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    • Rascal GT Drag Kit Assembly Manual

    Rascal GT Mini Bike Drag Kit Assembly Manual

    Complete Step-by-Step Build Instructions

    Table of Contents

    1. Introduction & Kit Overview
    2. Tools Required
    3. Safety Precautions
    4. Kit Contents Verification
    5. Tire and Wheel Assembly
    6. Hub Preparation and Installation
    7. Frame and Fork Assembly
    8. Handlebar and Steering Setup
    9. Front Wheel Installation
    10. Top Plate and Gas Tank Installation
    11. Stabilizer Installation
    12. Foot Pegs and Chain Roller
    13. Kickstand Installation
    14. Throttle System Setup
    15. Rear Wheel Installation
    16. Brake System Installation
    17. Seat Installation
    18. Final Inspection and Next Steps

    Introduction & Kit Overview

    Congratulations on purchasing the Rascal GT Mini Bike Drag Kit! This premium DIY roller kit is engineered for serious racers who demand maximum performance and minimal weight on the drag strip. At just 22.5 lbs for the frame and fork, this is one of the lightest weight mini bike frames on the market.

    This manual will guide you through every step of the assembly process. Take your time, follow each step carefully, and don't hesitate to contact us at 866-846-5278 if you have any questions.

    Important Note: This is a roller kit requiring additional components for completion. You will need to purchase separately:

    • Small block engine (Tillotson 225 recommended)
    • Clutch or torque converter
    • Drive chain and sprocket
    • Fuel line

    Tools Required

    Before beginning assembly, ensure you have the following tools:

    • Drill with 5/16" drill bit
    • Drill press (recommended) or standard drill
    • Socket set with 3/4" sockets (19mm will also work)
    • 6mm Allen key/hex wrench
    • Standard wrenches (various sizes)
    • Valve stem tool
    • Deburring tool or sharp knife
    • Bearing press (or alternative pressing method)
    • Air compressor with tire chuck
    • Soap or tire mounting lubricant
    • Blue Loctite (recommended)
    • Measuring tape or ruler

    Safety Precautions

    READ BEFORE STARTING:

    • Always wear safety glasses when drilling or using power tools
    • Use proper lifting techniques when handling components
    • Ensure work area is clean and well-lit
    • Keep fingers clear of pinch points during assembly
    • Adult signature required for delivery
    • This product is not recommended for use on public roads

    Kit Contents Verification

    Before beginning assembly, verify all components are present. Your kit should include:

    Frame Components:

    • Rascal GT lightweight frame
    • Fork assembly
    • Neck bushings and hardware

    Wheels and Tires:

    • Front tire and Douglas DWT aluminum wheel
    • Rear tire (10.5x4.5-6 OR 13x5-6 slick - your choice)
    • Rear Douglas DWT aluminum wheel

    Hardware and Components:

    • GPS Racing billet hubs (front and rear sets)
    • Bearings and spacers (multiple sizes)
    • 18.5" drag-style ducktail seat
    • 25¼" drag handlebars
    • Billet thumb throttle kit with dual cables
    • Hydraulic brake assembly with caliper and disc
    • 10" aluminum cylinder gas tank
    • Stabilizer assembly
    • Foot pegs
    • Chain roller
    • Kickstand with spring and hardware
    • Top plate and mounting brackets
    • All necessary bolts, washers, and mounting hardware

    Tip: Lay out all components and compare with the product page images to ensure nothing is missing before starting assembly.

    Tire and Wheel Assembly

    Step 1: Rear Tire Installation

    Important: Always remove any stickers from the inside of the wheel before mounting tires.

    1. Identify wheel orientation: Look at the wheel - there's a long side and a short side before it drops off. Start mounting from the short side as this allows the tire to drop down easier.

    2. Prepare tire and wheel:

      • Apply soap or tire mounting lubricant generously to both the tire bead and wheel rim
      • Cover both the outside and inside surfaces thoroughly

    3. Mount first bead:

      • Position the tire so the valve stem will be on the brake disc side (this makes it easier to access)
      • Work the first bead over the rim - this side should go on relatively easily

    4. Mount second bead:

      • This is the tricky part: compress the center of the tire and work it down to the direct center of the wheel
      • This gives you room to push the second bead over the rim all the way around
      • Critical: If you leave the tire up on the rim edge, you'll never get it seated properly

    5. Inflate tire:

      • While the soap is still wet, begin inflating
      • Inflate to higher pressure initially to ensure proper seating
      • Check valve stem for leaks by applying soap - if bubbling occurs, tighten with valve stem tool

    Step 2: Front Tire Installation

    Follow the same process as the rear tire:

    1. Remove any inside stickers
    2. Apply soap to tire and wheel
    3. Mount both beads (front tire is typically easier)
    4. Inflate and check for leaks

    Note: If tire won't inflate initially, you may need to remove the valve core and shoot air directly into the tire using a valve stem tool, then reinstall the core.

    Hub Preparation and Installation

    Step 3: Drilling Wheel Bolt Holes

    The Douglas DWT wheels come with 1/4" holes for go-kart racing, but we need 5/16" holes for our bolts.

    1. Drill rear wheel holes:

      • Use a 5/16" drill bit
      • Best practice: Use a drill press for perfectly straight holes
      • Alternative: If using a hand drill, hold it as straight as possible with steady downward pressure
      • Go slow with consistent pressure
      • Tip: It's easier to keep the wheel steady if the tire is already mounted

    2. Drill front wheel holes:

      • Follow same process as rear wheel
      • Ensure holes are drilled straight to prevent wheel wobble

    3. Deburr all holes:

      • Use a deburring tool or sharp knife to remove all burrs from drilled holes
      • This is critical for proper bolt fit and safety

    Step 4: Installing Bearings in Hubs

    Bearing specifications: 1/2" ID, 1 3/8" OD

    Rear Hubs:

    1. Press bearings into rear hubs:

      • Use a bearing press for best results
      • Critical: Drive bearings in perfectly straight - any angle will warp the hub
      • Install the side with thicker wall first
      • Flip hub over and install second bearing
      • Alternative method: Use the axle as a guide - put bearing on axle, insert through hub, and tap in straight

    2. Verify smooth operation:

      • Check that bearings are fully seated
      • Ensure no burrs remain that could affect wheel assembly

    Front Hub:

    1. Remove existing bearings:

      • Front hub comes with 5/8" bearings that need to be replaced
      • These usually tap out easily with a punch

    2. Install 1/2" bearings:

      • Press in new 1/2" bearings using same method as rear hubs
      • Ensure bearings are seated flush and straight

    Frame and Fork Assembly

    Step 5: Installing Neck Bushings

    1. Inspect neck tube:

      • Critical: Always check for burrs in the neck tube before installing bushings
      • Use a file to remove any burrs from the face or edges
      • Clean surfaces ensure proper bushing fit

    2. Install bushings:

      • Drive bushings into neck tube
      • These may be tight - this is normal for proper fit

    3. Install fork assembly:

      • Insert fork through neck bushings
      • Check for play between fork and bushings
      • Important: Some play is normal due to manufacturing tolerances

    4. Add washers as needed:

      • Kit includes washers to take up slack
      • Always put one washer on the head of the neck bolt
      • Add additional washers at bottom as needed to eliminate excessive play

    5. Tighten neck bolt:

      • Use two 3/4" wrenches (or 19mm)
      • Tighten until snug - you should not be able to move the fork by hand
      • Don't overtighten: You don't want to feel resistance when turning, but it should be secure
      • These will wear in with use

    Handlebar and Steering Setup

    Step 6: Installing Handlebar Risers

    1. Select proper bolts:

      • Kit includes both long and short bolts
      • Use SHORT bolts for the GT frame
      • Long bolts are for premium front ends with thick triple clamps

    2. Position risers:

      • Notice the holes in risers are offset toward one side
      • This allows you to adjust bar position forward or back
      • For standard setup, position as shown in images
      • You can experiment with different positions for comfort

    3. Install risers:

      • Start bolts but don't fully tighten yet
      • You'll do final tightening after handlebars are installed and aligned

    Step 7: Installing Handlebars

    1. Position handlebars:

      • Install 25¼" drag handlebars in risers
      • Angle them slightly upward toward rider position
      • This is preferred by most drag racers

    2. Center and align:

      • Measure side to side to ensure handlebars are perfectly centered
      • Ensure both sides are equal distance from frame centerline
      • Verify handlebars are level and properly angled

    3. Final tightening:

      • Once handlebars are positioned correctly, tighten riser bolts
      • Ensure handlebars are fully seated in risers before final tightening
      • Check that handlebars don't move when pressure is applied

    Front Wheel Installation

    Step 8: Installing Front Wheel Assembly

    1. Prepare spacers:

      • Kit includes multiple 25mm spacers and one 20mm spacer
      • Use THREE 25mm spacers per side for front wheel
      • This centers the wheel perfectly in the fork

    2. Install wheel:

      • Place spacers on both sides of wheel hub
      • Insert axle through fork, spacers, and wheel
      • Note: There's no crush sleeve in this wheel setup

    3. Adjust axle tension:

      • Install lock nut on axle
      • Tighten until wheel doesn't spin freely
      • Critical: Loosen slightly until wheel spins smoothly
      • Wheel should spin freely but have no side-to-side play

    4. Verify installation:

      • Check that wheel is centered between fork legs
      • Ensure wheel spins freely without wobble
      • Verify all spacers are properly positioned

    Top Plate and Gas Tank Installation

    Step 9: Installing Top Plate

    1. Identify hardware:

      • Set aside the two 8mm bolts (these are for brake caliper later)
      • Use 5/16" bolts for top plate installation

    2. Position top plate:

      • Place top plate on frame - it should sit flush
      • This creates a clean, lightweight mounting surface

    3. Install tank brackets:

      • Position brackets under top plate
      • Both brackets should point toward the rear of the bike
      • Start bolts but don't fully tighten yet

    Step 10: Installing Gas Tank

    1. Position tank:

      • Hold 10" aluminum gas tank in position
      • Align with mounting brackets
      • Ensure tank is centered on top plate

    2. Adjust brackets:

      • Fine-tune bracket position to align with tank mounting points
      • Check that hose clamps are properly positioned and won't fall off brackets

    3. Final alignment:

      • Center tank perfectly on top plate
      • Ensure top plate is centered on frame
      • Tighten all bolts once everything is properly aligned

    Stabilizer Installation

    Step 11: Installing Steering Stabilizer

    Critical: Proper stabilizer installation is essential for high-speed stability and safety.

    1. Prepare hardware:

      • Use two 5/16" bolts (one shorter, one longer)
      • Shorter bolt goes in upper position
      • Include lock washers on both bolts

    2. Install stabilizer clamp:

      • Position clamp on fork tube
      • Install with lock washers as specified
      • Don't fully tighten yet

    3. Align steering system:

      • Critical: Ensure fork is perfectly straight
      • Handlebars must be centered and aligned
      • This is crucial for high-speed stability (70-80 mph)

    4. Center stabilizer:

      • Adjust stabilizer so there's equal play in both directions
      • Fork should be centered with equal movement left and right
      • If not centered, steering will favor one direction

    5. Final tightening:

      • Once everything is perfectly aligned, tighten stabilizer clamp
      • Double-check that fork remains straight
      • Verify equal play in both directions

    Foot Pegs and Chain Roller

    Step 12: Installing Foot Pegs

    1. Choose peg position:

      • Multiple mounting holes available for different riding positions
      • Rear hole on middle bracket is most common for drag racing
      • Front positions available for more comfortable cruising

    2. Install pegs:

      • Use stainless steel M8 bolts provided
      • Install with lock washer first, then flat washer
      • Use 6mm Allen key for installation
      • Weight-saving tip: If not using pegs, they can be cut off (be very careful not to cut into main tube)

    Step 13: Installing Chain Roller

    1. Understand adjustment options:

      • Chain roller provides additional chain tensioning
      • Multiple mounting positions available
      • Works in conjunction with engine tensioning slots

    2. Install roller assembly:

      • Use all three washers as general rule
      • Roller is sized to bearing inner race for no drag
      • Position according to your specific sprocket setup
      • Can be moved to different holes if needed for unusual sprocket combinations

    Kickstand Installation

    Step 14: Installing Kickstand

    1. Install pivot pin:

      • Insert pin through kickstand mounting hole
      • Push pin all the way through

    2. Secure with cotter pin:

      • Install cotter pin through end of pivot pin
      • Bend cotter pin ends around so it cannot come out
      • Critical: Ensure cotter pin is properly secured

    3. Install spring:

      • Attach spring between kickstand and frame bracket
      • Spring provides automatic kickstand retraction
      • Test operation to ensure smooth function

    Throttle System Setup

    Step 15: Installing Billet Thumb Throttle

    Note: Thumb throttle vs. twist throttle is a matter of personal preference. This kit includes a high-quality billet thumb throttle system.

    1. Select proper cable:

      • Kit includes two different cables for different carburetor sizes
      • Shorter throw cable: For 22mm, 24mm, 26mm, 28mm carburetors
      • Longer throw cable: For 32mm, 34mm carburetors
      • (33mm carburetors use different throttle setup entirely)

    2. Install throttle body:

      • Kit includes adjustable billet piece for fine-tuning
      • Use stainless steel hardware provided
      • Position according to your specific setup needs

    3. Install cable:

      • Route cable through throttle body
      • Ensure smooth operation through full range
      • Critical: Set throttle stop properly to prevent cable snapping

    4. Set throttle stop:

      • Important: Improper throttle stop can cause cable failure at the starting line
      • Remove air filter from carburetor
      • Go to wide open throttle position
      • Ensure carburetor slide is fully up
      • Remove air filter from carburetor

     

      • Go to wide open throttle position
      • Ensure carburetor slide is fully up
      • Set throttle stop to prevent over-travel
      • Critical: This prevents cable snapping during racing

    2. Install throttle cap:

      • Replace cap with rubber seal to prevent dirt/dust entry
      • Use small stainless steel screws provided
      • Caution: These are small screws threading into aluminum - be gentle
      • Tighten just until they bottom out, then slightly more

    3. Install grips:

      • Grips are designed to match handlebar shape
      • Slide onto 7/8" handlebars
      • These are a snug fit and won't twist once installed
      • Install both grips the same way for uniformity

    4. Position thumb throttle:

      • Adjust angle for comfortable operation
      • Consider rider position - you'll be leaning forward in drag position
      • Angle throttle accordingly for easy thumb access
      • Test operation before final tightening

    Rear Wheel Installation

    Step 16: Installing Rear Wheel Assembly

    1. Prepare axle hangers:

      • Kit includes axle hangers for 12mm/1/2" axles
      • Also available in 5/8" (sold separately)
      • Check for burrs and file smooth if necessary
      • Position hex bolts in same orientation for consistency

    2. Install one axle adapter:

      • Install only ONE axle adapter initially
      • This makes spacer installation much easier
      • Position on the side you'll start from

    3. Prepare spacers:

      • Kit includes two different length spacers
      • Shorter spacer: Goes on brake side (general rule)
      • Longer spacer: Goes on sprocket side (general rule)
      • Note: Frame variances may require shimming with washers

    4. Install wheel and axle:

      • Place shorter spacer on brake side
      • Start sliding custom 1/2" axle through assembly
      • Note: These are precision-made axles (490-495 thousandths) vs. standard Home Depot bolts (460-470 thousandths)
      • Add longer spacer on sprocket side
      • Install second axle adapter

    5. Secure axle:

      • Use custom 1/2" axle bolts provided
      • These may require light tapping due to precision fit
      • This tight fit ensures no play in the bearing system
      • Tighten axle nuts securely

    6. Install brake disc:

      • Position brake disc on brake side hub
      • Use M6 x 15mm stainless steel bolts (shorter ones)
      • Apply light coat of blue Loctite (optional but recommended)
      • Pattern: Use 6mm holes, not the M8 x 1.25 holes
      • Tighten in cross pattern, snug first, then fully tighten

    7. Install sprocket carrier:

      • Position on sprocket side of hub
      • Use M6 x 25mm stainless steel bolts (longer ones)
      • Same bolt pattern as brake disc
      • Note: Sprocket not included - order separately based on your gearing needs
      • Available in 420 or 35 chain pitch, sizes 53-80 teeth

    8. Verify wheel operation:

      • Wheel should spin smoothly on four bearings
      • Check for any binding or rough spots
      • This setup provides excellent durability and true running

    Titanium Hardware Option: All rear wheel hardware is available in titanium for significant weight savings. Check product description for part numbers.

    Brake System Installation

    Step 17: Installing Hydraulic Brake System

    1. Install brake caliper:

      • Use the two 8mm bolts set aside earlier
      • Position caliper on brake mounting tabs
      • Install with lock washer first, then flat washer on each bolt
      • Note: Caliper will self-center as brake pads wear in

    2. Adjust caliper spacing (if needed):

      • If spacing is off and you want free-spinning wheel immediately
      • Kit includes extra washers for spacing adjustments
      • Place washers between caliper bracket and frame to adjust position

    3. Install brake lever:

      • Mount hydraulic brake lever on handlebars
      • Position between grip and kill switch for easy access
      • Ensure comfortable reach for rider

    4. Route brake line:

      • Run brake line from lever to caliper
      • Create service loop under seat area (like on Rascal models)
      • Secure line to prevent interference with moving parts
      • Ensure adequate length for full steering movement

    5. Test brake operation:

      • Check lever feel and travel
      • Verify caliper operation
      • Note: System will need bleeding and adjustment after initial setup

    Additional Components Installation

    Step 18: Installing Kill Switch

    Note: Kill switches are required at most racing venues.

    1. Position kill switch:

      • Install as close to grip as possible
      • Should be positioned between brake lever and grip
      • Ensure easy access while maintaining grip on handlebars

    2. Wire kill switch:

      • Follow manufacturer's wiring instructions
      • Ensure proper connection to ignition system
      • Test operation before first ride

    Seat Installation

    Step 19: Installing Drag Seat

    1. Prepare seat mounting:

      • 18.5" ducktail drag seat included in kit
      • Determine optimal position for rider comfort and weight distribution

    2. Drill mounting hole:

      • Use 1/4" drill bit for seat mounting bolt
      • Tip: Measure and mark carefully before drilling
      • Drill through seat and frame mounting point

    3. Install seat:

      • Use provided bolt and hardware
      • Start threads by hand to prevent cross-threading
      • Tighten securely but don't over-torque

    4. Verify seat security:

      • Check that seat is firmly mounted
      • Test by applying downward pressure
      • Ensure no movement or flex at mounting point

    Final Inspection and Next Steps

    Step 20: Pre-Ride Inspection

    Complete the following checklist before adding engine and riding:

    Frame and Structure:

    • All bolts properly tightened
    • No loose hardware anywhere on bike
    • Frame shows no signs of stress or damage
    • Welds appear sound and complete

    Wheels and Tires:

    • Both tires properly inflated to recommended pressure
    • Wheels spin freely without wobble
    • All wheel bolts properly tightened
    • Brake disc runs true without rubbing

    Steering System:

    • Handlebars turn smoothly through full range
    • No binding in steering head
    • Stabilizer properly adjusted with equal play both directions
    • All steering components tight

    Brake System:

    • Brake lever operates smoothly
    • Caliper properly aligned with disc
    • Brake line properly routed and secured
    • No leaks in hydraulic system

    Controls:

    • Throttle operates smoothly through full range
    • Throttle returns to closed position when released
    • Kill switch operates properly
    • All controls easily accessible from riding position

    Step 21: What You Still Need

    Essential Components to Complete Your Build:

    Engine System:

    • Small block engine (Tillotson 225cc recommended)
    • Engine mounting hardware
    • Air filter and carburetor (if not included with engine)

    Drive System:

    • Clutch or torque converter (Disc Clutch or Jugg-A-Verter recommended)
    • Drive chain (gold racing chain recommended for durability)
    • Drive sprocket (size depends on desired gearing)
    • Master link for chain

    Fuel System:

    • Fuel line from tank to carburetor
    • Fuel filter (recommended)
    • Fuel shut-off valve (recommended)

    Recommended Performance Upgrades:

    • Racing header pipe for enhanced performance
    • Oil catch can for debris protection
    • Titanium hardware kit for weight reduction

    Step 22: Engine Installation Preparation

    Before installing your engine:

    1. Mock up all parts:

      • Important: It's recommended to mock up all parts on the frame before painting
      • This ensures everything lines up properly
      • You may need to make minor adjustments or re-drill holes
      • Make all modifications BEFORE painting or powder coating

    2. Frame finishing:

      • Frame and forks come as bare mild steel
      • Ready for your choice of paint or powder coat
      • Consider weight when choosing finish options

    3. Final measurements:

      • Verify all clearances for your chosen engine
      • Check chain line alignment
      • Ensure adequate clearance for exhaust system

    Step 23: Break-In and Tuning

    After completing your build:

    1. Initial break-in:

      • Follow engine manufacturer's break-in procedures
      • Start with conservative settings
      • Gradually increase performance as components wear in

    2. Suspension and handling:

      • All components will wear in with use
      • Steering may feel slightly different after first few rides
      • Re-check all bolts after initial rides

    3. Performance tuning:

      • Experiment with different sprocket combinations
      • Adjust tire pressure for track conditions
      • Fine-tune throttle and brake lever positions

    Troubleshooting Common Issues

    Wheel Wobble:

    • Check that all wheel bolts are properly tightened
    • Verify bearings are properly seated in hubs
    • Ensure axle is straight and not bent
    • Check that spacers are properly positioned

    Steering Issues:

    • Verify neck bolt tension - should be snug but not binding
    • Check stabilizer adjustment and centering
    • Ensure fork is straight and not bent
    • Verify handlebar alignment

    Brake Problems:

    • Check caliper alignment with disc
    • Verify proper spacing with washers if needed
    • Ensure brake line is properly bled
    • Check for leaks in hydraulic system

    Throttle Issues:

    • Verify proper cable routing without binding
    • Check throttle stop adjustment
    • Ensure grip and throttle body are properly secured
    • Verify cable is appropriate for your carburetor size

    Maintenance Schedule

    After First Ride:

    • Re-check all bolt torques
    • Verify wheel bearing adjustment
    • Check brake operation and fluid level
    • Inspect all connections and hardware

    Every 5 Rides:

    • Check tire pressure
    • Inspect chain tension and lubrication
    • Verify throttle and brake operation
    • Check for any loose hardware

    Every 10 Rides:

    • Inspect bearings for wear
    • Check brake pad wear
    • Verify steering head adjustment
    • Inspect frame for any stress cracks

    Seasonally:

    • Complete disassembly and inspection
    • Replace any worn components
    • Fresh fluids in all systems
    • Detailed cleaning and inspection

    Warranty and Support

    Frame Warranty:

    • Refer to GoPowerSports warranty policy
    • Keep all documentation and receipts
    • Register your product for warranty coverage

    Technical Support:

    Parts and Service:

    • All replacement parts available through GoPowerSports
    • Authorized service centers available
    • Technical bulletins and updates posted online

    Safety Reminders

    Before Every Ride:

    • Always wear proper safety equipment including helmet and gloves
    • Inspect bike for any loose or damaged components
    • Check tire pressure and condition
    • Verify brake operation
    • Ensure kill switch functions properly

    Track Safety:

    • Follow all track rules and regulations
    • Participate in rider meetings
    • Respect other riders and track personnel
    • Never ride beyond your skill level

    Legal Compliance:

    • This product is not recommended for use on public roads
    • Check local laws regarding off-road vehicle use
    • Ensure compliance with all applicable regulations
    • Use only in appropriate venues and conditions

    Conclusion

    Congratulations! You have successfully assembled your Rascal GT Mini Bike Drag Kit. This precision-engineered frame provides an excellent foundation for a competitive drag racing mini bike.

    The lightweight design, quality components, and modular construction make this kit perfect for both beginners and experienced builders. Take your time with the engine installation and tuning process, and don't hesitate to contact our technical support team with any questions.

    Remember that this manual covers only the roller kit assembly. Engine installation, tuning, and performance optimization are separate processes that require additional knowledge and components.

    Stay tuned for our follow-up videos and manuals covering:

    • Engine installation and setup
    • Performance tuning and optimization
    • Advanced modifications and upgrades
    • Racing techniques and strategies

    Thank you for choosing GoPowerSports!

    This manual is a living document and may be updated as we receive feedback from customers and make improvements to the kit. Check our website regularly for the latest version and any technical bulletins.

    Document Version: 1.0
    Last Updated: [Current Date]
    Kit Compatibility: Rascal GT Mini Bike Drag Kit (RASCALGTDRAG)