#Diy mini bike kit install

With the chain adjusted we noticed the chain was too close to the chain guard.

The front portion of the chain guard does not fit the 6.5hp motor. The rear portion of the chain guard went back on. Note: We removed two links from the chain for a better fit. Now slide the engine forward to take the slack out of the chain and tighten the four nuts on the bottom of the mounting plate.

#Diy mini bike kit install

Install the chain, square up the engine and tighten the four engine nuts and bolts. We removed the rear portion of the chain guard to make installing and aligning the chain easier. Note: The Harbor Freight engine we used has a billet rod, Honda aluminum flywheel, flat top piston, 14cc cylinder head, 265M cam, chromoly pushrods, 18lb valve springs, 92 main jet, bored carburetor and a high grade bolt kit. Put the adapter plate in place with the 8 bolts. The adapter plate also provides front/rear and side to side adjust-ability making the engine swap much easier. You can drill four holes to mount the motor on without the adapter plate, however the plate is very flimsy without the support from the adapter plate. Here is the motor plate with the four 5/16' holes drilled. Line up the adapter plate and drill the four holes per the adapter plate instructions. Remove this spacer the stock engine was sitting on. Remove the four bolt from beneath the motor plate. Remove the black portion of the chain guard. Unscrew the wire stop and pull the cable out. We start our engine swap by removing the stock throttle cable. Now the handling is much smoother especially when going over bumps. This problem was addressed by installing a spacer. This causes some undesirable slop in the steering. There is a good size gap between the neck of the frame and the top cross plate on the forks. The first area of concern is the front forks. We've opted to install a 6.5hp clone motor on this Doodlebug. Installing our jackshaft unit brings the 2.8hp motor alive and makes the Doodlebug fun to ride.

The stock gearing makes the 2.8hp motor very sluggish and weak. We'll take out the stock motor and replace it with a 6.5hp Harbor Freight clone motor. Since the stock 97cc engine does not have the power to pull us up a slight uphill grade we will start with an engine swap. We are taking a stock Doodlebug mini bike and modifying it in steps.