Step 1> UNCRATE THE BIKE:

  • Remove the box.
  • Remove all parts that are secured inside the steel crate.
  • Remove all wire holds that secure bike to crate
  • Unscrew (8) phillips head bolts from perimeter of the bottom of the crate.
  • Remove top of crate, leaving bike secured to the bottom of the crate.
  • Leave handlebar controls tied to fork leg of bike for now.

Step 2> REMOVE FRONT AXLE

  • Unbolt front axle from crate axle stay
  • Lift bike onto a motostand to install front wheel

Step 3> NOTE: BRAKE CALIPER

  • Notice the plastic seperation device wedged in between the brake pads in the brake caliper
  • Do not remove until you are ready to line front wheel up with axle holes in forks

Step 4> INSTALL FRONT WHEEL

  • Insert wheel spacers into axle holes on front wheel
  • NOTE: There are 2 spacers - one on either side of the wheel
  • NOTE: Some models have different width spacers - Be sure to put proper length spacer in proper axle hole so as to align brake rotor into brake caliper
  • Remove brake pad seperator from between brake pads
  • NOTE: Do not apply front brakes until wheel is completely mounted
  • Keeping both fork legs straight, align rotor into caliper until wheel spacer holes lign up with axle holes in fork legs
  • Put axle through forks, wheel spacers and wheel
  • Tighten nut onto axle
  • Wheel should spin freely

Step 5> INSTALL HANDLEBARS

  • Remove 4 allen head screws from top bar mount on triple clamp
  • Affix handlebars into recesses of bottom bar mount
  • With 4 allen head screws, attach top bar mount over handlebars so as to clamp bars to triple lamp in between top and bottom bar mounts
  • Be sure to center bars perfectly before tightening allen head screws

Step 6> INSTALL CONTROLS

  • NOTE: There is a pre-drilled hole in the right side of the handlebars
  • NOTE: There is a set pin at the bottom inside of the throttle tube
  • Slide throttle tube assembly onto right side of handlebars
  • Align throttle tube set pin into the pre-drilled hole on the handlebar
  • Tighten 2 screws on throttle tube to secure throttle to bars

Step 7> Install Hydraulic brake lever on right side inside throttle tube by tightening 2 set screws

Step 8> Install clutch lever on left side by tightenng 2 set screws

Step 9> Install Kill Switch between left hand grip and clutch lever