May 20th, 2025

The TrailMaster Hurricane 200 Pro is a popular choice among mini bike enthusiasts, known for its robust features and reliable performance. Whether you're a seasoned rider or a beginner, assembling this mini bike can be a rewarding experience. In this blog, we'll walk you through the process of building your Hurricane 200 Pro, ensuring you get it right the first time.

Before you start, gather the following tools and materials:

• 13mm socket and wrench
• 10mm sprocket and wrench
• Crescent wrench
• Impact driver (optional)
• Screwdriver
• Air pump for tires
• Oil (Tillotson synthetic recommended)
• Fuel (unleaded 87 octane)

Unboxing and Initial Setup

• Removing the Box: Begin by carefully removing the outer box. Use a 13mm socket and wrench to detach the protective cage from the mini bike.
• Detach the Mini Bike: Use a 13mm socket and wrench to remove the nuts and bolts securing the bike to the frame. Keep the axle safe for later use.

Assembling the Handlebars

• Position the Handlebars: Place the handlebars on top of the forks. Use the risers and bolts from the battery box cover bag to secure them.
• Install the Electric Key Start: Attach the electric key start to the handlebar risers. Ensure the key plate is aligned correctly with the risers before tightening.

Installing the Front Brake Caliper

• Position the Caliper: Locate the brake caliper from your parts bag. Align it with the brake disc on the wheel.
• Secure the Caliper: Use the bolts, lock washers, and flat washers provided to attach the caliper to the fork. Hand-tighten initially, then secure with a 10mm socket. Ensure the caliper is firmly attached but avoid overtightening.
• Remove the Spacer: Inside the caliper, there is a spacer to prevent collapse during shipping. Remove this spacer before finalizing the installation.
• Test the Brake: Squeeze the brake lever to ensure the caliper engages the disc properly. The wheel should stop smoothly without any excessive play or noise.

Mounting the Front Fender

• Prepare the Fender: Gather the front fender and the bolts from the "Front Fender" bag.
• Align and Secure: Position the fender over the front wheel, aligning the two front holes and one rear hole with the fork's mounting points. Insert the bolts through the fender bracket and tighten them using a 10mm socket and wrench.
• Adjust as Needed: If the bracket is slightly bent, gently adjust it by hand for a snug fit. Make sure the fender is stable and properly centered over the wheel.

Installing the Front Wheel

• Prepare the Front Wheel: Begin by inflating the tire using an air pump. Ensure the tire is inflated to the recommended pressure of 25 psi for optimal performance and handling.

• Attach the Wheel: Slide the front axle through the fork, ensuring the brake disc fits inside the caliper. Remove the spacer from the caliper before fitting the wheel. Tighten using a 17mm socket and crescent wrench, ensuring the wheel spins freely.
• Check the Brake Functionality: After securing the wheel, squeeze the brake lever to ensure the caliper engages the disc properly. The wheel should stop smoothly, providing reliable stopping power.

Installing the Battery

• Access the Battery Box: Remove the side panel using a 10mm socket to expose the battery component.
• Secure the Battery: Place the battery in the box with terminals facing inward. Connect the positive (red) and negative (black) wires, securing them with the provided bolts. Ensure the battery strap is properly fitted to hold the battery in place.

Final Checks and Testing

• Add Oil and Fuel: Check the engine for oil. If needed, add Tilson synthetic oil. Fill the fuel tank with unleaded gasoline.
• Test the Bike: Start the bike using the electric start button. Check the brakes, throttle, and other controls to ensure everything is functioning properly.

• Keep Parts Organized: As you unbox, keep all parts and tools organized to avoid losing any small components.
• Follow the Manual: Refer to the owner's manual for specific instructions and safety guidelines
• Seek Help if Needed: If you're unsure about any step, consider watching tutorial videos or consulting with a professional.

Building your TrailMaster Hurricane 200 Pro is not just about assembling a mini bike; it's about creating a reliable companion for your outdoor adventures. With this guide, you can confidently put together your bike and enjoy the thrill of riding. Remember, safety first—always wear protective gear and follow riding guidelines.