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Distributed exclusively in the USA by: Nationwide Access. www.gasbike.net
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLATION
www.grubeeinc.com
GT5
GT2A
GT2B
GT2-SM > 48cc / 40mm x 38mm bore and stroke: Angle Fire Sq. Head;
GT5
GT5-SR > 66cc / 47mm x 38mm bore and stroke: Angle Fire Sq. Head;
2 cycle gas engine with dual needle bearing:
plated inside;
Bicycle ½" x 1/8" drive chain; Chain guard;
hardware for 36 spoke wheel;
approved carburetor with external choke control: New design CD Ignition,
switch: Tool kit with Extra spark plug; Extra mt. block, Extra head gasket:
To ensure continued engine performance: DO NOT use other than original SkyHawk replacement parts.
Note: Failing to follow these instructions when installing a certified engine in a piece of non-road
equipment violates Federal Law 40CFR-1068.05 (b) and is subject to fines or other penalties as described in
the Clean Air Act of 1970.
"do it yourself" backyard mechanics will find this project rewarding. A love of small engines is the only
required catalyst for this project. However, installation is sometimes best done by a professional auto or
motorcycle mechanic. Frame size should be 28mm to 30mm dia. with 70 degree included V angle. For
sufficient engine clearance select a bike with a seat tube length of at least 12 ½ inches measured between
bottom of top tube and top of pedal sprocket tube. A rewarding joy and challenge is found in designing a
custom installation of your own. Remember, a quality installation is paramount to safe usage and long term
satisfaction. You may find many uses for this engine kit from stationary machine power to off road riding
machines. Have fun and good luck on your motorized project. Happy trails to you from China GAS:
STEP #1
Mounting the Engine:
1. The engine mounts in a 70 degree angle "Vee" tube frame. It is best to make sure all 4 engine studs are
securely bottomed out in the engine before mounting. Use a Jam nut procedure to tighten.
2. Consider using Masking or Duct Tape on the front down-tube & seat tube of your bicycle to protect the
paint finish while test fitting the engine to your donor bike. If the distance between the two frame tubes
exceeds the engine mounting span then additional spacers or welded brackets may be required. Mount
the engine to the seat tube first and then fit to the front tube. If frame tube fit is smaller than engine
clamp dia. use strip shims to fit. See figure one for example of installation on a wide frame bike..
These Instructions are Copy Righted:
GT2A
GT5-SR
YuanDong
> 48cc / 40mm x 38mm bore and stroke: Center Fire Sq. Head.
> 48cc / 40mm x 38mm bore and stroke: Angel Fire Rd. Head.
> 66cc / 47mm x 38mm bore and stroke: Center Fire Sq. Head;
Kit Box Contents:
Black Catalytic exhaust muffler; Tear Drop 2.5L Fuel Tank
Ball bearing chain idler: Push button clutch lever, CNS premium EPA
Mechanical aptitude and ability is required to perform this installation. Many
Rev. Oct 24, 2010
SkyHawk
44 tooth Sprocket with 9 hole mounting
Twist throttle with integral kill
1
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Table of Contents
Summary of Contents for YuanDong GT2A
- Page 1 Distributed exclusively in the USA by: Nationwide Access. www.gasbike.net PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLATION www.grubeeinc.com These Instructions are Copy Righted: Rev. Oct 24, 2010 GT2A GT5-SR YuanDong SkyHawk GT2A > 48cc / 40mm x 38mm bore and stroke: Center Fire Sq. Head.
- Page 2 Special Front Mounting When installing engine in a odd size frame it may be necessary to modify the existing front mount. This is due to some oversized down tube frames being longer or wider then the motor is designed to fit.. If you find that the front engine mount will not reach the down tube when the motor is mounted to rear tube you will need to make modifications.
- Page 3 MOUNT ENGINE IN FRAME as low as possible: AVOID BEING TOO HIGH UP IN THE FRAME. Master Link rd. side in direction of pull. Need clearance here If engine is mounted at a high angle position the chain will hit the sprocket cover. Keep as low as possible. Beach Cruiser bike frames work good as well as do the classic 70 degree Old time European style.
- Page 4 Figure 1. Bike with wide frame or big down tube: Use ¼” thick 1-1/8” x 2-1/2” steel plate with one hole in the center for a bolt to go through a drilled hole in tube frame and two holes for cap screws to go into engine block.
- Page 5 3. The Chain Sprocket on the Wheel must align within 1/2 cm to the Chain Sprocket on the Engine. 4. The wheel chain sprocket is mounted with teeth-out and dish-in next to spokes. SEE FIG. #2 Place Sprocket’s bright chrome side inward next to spokes with dished side outward: 5 plates: 9 - 4.8 M6 bolts with...
- Page 6 narrow sprocket but a std. 1/2”-1/8” bike chain will not go over a wide drive sprocket. Note: Install chain with master link clip on outboard side of the primary drive sprocket teeth. ( Note: wide tires larger than 2.125 may rub on a wide 415HD chain: ) C.
- Page 7 B) Squirt oil down the cable sleeve: Route clutch cable through the ball-mount on the engine with the big spring around the cable jacket and ahead of the ball mount. The big spring serves as a cable heat shield. C) Insert cable wire through small spring and route through clutch arm and attach brass cable-end and screw.
- Page 8 GT5 and GT2A models with external CDI use this kill switch hook up...
- Page 9 Optional 2010 YD CNS Carb. Unwrap throttle from carb. Install carb. on intake tube and choke lever on handlebar. Install external CDI module on down tube as far away from engine heat as possible. Blk. wire from engine to Blk. of CDI Blue wire from engine to Blue of CDI For CDI Color code is very important: Two kill switch wires can go to either of the remaining 2...
- Page 10 Big Intake Tube is on GT5-SR / GT2-SM / GT2A and a Little Tube is on GT2B / & GT5. Intake gaskets are different: 40mm hole spacing for the big one and 30mm on the little one. Ensure all bullet...
- Page 11 GT5SR & GT2-SM Kill switch wires can go to either wire from engine. For GT5-SR and GT2-SM use this kill switch hook up; 2010 / 2011 models have a special CNS YD EPA Carb. especially for Skyhawk engines. This new carb. has adjustment screws sealed and has an external cable choke control. Be sure to check carb.
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Page 12: Maintenance Section
B) After installing cable inside the carburetor mount it on engine intake tube and tighten clamp screw. Mount engine so carburetor sets as level as possible. 1. Note: Factory Sealed ratio screw. Factory set by turning adjustment screw to closed Air /Fuel position and then opened ¾... - Page 13 Instructions: Drive Sprocket & Crankshaft Gear Puller. This tool is found in the engine kit tool bag: It is used to remove both the output gear B-5 and the 10T drive sprocket. To remove primary 10T drive sprocket secure sprocket from moving and remove nut. Screw in puller tool to the threads in sprocket internal ID.
- Page 14 Reverse bolt in puller tool; Secure tool in output gear; Hold tool with end wrench and ratchet bolt CW to remove gear. *Clutch Adjust Nut 2. Carburetor Per instructions from the Dept. of EPA the idle and air fuel mixture screws have been epoxy sealed at the factory to avoid end-user tampering.
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Page 15: General Information
Left side drive: Routinely pack grease in the shaft hole behind 10T sprocket and also in cover bushing hole. This will also help deduce noise. SkyHawk Engine ID plates: General Information Obey all traffic regulations. Always wear a helmet while riding. Remember that you are riding a motorized bicycle and other traffic may not be able to see you. - Page 16 Special Items, tools and extra service parts in tool kit; YuanDong SkyHawk mfg. & NationwideAccess > ENGINE WARRANTY POLICY: Proper use and maintenance is required for the continued enjoyment of your Bike Engine. This product has been manufactured to strict quality control standards.
- Page 17 Ask your dealer for the China GAS Alum. frame w/ built in gas tank & pedestal mount. For a ProShop installation ask your dealer for the China GAS Model #2 HD axle kit; ( Complete assembled Rear Wheels for 1 speed or Multi speed 26” bikes are available.) Pull 2 pins to pedal with no restriction and stick them back in to motor.
- Page 18 Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates Federal Law 40CFR-1068.05 (b) and is subject to fines or other penalties as described in the Clean Air Act of 1970. Parts Reference: When replacing the spark plug in an Angle Fire head it’s best to use a 3 point electrode spark plug P/N Z4JC to ensure total combustion.
- Page 19 GT2-SM GT5-SR GT5 and GT2B...
- Page 20 CNS Carburetor p/n C-32CNS66-EPA...
- Page 21 Long & Short expansion chamber racing exhaust Improved catalytic muffler for 2010 Two psc. STREET POO POO PIPE EPA requirements with twice the size of available in dealer service parts. palladium insert plus an outside air shield; 2.5 liter gas tank plated inside to help reduce rust from occuring...
- Page 22 44T REAR WHEEL Drive Sprocket...
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