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the transmission plate fits perfectly to the transmission, then slide the front bolts that bolt the transmission plate to the frame through the holes in the transmission plate before tightening the nuts holding the transmission plate to the transmission. With some transmissions it is not possible to install these bolts with the plate bolted fully to the transmission. Bolt transmission plate to transmission.


the frame, the transmission plate or the motor plate to achieve this smooth alignment. A shim may occasionally be necessary between the transmission fifth mount stud and frame. Do not tighten anything down yet.


Now is the time to bolt your rear fender into the frame, as the bolts attaching the fender struts to the frame axle blocks are hard to access once the rear wheel is in place. Consider mounting/wiring your tail-light at this point, and also your license plate if either one is related to the rear fender. Mount the rear sprocket or pulley to the


Position transmission with plate attached into the frame. Install the hardware to mount the plate to the frame, but do not tighten. Install the transmission sprocket or pulley. Don’t forget the locking screw or plate that prevents the sprocket nut from coming loose.


Install your inner primary or motor plate. This is the step where you should expend the time and effort to get it right. The plate or inner primary should bolt up smoothly to both the transmission and the motor with out being forced to ‘bend’ into place. If you are using our motor plate there may be a spacer between the motor plate and the transmission, and you will need to use a couple of shorter bolts to ‘mock’ fit the plate at this stage. The motor will be able to shift and rotate slightly in the frame and so will the transmission, and you must get them positioned so the primary plate or case aligns with them without effort. Rarely, it may be necessary to take a file to the holes in


rear wheel and install the wheel in the frame using the axle spacers provided. Be sure to follow the instructions and use plenty of red loctite when installing a sprocket/rotor. If you are using a Sprocket Brake then the order of components on the axle is typically this: longest spacer, wheel, shim washer supplied with caliper, caliper, shortest spacer. If we have mocked up the bike then the axle adjusters will probably be in their final position (note that there may be a lock screw in the axle adjuster on one or both sides). Do not tighten the axle nut at this point. You will need to mock fit your chain at this time. Offer the chain up to the sprockets and determine the length needed. Your chain will be probably be slightly over-length, so you will need to remove a few links. Do this by grinding the heads completely off of the two pins over the side plate at the point you need to break the chain. Take precautions not to cover the entire chain with grinding dust! Position the chain on the sprockets and insert the master link, but do not connect the master link at this point. Check that the chain or belt tension is close to that which is required. At this point we want to check the alignment of the final drive pulley or sprockets. Offer a straight edge along the face of the rear wheel sprocket and the transmission sprocket (or pulleys). Adjust the axle adjusters until the two are parallel and check that the chain or belt tension is still good. At this point we need to tighten the rear axle but as we will need to remove it again you should use some form of spacer or washers under the nut so that you do not use the ‘Nyloc' part of the thread. Tighten the


axle nut and recheck alignment. Note that the sprockets are not as wide as the ‘space’ in the chain, which means that some slight ‘stagger’ between sprockets will not be a problem (0.050”), but they do need to be parallel. If your primary mounts smoothly, your belt or chain tension is good and your final drive sprockets or pulleys are parallel, then you have successfully mocked up the entire drive train. Start to tighten down the drive train components. Tighten the motor plate (or primary case) to the motor and transmission. If you are using our electric start kit, then install it at this point (except the starter nose). Tighten the bolts holding the engine and the transmission plate in the frame. The point is to tighten down your drive train without stressing any components or upsetting the alignment. It is worth taking the time to install your drive train and align the primary and final drives properly. DO NOT forget to connect the chain master-link before heading down the road, but don’t do it until the final tightening of the axle AFTER the Sprocket Brake caliper has been bled. The top motor mount can be installed


at this point. If you are using our one-piece billet mount then it may be necessary to use shims between the frame and the mount. (Different motors have different cylinder heights). Mount the coil at this point whilst you have good access to the area.


This is a good time to install the kickstand. Check the pin fits easily into the hole in the stand and through the hole in the frame tab. Hook the spring to the stand and to the frame and then lever the stand into position. Have the pin to hand so you can push it into place as soon as the holes line up. Install the primary drive as per the manufacturer’s instructions. Don’t forget to bolt the starter ring gear to the clutch


39


COMPLETE BIKE KIT – ASSEMBLING THE BIKE


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