable to most mini-bike kits. With any particular kit, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that kit. Read and follow the manufacturer's directions and precautions that come with your kit and/or parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools and air tools.

Safety Alert: Always wear eye protection, ensure adequate ventilation and follow proper safety precautions when working with spray paints or other aerosols or solvents.

Tires and Frame Prep

• The restoration work on our vintage mini-bike frame is as simple as scrubbing it clean and spray-painting the frame pieces (figure A). Use a high-quality rust-proof enamel spray-paint for this job. Apply two coats, but avoid over-application which can cause runs or clog bolt-holes.

  Note: If you're restoring a vintage frame that has rust on it, you'll need to sand off the rust before spray-painting.

• With the wheels and tubes installed in the tires, check the side-wall of the tire for maximum pressure and inflate your tires (figure B).

• Check with a tire gauge (figure C) to ensure that you don't under-inflate or over-inflate the tires. Also check with your kit's instructions for proper tire pressure for the mini-bike you're building. Average tire pressure for most is around 10 to 15 psi.

• As you inflate the tires, visually check to ensure that the bead of the tire is seating snugly against the wheel (figure D).

• Once the paint on the frame has dried, remove any masking tape that you used to mask off unpainted areas (figure E).

• Tip: Rubber hand-grips can sometimes be tight and difficult to install on the handlebars. As with the tires, applying some liquid soap to the rubber can help them go on much easier.

• Next, attach the kick-stand with the bolt and nut provided with the kit (figure F).

• With the kick-stand installed, turn the frame over to install the front-fork assembly. This component is held on with one bolt, and is the pivot point for the front-end of the bike. Before installing the bolt, use a grease gun to place chassis grease into the bolt-hole on the frame (figure G) and on the bolt itself.

• Place the fork in position, insert the bolt and push the bolt home (figure H).

• Wipe away any excess grease and install the lock-nut provided with the bolt.

• The next step is to install the rear wheel. Align the holes in the sissy-bar with the holes in the frame, and place the wheel in position. Slide the spacers that are designed to account for the depth of the spindle into the wheel-hub and over the rear axle bolt (figure I).

• Work the bolt through the bearing and install a locking nut on the opposite side.

• Install the rear-housing that holds the tail-light (figure J) and install the tail-light (figure K). (In our project, we opted not to wire the light since it was not called for in the original plans. The light could easily be wired later on if desired.)

• The seat is installed next (figure L), and is attached to the frame with four bolts.

• Finally, the rear fender is fastened to the plastic housing that holds the tail-light (figure M).

• Install the front-wheel assembly, following the manufacturer's instructions and the same basic steps as were used on the rear wheel.

In the segment that follows, the engine and related accessories are installed.

RESOURCES :

The Haynes Small Engine Repair Manual
ISBN: 1850106665
Author: Curt Choate, John H. Haynes
Haynes Publishing Group

Chilton's Small Engine Repair Up to 20 Hp
Model: 0801983258
Author: Kerry A. Freeman
Nichols Publishing

Go-Kart Racing Chassis Setup
Model: 0960506845
Author: Brian Martin
Martin Motorsports Pub. Co.

International Karting Industry Buyer's Guide
Model: 0966146743
Author: Darrell E. Sitarz
Kart Marketing Association of America

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