MM-B80/105 ASSEMBLY INSTRUCTIONS READ ALL OF THE INSTRUCTIONS BEFORE REMOVING BIKE FROM THE STEEL SHIPPING CRATE AND ASSEMBLING THE BIKE. MAKE SURE YOU UNDERSTAND THE INSTRUCTIONS BEFORE YOU BEGIN. For instructional videos visit: megamotousa.
MM-B80/105 ASSEMBLY INSTRUCTIONS UNPACKING WEAR PROTECTIVE GLOVES WHEN HANDLING THE STEEL CRATE 1 e 2 3 After you have removed bike in the steel crate from the cardboard box: 1) Cut the ties that secure the handlebar and front fork to the steel packing frame 2) Remove the bolt and nut that secures the mini bike steering head to the top steel shipping crate 3) Loosen and remove the 6 bolts and nuts that secure the upper steel crate and vertical supports to the crate base.
MM-B80/105 ASSEMBLY INSTRUCTIONS UNPACKING RIGHT SIDE OF BIKE NEAR THE FOOTPEG RIGHT SIDE OF BIKE NEAR REAR WHEEL LEFT SIDE OF BIKE NEAR THE FOOTPEG NOTE: LEAVING THE BIKE ATTACHED TO THESE THREE BRACKETS WILL MAKE THE FRONT FORK AND FRONT WHEEL ASSEMBLY MUCH EASIER. WHEN ASSEMBLY IS COMPLETE AND OIL HAS BEEN ADDED TO THE ENGINE, THEN YOU CAN UNBOLT THE THREE BRACKETS AND REMOVE THE SHIPPING CRATE BASE AND DISCARD IT.
MM-B80/105 ASSEMBLY INSTRUCTIONS PARTS: Oil is not provided with the mini bike. 12oz of 10W30 Motor Oil is needed.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FORK 1 2 1) With the upper part of the steel shipping crate removed, the forks and handlebar are resting on the right side of the bike. The bike should still be attached to the base of the shipping crate. 2) Without twisting the wires and cables, lift up the handlebar and front fork placing the handlebar on the top of the bike frame and resting the fork on the steering head as shown in the photo.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FORK Steering Head Steering stop pins Steering stop Number Plate Tab Lower Fork Plate 3 3) Make sure the number plate tabs on the forks are facing forward and slide the lower fork plate under the steering head. Make sure the steering stop pins are behind the steering stop as shown.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FORK 4 5 4) While keeping the steering stop pins behind the steering stop, move the upper fork plate back and over the steering head. 5) Line up the hole in the upper fork plate with the hole in the steering head. 6 6) Insert the steering bolt through the top fork plate and into the steering head.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FORK 7 7) Push the steering bolt all the way through the steering head and the lower fork plate 8 8) Install the nut on the steering bolt as shown in the photo. 9 9) Tighten the nut securely, (39N.m/20ft.lbs.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FORK NOTE: Make sure the wires and cables do not pinch between the frame and the lower fork plate or the steering stop pin and the frame when the handlebar is turned to the right, (as seated on the bike). If they do, simply twist the cable tie, wires, and cables toward the rear, away from the lower fork plate.
MM-B80/105 ASSEMBLY INSTRUCTIONS HANDLEBAR 10 10) Rotate the lower portion of the handlebar forward and under the grips and lever portion of the handlebar and rest the handlebar on the top fork plate and frame as shown. The brake lever should be facing up and the cables should not be twisted. 11) Locate the 2 upper and 2 lower handlebar clamps. 12 12) Place one lower handlebar clamp under the handlebar as shown and align the holes in the clamp with the holes in the upper fork plate.
MM-B80/105 ASSEMBLY INSTRUCTIONS HANDLEBAR 13 14 13) Place the upper handlebar clamp as shown. 14) Insert the 2 handlebar clamp bolts through the holes in the upper and lower clamps and the holes in the upper fork plate as shown.
MM-B80/105 ASSEMBLY INSTRUCTIONS HANDLEBAR 15 15) Install the nuts on the handlebar clamp bolts as shown. Do Not tighten. 16 16) Install the clamps, bolts, and nuts on the other side (as in steps 12 through 15).
MM-B80/105 ASSEMBLY INSTRUCTIONS HANDLEBAR 17 17) Center the handlebar on the two clamps. 19 18 18) Angle the handlebar to align with the angle of the forks. This is a good initial setting, you can adjust the handlebars at a different angle if you prefer. 19) Tighten the handlebar clamps so that the space between the upper and lower clamps at the front of the clamps is equal to the space at the back of the clamps. Tighten securely (26N.m/19ft.lbs.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT FENDER 20 20) With the Mega Moto logo facing forward, place the front fender over the mounting brackets on the front forks 22 21 21) Align the holes in the fender with the threaded holes in the mounting brackets. 22) Insert the Philips head screw through the plastic washer, the fender and into the threaded hole of the mounting bracket and hand tighten. Have all 4 screws and washers installed by hand before tightening with a screwdriver.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT WHEEL 23 23) Insert the front axle bolt through the right fork, (as seated on the bike), so that only an inch or 2 of the bolt is through. 24 24) Place 1 axle spacer on the bolt, position the wheel between the forks with the tread as shown, and insert the axle bolt through the wheel. 25 25) Push the axle bolt through the other side of the wheel so that only about an inch of it extends past the wheel bearing.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT WHEEL 26 26) Place the second axle spacer on the axle where it extends from the wheel. 28 27 27) Align the spacer and the hole in the fork and push the axle bolt all the way through. 28) Install the nut on the axle and tighten securely. (54N.m/40ft.lbs.
MM-B80/105 ASSEMBLY INSTRUCTIONS FRONT NUMBER PLATE AND GUSSET COVER 29 29) Place the number plate over the number plate tabs on the front fork, align the holes in the number plate with the threaded holes of the tabs and insert a screw with a plastic washer through the top hole and hand tighten. Install the screw and washer in the lower hole. Tighten the upper and lower screws with a screwdriver 30 30) Align the tabs on the right side gusset cover with the rubber mounting holes in the frame.
MM-B80/105 ASSEMBLY INSTRUCTIONS ADD OIL Oil is not provided with the mini bike. 12oz of 10W30 Motor Oil is needed. 32 32) BEFORE YOU START THE BIKE YOU MUST ADD 12oz. OF 10W30 MOTOR OIL TO THE ENGINE. The bike should be on the steel shipping crate base so that it is vertical. Add oil into the oil filler neck on the front of the engine.
MM-B80/105 ASSEMBLY INSTRUCTIONS ADD OIL WEAR PROTECTIVE GLOVES 34) Unbolt the 3 clamps that secure the mini bike to the steel crate base, roll the bike off the base and discard the base.
MM-B80/105 ASSEMBLY INSTRUCTIONS STARTING THE MINIBIKE BE SURE TO OIL THE CENTRIFUGAL CLUTCH BEFORE AND AFTER EACH RIDE AS INSTRUCTED IN YOUR OWNER’S MANUAL. 35 35) After adding fuel to the fuel tank, push the fuel lever forward to start fuel flow into the carburetor 37 37) Press small red button on the Engine Stop Switch so that the small button is pushed in and the larger red button sticks out. This is the “RUN” position. 36 36) Move the choke lever to the right, “START” position.
MM-B80/105 ASSEMBLY INSTRUCTIONS STARTING THE MINIBIKE 39 39) After the bike has started and has had a minute or two to warm up, push the choke lever to the left, “RUN” position ALWAYS WEAR PROTECTIVE GEAR SUCH AS A HELMET, GLOVES, BOOTS, LONG SLEEVE SHIRT, AND PANTS WHEN RIDING. 40 40) To turn off the bike push the large red button on the Engine Stop Switch. 41 41) When you are finished riding, turn the Fuel Lever to the “OFF” position.
