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Table of Contents
Summary of Contents for American Racer 215 Mini Bike
- Page 1 MINI BIKE OWNER GUIDE GOKARTS USA...
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Page 2: Table Of Contents
CONTENTS SAFETY INFORMATION ................... 2 AMERICAN RACER MINI BIKE................ 3 UNPACK AND SEPARATE PARTS ..............4 Parts List: ......................4 PAINT ........................ 5 ASSEMBLY INSTRUCTIONS ................6 FORK ......................6 WHEELS ....................... 7 TIRES ......................8 SPROCKET/DRUM ..................9 BRAKE ......................10 REAR WHEEL .................... -
Page 3: Safety Information
SAFETY INFORMATION POWERSPORTS Products MUST NOT BE OPERATED ON THE STREET. They are FOR USE ON A CLOSED COURSE ONLY. DEATH OR INJURY CAN OCCUR PERSONS UNDER THE AGE OF 16 must be SUPERVISED by a competent adult. MECHANIC REQUIRED Minibikes, Gokarts, ATVs... -
Page 4: American Racer Mini Bike
AMERICAN RACER MINI BIKE The American Racer 215 Mini Bike is sold fully assembled. The 215 is also available as a kit. -
Page 5: Unpack And Separate Parts
UNPACK AND SEPARATE PARTS 215 Frame and Fork PARTS LIST: L1065-3020 Front Wheel, 8" L1065-3021 Front Wheel Bearing L1065-3052 Front Tire 480 x 8 L1065-3053 Front Tube 480 x 8 L1065-3012 Front Wheel Spacers, (2) L1065-3013 Front 5/8 Axle L1065-3014 Front 5/8 Nut for Axle L1065-3017 Kickstand L1065-3059 Long Seat L1065-3020 Rear Wheel, 8"... -
Page 6: Paint
PAINT ❍ Thoroughly clean the Fork, and Frame, 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. -
Page 7: Assembly Instructions
ASSEMBLY INSTRUCTIONS FORK • Place your frame on a stand. • Align the Fork onto the Frame Neck. Slide the Fork Bolt down 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. -
Page 8: Wheels
WHEELS Each wheel has two halves, marked 8020 and 8021. • Drill out the three sprocket mounting holes on the 8020 wheel half for the rear wheel. Drill from the inner side of the wheel. You will see channels for the holes. Your holes will pop through the bumps on the outer side of the wheel. -
Page 9: Tires
TIRES ❍ Insert Innertube into the Tire so that it is snug and resting completely within the tire. Inflate the Innertube with just enough air to remove the folds from the tube (1 or 2 psi). ❍ Mount the Tire onto a Wheel set, as follows: ❍... -
Page 10: Sprocket/Drum
SPROCKET/DRUM Your 215 Mini Bike is equipped with a lazer cut, precision welded, heavy duty Sprocket/Brake Drum to ensure smooth, reliable operation of the drivetrain. • Bolt the sprocket/drum onto the rear wheel using three additional bolts into the holes you previously drilled on the 8020 wheel half. -
Page 11: Brake
BRAKE • Insert the two bolts of the brake ancher/spacer through the brake plate, then place the assembly into the drum. Slide the Axle through to hold the wheel and brake assembly in place. Spin the wheel and check the sprocket for true and •... -
Page 12: Rear Axle
REAR AXLE • Axle and Nut • Chain Adjusters (2) • Note: There are only two chain 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. •... -
Page 13: Engine
ENGINE 215 Frame will accept these engines • Honda GX120/160/200 • Titan TX200 • Predator 212 Titan TX200 engine has the side mounted fuel neck for easy fueling. Honda Engines will fit, we recommend using a low profile gas cap Predator 212 will fit, but the stock gas cap is large, making re-fueling a bit difficult. - Page 14 • Place the Engine on the Frame’s engine mounting plate, aligning the engine’s mounting holes with the slots in the Frame’s mounting plate. • Insert the engine mounting bolts down into the engine’s mounting holes until they extend through the bottom of the Frame’s mounting plate slots.
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Page 15: Torque Converter
TORQUE CONVERTER We recommend installing the Torque Converter onto the engine prior to installing the engine on the bike. • Please use the link below to download the GTC TC2 Installation Instructions • http://gtcmanufacturing.com/tc2installation.pdf • There is a cut-away on the motor plate for the Torque Converter. -
Page 16: Throttle Control (Stock Carburetor)
THROTTLE CONTROL (STOCK CARBURETOR) • Measure the conduit to the desired length and cut to fit. The conduit should be about 6” shorter than the cable. Don’t cut too short, leave a little extra room. You can always cut a little more, but you cannot add any length. - Page 17 • Route the Throttle Cable and Housing down the Fork and right of the Frame toward the carburetor, using conduit clips to secure the Cable and Housing to the Fork and frame as you go. Go past the carburetor, then loop the cable back to the carb. Remove the air cleaner assembly from the •...
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Page 18: Brake Lever
BRAKE LEVER ❍ Loosen both clamp screws on the Brake Lever and install it onto the Frame’s left handlebar about 4" from the end with the steel ball end of the Lever pointing left and forward. ❍ Secure the Brake Lever into position by tightening the mounting collar screws CAUTION: Prior to any operation, be sure to adjust the position of the Brake Lever so that it is readily available to and easily... -
Page 19: Adjust Brake
ADJUST BRAKE When adjusted properly, the brake should fully engage and lock a spinning rear wheel, well before the depressed brake lever comes into contact with the handlebar ❍ Adjust the Brake by loosening the screw on the brake barrel connector and tightening up the excess slack in the cable. -
Page 20: Test Run
TEST RUN AVOID RUN-AWAY BIKE. WARNING Until you properly adjust your throttle, the first few times you start your bike, the engine may accelerate to full throttle. We strongly recommend a two 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. -
Page 21: Features
FEATURES 1" Heavy Duty Frame 5° Engine Mount with Cut-Away for TC2 Torque Converter 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... -
Page 22: Performance Parts
PERFORMANCE PARTS BOOST YOUR HONDA, TITAN OR PREDATOR UP TO 26HP... HIGH FLOW EXHAUST The stock exhaust is also very restrictive. A favorite among Kart Racers, the RLV Header Pipe and Silencer will give you a substantial boost in power and that great sound for a low cost.
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