- 1). Put a new intake manifold gasket on the Mikuni carburetor flange. Mount the carburetor on the 75 cc engine with a metric socket and ratchet.
- 2). Remove the chain cover at the side of the crankcase on the 75 cc engine. Save the bolts and the cover.
- 3). Secure the spark plug wire, throttle cable and clutch cable away from the engine compartment on the motorcycle with nylon ties.
- 4). Position the engine at the engine compartment. Align the engine mounts on the frame with the threaded ports on the underside of the crankcase. Attach the engine to the frame using the original engine-mount bolts. Tighten the bolts to 75 ft. lbs. with a torque wrench.
- 5). Loop the front of the motorcycle chain around the crankcase sprocket on the side of the engine. Reattach the chain cover with the saved bolts. Adjust the chain tension to 1/4-inch deflection by tightening the chain tension adjuster at the rear wheel with a metric wrench.
- 6). Clip the nylon ties that secure the spark plug wire, throttle cable and clutch cable with wire cutters. Push the cap of the spark plug wire onto the spark plug at the cylinder head. Connect the timing ignition wires from the engine to the ignition coil on the mini bike.
- 7). Connect the throttle cable to the throttle cable adjuster at the top of the Mikuni carburetor. Tighten the adjuster with a metric wrench.
- 8). Connect the clutch cable to the end of the operating rod on the upper side of the crankcase using the original shoulder bolt and lock nut. Adjust the clutch cable with the adjuster at the hand lever so you have 1/4 inch of free play at the lever.
- 9). Secure loose sections of the clutch and throttle cable to the mini bike frame with nylon ties.
- 10
Mount the gas tank on the mini bike and connect the fuel line to the Mikuni carburetor with the original clamp. Put a new exhaust manifold gasket on the exhaust manifold and reattach the exhaust pipe to the mini bike.
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