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    • Rascal GT Cruiser Kit Assembly Manual

    Rascal GT Mini Bike Cruiser Kit Assembly Manual

    Introduction

    Welcome to the complete assembly guide for the Rascal GT Mini Bike Cruiser Kit from GoPowerSports.com. This manual will walk you through every step of building your custom minibike from the ground up. The Rascal GT frame is crafted with precision in the USA and designed for easy assembly using everyday tools - no welding required.

    This kit arrives in unpainted raw steel, giving you complete freedom to customize your ride with spray paint, powder coat, or clear coat finishes. Take your time with each step and follow the best practices outlined in this manual for a successful build.

    What's Included in Your Kit

    Your Rascal GT Cruiser Kit contains the following components:

    Frame & Structure

    • Rascal GT Minibike Frame
    • 7/8" Billet Handlebar Risers, Short - Silver
    • Minibike Handlebars, 12" Vintage
    • UniTank with two petcock options

    Seating & Controls

    • 18.5" Minibike Seat (Cruiser or Drag seat options)
    • Mega Moto Throttle Twist Grip
    • Throttle cable for stock carburetor setup
    • 52" Mikuni Minibike Cable
    • Mega Minibike Engine Kill Switch

    Wheels & Braking

    • 10" GPS Machined Aluminum Rear Wheel
    • 10" GPS Machined Aluminum Front Wheel
    • Universal Sprocket Adapter, 8" Wheels
    • Split Sprocket #41/420 - 52T & 62T options
    • Big Brake Adapter, Rascal GT
    • Mega Moto B212 Rear Hydraulic Brake Assembly, Left Hand

    Hardware & Accessories

    • Billet Foot Pegs, Foldable, Smooth Knurl - Silver
    • Rascal Kickstand
    • Rascal GT Chain Roller
    • Various axles, spacers, and mounting hardware
    • Tire options: 130/90-10 Street, 110/80-10 Street, 400-10 Trials, 350-10 Universal, or 300-10 Street
    • 7/8" Plastic Caps
    • Complete Hardware Pack
    • Rascal GT Sticker

    Required Tools

    Before beginning assembly, ensure you have the following tools available:

    Wrenches and Sockets

    • 3/4" or 19mm
    • 18mm
    • 17mm
    • 14mm
    • 13mm
    • 12mm
    • 7/16"
    • 10mm
    • 8mm
    • Crescent wrench (if you don't have multiple wrenches/sockets)

    Allen Wrenches (Metric)

    • 8mm
    • 6mm
    • 4mm

    Additional Tools

    • Phillips Head Screwdriver
    • Cutters/Dykes
    • Round File/Deburring Tool
    • Hammer
    • Punch
    • Valve Stem Puller/Pliers
    • Drill
    • 1/2" Drill Bit
    • 1/4" Drill Bit
    • Impact Driver/Wrench (optional)
    • Ruler or measuring tape
    • Sharpie marker

    Pre-Assembly Checklist

    IMPORTANT: Before starting assembly, complete these critical steps:

    1. Inventory Check: Use the included packing slip to verify all components are present. Cross off each item as you locate it.

    2. Mock-Up Recommendation: It's highly recommended to mock up all parts on the frame before painting to ensure proper fit and alignment. Minor adjustments or re-drilling may be necessary.

    3. Safety Preparation: Gather safety equipment including gloves and eye protection.

    4. Workspace Setup: Ensure you have adequate lighting and workspace. A vice or clamping system will make tire mounting significantly easier.

    Step-by-Step Assembly Instructions

    Step 1: Tire and Wheel Assembly

    Materials Needed:

    • Front and rear wheels
    • Selected tires
    • Valve stems
    • Tire mounting lubricant (slip-tac or soapy water)

    Best Practices:

    • Clean workspace prevents contamination
    • Use adequate lubrication for easier mounting
    • Check valve stems for leaks after installation

    Instructions:

    1. Prepare the workspace: If available, secure the wheel in a vice with the valve stem facing up. This makes tire mounting much easier.

    2. Apply lubrication: Generously apply tire mounting lubricant (slip-tac preferred, soapy water acceptable) to:

      • Entire tire bead (inside and outside)
      • Wheel rim surfaces
      • Top lip where tire will be pushed down

    3. Mount the tire:

      • Position tire on wheel, ensuring proper orientation
      • For front wheel: orientation doesn't matter significantly
      • For rear wheel: plan brake disc placement (typically right side)
      • Work tire bead over rim, starting at valve stem
      • If tire seems stuck, lift it to center of wheel for easier mounting

    4. Install valve stem: Use valve stem puller or pliers to pull stem through rim hole until properly seated.

    5. Initial inflation: Add significant air pressure initially to help tire bead seat properly. Adjust to final pressure after complete assembly.

    6. Check for leaks: Apply soapy water to valve stem and check for bubbles.

    7. Tighten disc bolts: The brake disc bolts are installed loose for shipping. Tighten all disc bolts using appropriate torque. Consider using flat washers, lock washers, or thread locker for security.

    Pro Tip: The 410 flat track tires have thick, hard sidewalls and require more effort to mount than street tires.

    Step 2: Front Fork Installation

    Materials Needed:

    • Neck bolt and nut
    • Washers
    • Bushings
    • File or deburring tool

    Instructions:

    1. Prepare bushing holes: Use a file or deburring tool to:

      • Create slight taper on bushing holes
      • Remove any lips that would prevent bushing installation
      • Ensure smooth entry

    2. Install bushings:

      • Use old neck bolt or kit bolt as driver
      • Hold bottom bushing in place while driving top bushing
      • Drive until bushings are fully seated
      • Run 1/2" drill bit through lightly to ensure smooth operation

    3. Assemble neck:

      • Install bottom washer
      • Insert neck bolt from top
      • Add top washer and nut
      • Use two 3/4" wrenches to tighten

    4. Adjust tension:

      • Tighten until snug, then back off slightly
      • Fork should turn smoothly without drag
      • No binding should be felt when turning
      • Note: Connection will loosen slightly during initial riding

    Step 3: Front Wheel Installation

    Materials Needed:

    • Front axle (shorter of the two 12mm bolts)
    • Front wheel spacers (1.8" and 2.3")
    • Assembled front wheel

    Instructions:

    1. Install handlebar plugs: Insert 7/8" plastic caps into handlebar ends.

    2. Position wheel: Place assembled front wheel between fork legs.

    3. Install spacers:

      • For brake disc on right side: Use 2.3" spacer on right, 1.8" on left
      • Adjust spacer placement based on your brake disc orientation preference

    4. Insert axle: Thread front axle through spacers and wheel hub.

    5. Tighten: Use 14mm wrench on bolt head and 17mm on nut. Tighten securely.

    Step 4: Rear Axle Bracket Installation

    Materials Needed:

    • Axle brackets (left and right)
    • 12mm bolts
    • Flanged serrated nuts

    Instructions:

    1. Install one bracket: Start with either left or right bracket.

    2. Use serrated nuts: The flanged serrated nuts often don't require holding with a wrench as they bite into the frame.

    3. Partial assembly: Install only one bracket initially to allow for rear wheel installation.

    Step 5: Sprocket and Rear Wheel Assembly

    Materials Needed:

    • Split sprocket (52T or 62T)
    • Sprocket carrier
    • 3/8" bolts (8mm Allen head)
    • Rear wheel assembly

    Sprocket Selection Guide:

    • 52T sprocket: Higher top speed, less takeoff power
    • 62T sprocket: More takeoff power, lower top speed
    • With smaller tires + 62T: Excellent acceleration

    Instructions:

    1. Check sprocket carrier bolts: Verify these bolts are tight before installation - they cannot be accessed after sprocket installation.

    2. Assemble split sprocket:

      • Match numbered halves of split sprocket
      • Use three-hole pattern on carrier
      • Install with 8mm Allen bolts (7/16" head)

    3. Alignment: Push sprocket to one side to minimize play and ensure best alignment.

    4. Torque warning: Use caution not to over-torque bolts threading into aluminum carrier to prevent stripping.

    Step 6: Rear Wheel Installation and Spacing

    Materials Needed:

    • Rear axle (longer 12mm bolt)
    • Rear spacers (2.5" right, 2.2" left)
    • Shim washers
    • Measuring tools

    This is the most critical step for proper wheel alignment:

    Instructions:

    1. Install left spacer:

      • Clean spacer interior of any burrs
      • Test fit on axle to ensure smooth operation
      • Place 2.2" spacer in left side wheel recess
      • Use Sharpie to center crush sleeve

    2. Temporary positioning:

      • Insert axle bolt to hold wheel in position
      • Push wheel firmly against left spacer

    3. Measure for center:

      • Measure gap on right side
      • Add shim washers as needed (typically 1-2 washers)
      • Target measurement: approximately 2.50"

    4. Final assembly:

      • Install right rear spacer (2.5")
      • Add remaining shim washers to achieve perfect centering
      • The undersized spacers plus shims allow precise wheel positioning

    5. Tighten axle:

      • Use 18mm wrench on one side
      • Use 19mm or 3/4" wrench on other side
      • Ensure wheel spins freely and is properly centered

    Pro Tip: The single-sided mounting system allows for precise wheel alignment adjustment using the shim washers.

    Step 7: Fuel Tank Installation

    Materials Needed:

    • UniTank
    • 6 mounting bolts with lock washers
    • Selected petcock
    • 1/4" drill bit

    Petcock Options:

    • Plastic with filter: Includes on/off function and built-in filter
    • Metal push-in: Requires separate inline fuel filter and shut-off valve

    Instructions:

    1. Position tank: Place UniTank on frame, ensuring proper alignment with seat area.

    2. Mark mounting holes: Use 4 of the 6 available mounting points (typically the outer points).

    3. Install petcock:

      • Choose desired petcock location
      • Drill 1/4" hole carefully
      • Clean plastic debris from hole
      • Apply light oil to petcock threads
      • Thread in petcock until snug (don't over-tighten plastic)

    4. Mount tank: Install with selected bolts and lock washers, leaving slightly loose for final adjustment.

    Step 8: Seat Preparation

    Materials Needed:

    • Selected seat (Cruiser or Drag style)
    • 3 seat mounting bolts
    • 1/2" drill bit

    Instructions:

    1. Position for marking: With tank in place, position seat to take up gap between seat and tank for best appearance.

    2. Mark holes: Use seat mounting points to mark frame locations.

    3. Drill holes: Use 1/2" drill bit to create mounting holes.

    4. Test fit: Verify proper alignment before final installation.

    5. Set aside: Remove seat for remaining assembly steps.

    Step 9: Handlebar and Riser Installation

    Materials Needed:

    • 7/8" Billet handlebar risers
    • 12" Vintage handlebars
    • Mounting bolts (two lengths provided)
    • 8mm and 6mm Allen wrenches

    Instructions:

    1. Select bolt length: Use shorter bolts for thin triple clamps (as on Rascal GT).

    2. Install risers:

      • Position risers with offset toward rear (pushes bars forward)
      • Use middle mounting hole typically
      • Install with 10mm stainless bolts, lock washers, and flat washers
      • Snug but don't fully tighten yet

    3. Mount handlebars:

      • Center handlebars in risers
      • Align with front fork direction
      • Use 6mm Allen wrench for 8mm bolts
      • Tighten riser bolts after handlebar alignment

    Step 10: Foot Peg Installation

    Materials Needed:

    • Billet foldable foot pegs
    • 8mm stainless bolts with washers

    Instructions:

    1. Choose position: Multiple mounting holes available for comfort preference.

    2. Install pegs:

      • Align flat surfaces of peg bracket with frame
      • Use provided stainless hardware
      • Position affects handling and comfort

    3. Test fold function: Verify pegs fold properly for storage/transport.

    Step 11: Chain Roller Installation

    Materials Needed:

    • Chain roller assembly
    • Spacer washers
    • 13mm wrench and 10mm socket

    Instructions:

    1. Select position: Choose roller slot based on tire size:

      • Lower slot for smaller tires
      • Upper slots for larger tires or as chain guide only

    2. Align with sprocket:

      • Use spacer washers to align roller with sprocket
      • Proper alignment prevents chain wear and noise

    3. Install and tighten: Secure with appropriate hardware.

    Step 12: Kickstand Installation

    Materials Needed:

    • Kickstand assembly
    • Cotter pin
    • Spring

    Instructions:

    1. Disassemble for installation: Remove cotter pin and separate components.

    2. Install kickstand: Thread through frame bracket.

    3. Install spring: Hook spring on front tab, ensuring it sits in slot properly.

    4. Secure with cotter pin:

      • Some pins fit directly, others may need one leg cut off
      • Bend pin ends to prevent removal
      • Orient opening toward rear of bike

    Step 13: Brake System Installation

    Materials Needed:

    • Big brake adapter
    • Brake caliper assembly
    • Brake spacers
    • 5/16" bolts and serrated nuts
    • 8mm bolts
    • Master cylinder

    Instructions:

    1. Install brake adapter:

      • Position adapter to align with frame
      • Use 5/16" bolts and serrated nuts
      • Ensures proper caliper positioning

    2. Prepare caliper:

      • Remove shipping spacer from between brake pads
      • Compress caliper and pull tab to remove spacer

    3. Mount caliper:

      • Thread through frame opening
      • Align with brake adapter
      • Install rear spacer and bolt
      • Use 8mm bolts with spacers

    4. Adjust brake hose orientation:

      • CAUTION: Loosening fitting too much will introduce air into system
      • Carefully crack loose the fitting
      • Rotate hose to desired position while keeping bolt head stationary
      • Re-tighten immediately

    5. Route brake hose:

      • Run hose through frame and up to handlebars
      • Use zip ties as guides, not tight restraints
      • Keep hose away from moving parts

    6. Install master cylinder:

      • Position on handlebars at comfortable height
      • Lever should be flush with bar end when fully extended
      • Use 8mm Allen wrench
      • WARNING: Don't over-torque cast components - they can break

    Step 14: Throttle Installation

    Materials Needed:

    • Throttle grip assembly
    • Selected throttle cable (stock or Mikuni)
    • Kill switch
    • Zip ties

    Cable Selection:

    • Stock cable: For stock carburetor setup
    • 52" Mikuni cable: For performance carburetors

    Instructions:

    1. Prepare throttle housing:

      • Remove cable guide from housing
      • Install selected cable
      • Replace guide, matching shape orientation
      • Guide acts as cable stop

    2. Install on handlebars:

      • Position throttle housing on right handlebar
      • Bottom out cable adjuster, then back out slightly
      • Don't let grip ride on bar end (creates drag)
      • Leave adjustment loose until cable is connected

    3. Route throttle cable:

      • Run cable through frame routing points
      • Use zip tie guides created during brake hose installation
      • Follow similar path as brake hose for clean appearance

    4. Install kill switch:

      • Mount in convenient location on handlebars
      • Use Phillips head screws (don't over-tighten plastic housing)
      • Connect ground wire to engine ground point
      • Toggle switch controls on/off function
      • Connector plugs into engine ignition system

    5. Secure cables:

      • Use zip ties to bundle throttle and brake cables
      • Create clean, professional appearance
      • Ensure cables don't interfere with steering

    6. Final throttle adjustment:

      • Connect cable to carburetor
      • Use 14mm wrench on cable adjusters
      • Remove all slack from cable
      • Test full throttle operation

    Step 15: Final Assembly

    Materials Needed:

    • Seat and mounting bolts
    • Any remaining hardware
    • Final adjustment tools

    Instructions:

    1. Install seat:

      • Position seat using previously drilled holes
      • Push forward against tank to minimize gap
      • Use mounting hole wiggle room for perfect centering
      • Install 3 seat bolts and tighten securely

    2. Final tank tightening:

      • Tighten all tank mounting bolts
      • Ensure tank is secure and properly positioned

    3. Cable management:

      • Add final zip ties for cable routing
      • Trim zip tie ends flush with flat-face cutters
      • Ensure no cables interfere with moving parts

    4. Final inspection:

      • Check all bolt torques
      • Verify wheel alignment and free rotation
      • Test brake lever operation
      • Check throttle operation through full range
      • Verify kickstand operation
      • Test steering smoothness

    Post-Assembly Requirements

    Your Rascal GT Cruiser Kit is now a complete roller. To make it operational, you'll need:

    Required Additional Components

    • Engine: 212cc, 225cc, or similar small block engine
    • Drivetrain: Torque converter or centrifugal clutch
    • Chain: #420 chain, approximately 5 feet
    • Fuel: Appropriate gasoline for your engine

    Recommended Components

    • Tillotson 212 Engine: High-performance option
    • Rascal GT Header Pipe: Custom exhaust system
    • Jugg-A-Verter 30 Series TAV Kit: Torque converter option
    • 1041 Centrifugal Clutch: Alternative drivetrain option

    Important Safety and Legal Information

    Safety Requirements

    • Always wear proper safety equipment: Helmet, gloves, and protective clothing
    • Inspect before each ride: Check bolts, brakes, and steering
    • Break in brake system: New brakes require break-in period for optimal performance

    Legal Considerations

    • Not for public road use: This vehicle is designed for private property only
    • Check local laws: Verify regulations in your area before operation
    • Age restrictions: Ensure appropriate supervision for younger riders

    Maintenance Schedule

    • After first ride: Re-check all bolt torques
    • Regular inspection: Check brake fluid, chain tension, and tire pressure
    • Seasonal maintenance: Comprehensive inspection and lubrication

    Troubleshooting Common Issues

    Wheel Alignment Problems

    • Symptom: Bike pulls to one side
    • Solution: Re-check rear wheel spacers and shims

    Brake Issues

    • Symptom: Spongy brake feel
    • Solution: Check for air in brake lines, may need bleeding

    Throttle Problems

    • Symptom: Sticky or binding throttle
    • Solution: Check cable routing and adjustment

    Chain Alignment

    • Symptom: Chain noise or premature wear
    • Solution: Verify chain roller alignment with sprocket

    Customization Options

    Paint and Finish

    • Preparation: Clean frame thoroughly before painting
    • Options: Spray paint, powder coating, or clear coat over raw steel
    • Tip: Mask threaded holes and bearing surfaces

    Performance Upgrades

    • Engine modifications: Various performance engines available
    • Exhaust systems: Custom headers and mufflers
    • Suspension: Upgraded shock options
    • Tires: Different compounds and tread patterns for various conditions

    Aesthetic Modifications

    • Seat options: Various styles and colors available
    • Handlebar choices: Different rise and sweep options
    • Wheel finishes: Anodized colors and custom powder coating
    • Graphics packages: Custom decals and stickers

    Final Assembly Tips

    Best Practices for Success

    1. Take your time: Rushing leads to mistakes and frustration
    2. Double-check everything: Verify each step before proceeding
    3. Keep workspace organized: Prevents lost parts and confusion
    4. Document your build: Take photos for future reference
    5. Ask for help: Contact GoPowerSports support if needed

    Quality Control Checklist

    • All bolts properly torqued
    • Wheels spin freely without wobble
    • Brake system functions properly
    • Throttle operates smoothly
    • Steering is smooth and precise
    • All cables properly routed and secured
    • Kickstand operates correctly
    • Seat is securely mounted and aligned

    Warranty and Support Information

    Kit Warranty

    • Kit sold as-is with no substitutions
    • Adult signature required for delivery
    • Free shipping to contiguous 48 states only

    Technical Support

    • Contact GoPowerSports.com for technical assistance
    • Include photos of your build for faster troubleshooting
    • Reference this manual and your packing slip for parts identification

    Community Support

    • Share photos of your completed build with GoPowerSports
    • Join online communities for tips and modifications
    • Document your customizations to help other builders

    Conclusion

    Congratulations on completing your Rascal GT Mini Bike Cruiser Kit assembly! You've built a high-quality, customizable minibike that will provide years of enjoyment. The modular design of the Rascal GT frame allows for endless customization possibilities as your needs and preferences evolve.

    Remember to break in your new minibike gradually, perform regular maintenance, and always prioritize safety. Most importantly, enjoy the satisfaction of having built your own custom ride from the ground up.

    For additional support, parts, and accessories, visit GoPowerSports.com or contact their technical support team. Share photos of your completed build – the team loves to see the creative color schemes and modifications their customers create.

    Happy riding, and welcome to the Rascal family!

    This manual is based on the official GoPowerSports assembly video and product specifications. For the most current information and updates, always refer to GoPowerSports.com.