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    • Rascal Lite Minibike Build Instructions

    Posted by Jason Merrell on 18th Jul 2025

    Person assembling a minibike in a workshop environment.

    Rascal Lite Mini Bike Assembly Manual

    Complete Step-by-Step Build Instructions

    Table of Contents

        1. Kit Contents & Overview
        2. Required Tools
        3. Safety Information
        4. Assembly Instructions
        5. Final Setup & Testing
        6. Maintenance & Troubleshooting

    Kit Contents & Overview

    What's Included in Your Rascal Lite Kit:

        • Frame: Raw steel Rascal frame
        • Engine: 98cc gasoline engine (Coleman-style)
        • Handlebars: 12" vintage-style handlebars
        • Wheels: Front and rear 6" wheels with tires
        • Brake System: Complete disc brake assembly (caliper, bracket, lever, cable)
        • Drive System: #35 chain, 12T clutch, 75T rear sprocket
        • Seat: CT100 Coleman-style seat
        • Hardware: All necessary bolts, nuts, washers, and mounting hardware
        • Accessories: Kickstand, foot pegs, grips, kill switch, throttle assembly

    Key Features:

        • Beginner-friendly assembly
        • Raw steel frame ready for custom painting/powder coating
        • Free shipping to lower 48 states
        • Can be assembled in one afternoon
        • Suitable for all skill levels

    Required Tools

    Essential Tools:

        • Wrenches: 3/4", 1/2", 7/16"
        • Sockets: 10mm, 13mm, 14mm, 17mm
        • Allen Keys: T30 Torx bit
        • Drill: With 17/64" drill bit
        • Screwdrivers: Phillips head, flathead
        • Pliers: Needle-nose pliers
        • Hammer: Rubber mallet preferred
        • Measuring Tools: Silver Sharpie marker
        • Miscellaneous: WD-40, zip ties, pocket knife

    Optional but Helpful:

        • Impact driver/wrench
        • Socket extensions
        • Work light
        • Assembly table or workbench

    Safety Information

    Before You Begin:

        • Read all instructions completely before starting
        • Ensure adequate workspace and lighting
        • Wear safety glasses when drilling or using power tools
        • Keep workspace clean and organized
        • Have a fire extinguisher nearby when working with fuel
        • Never smoke or use open flames near gasoline

    Important Notes:

        • This mini bike is designed for off-road use only
        • Always wear appropriate safety gear when riding
        • Check local laws and regulations before operating
        • Adult supervision required for minors during assembly and operation

    Assembly Instructions

    Step 1: Frame Preparation & Neck Bushing Installation

    Time Required: 15-20 minutes

    Components Needed:

        • Rascal frame
        • 2 neck bushings
        • Neck bolt
        • 3/4" nut and washer

    Instructions:

        1. Place the Rascal frame on your work surface with the neck (steering head) accessible
        2. Take the first neck bushing and slide it onto the neck bolt
        3. Insert the bolt with bushing into the top of the neck tube
        4. Thread the 3/4" nut and washer onto the bottom of the bolt
        5. Using a 3/4" wrench to hold the bolt head and a 3/4" socket to turn the nut, pull the bushing into the neck tube until it's flush and snug
        6. Remove the nut and bolt
        7. Insert the second bushing from the bottom of the neck tube
        8. Repeat the pulling process from the bottom
        9. Once the second bushing is seated, tap the bolt out most of the way and let it fall out

    Pro Tips:

        • The bushings should fit snugly without excessive force
        • Ensure both bushings are fully seated and flush
        • Clean any metal shavings from the neck tube

    Step 2: Seat Installation

    Time Required: 10-15 minutes

    Components Needed:

        • CT100 Coleman seat
        • Silver Sharpie marker
        • 17/64" drill bit
        • 3 self-tapping seat bolts (13mm head)
        • Pocket knife

    Instructions:

        1. Position the seat on the frame in the desired location
        2. Using the silver Sharpie, mark the mounting holes:
          • Two holes at the front of the seat
          • One hole at the rear of the seat
        3. Important: Once you mark the first hole, do not move the seat to ensure proper alignment
        4. If there are staples in the way of drilling locations, carefully remove them with a pocket knife
        5. Drill the three marked holes using the 17/64" drill bit
          • Note: Do not use a larger bit as you want the bolts to fit snugly
        6. Position the seat back on the frame, aligning the drilled holes
        7. Start all three self-tapping bolts by hand
        8. Using a 13mm socket or 1/2" socket, tighten the bolts by hand (not with impact)
          • The seat bottom is plastic, so hand-tightening prevents over-torquing
        9. Ensure all bolts are snug but not over-tightened

    Pro Tips:

        • Take your time with hole placement - measure twice, drill once
        • Hand-tightening prevents stripping the plastic seat material
        • The self-tapping bolts will create their own threads in the frame

    Step 3: Fork Installation

    Time Required: 10-15 minutes

    Components Needed:

        • Front forks (American steel, made in Texas)
        • Neck bolt
        • 3 washers
        • Locking nut

    Instructions:

        1. Elevate the frame on blocks to allow fork installation
        2. Remove the neck bolt from the neck tube
        3. Install washers in this order (from top to bottom):
          • First washer on top of the forks
          • Insert forks through neck tube
          • Second washer between the bottom of the forks and top of the frame
          • Third washer under the frame
        4. Insert the neck bolt from the top
        5. Thread on the locking nut from the bottom
        6. Using a 3/4" socket and 3/4" wrench, tighten the assembly
        7. Critical: Do not over-tighten - forks should move freely left and right
        8. Test fork movement:
          • Should turn smoothly left and right
          • No up/down play
          • No forward/back play
          • No binding or sticking

    Adjustment Process:

        1. If too tight: Back off the nut slightly until forks move freely
        2. If too loose: Tighten gradually until play is eliminated
        3. Final check: Forks should have smooth steering action without slop

    Pro Tips:

        • The middle washer (between forks and frame) is optional but recommended for better fit
        • Proper fork tension is crucial for safe steering
        • Take time to get the adjustment right

    Step 4: Front Wheel Assembly

    Time Required: 15-20 minutes

    Components Needed:

        • Front wheel (without brake mounts or sprocket mount)
        • Front axle
        • 8 washers (to be used as spacers)
        • Axle nut

    Instructions:

        1. Identify the front wheel (it will NOT have brake disc mounts or sprocket mounts)
        2. Separate the 8 washers into two groups of 4 washers each
        3. Assembly order (from left to right):
          • 4 washers
          • Front wheel
          • 4 washers
        4. Insert the axle through the assembly:
          • Start with axle
          • Add first set of 4 washers
          • Thread through wheel hub
          • Add second set of 4 washers
        5. This may require some finesse to align everything properly
        6. Once aligned, use a mallet or hammer to tap the axle completely through
        7. Thread on the axle nut
        8. Tighten using a 14mm socket and 17mm wrench
        9. Important: Tighten snugly but do not over-torque
        10. Test wheel spin - should rotate freely without drag
        11. Install the wheel assembly into the front forks
        12. Secure with appropriate hardware

    Pro Tips:

        • Equal spacing (4 washers per side) ensures proper wheel alignment
        • The wheel should spin freely when properly installed
        • If there's drag, check for over-tightening or misalignment

    Step 5: Rear Wheel Assembly

    Time Required: 25-30 minutes

    Components Needed:

        • Rear wheel (6-bolt pattern)
        • Brake disc
        • Brake disc spacer (6-hole)
        • Rear sprocket (75T)
        • Sprocket spacer
        • 12 M6 serrated bolts
        • Rear axle
        • 2 symmetrical spacers
        • Axle nut (locking nut)

    Part A: Brake Side Assembly (Right Side)

        1. Important: Ensure tire tread pattern faces forward (V-tread points forward)
        2. Place the 6-hole brake spacer against the right side of the wheel
        3. Position the brake disc on top of the spacer
        4. Align all holes (wheel, spacer, and brake disc)
        5. Insert 6 M6 serrated bolts through the assembly
        6. Start all bolts by hand to ensure proper threading
        7. Using a 10mm socket, tighten bolts in a cross pattern:
          • First pass: Snug all bolts lightly
          • Second pass: Fully tighten in cross pattern
        8. Note: Serrated bolts don't require Loctite

    Part B: Sprocket Side Assembly (Left Side)

        1. Place the sprocket spacer against the left side of the wheel
        2. Position the 75T rear sprocket on top of the spacer
        3. Align all holes (wheel, spacer, and sprocket)
        4. Insert 6 M6 serrated bolts through the assembly
        5. Start all bolts by hand
        6. Tighten using the same cross pattern as the brake side

    Part C: Axle Installation

        1. Assembly order (left to right):
          • Rear axle
          • First symmetrical spacer
          • Wheel assembly (sprocket side on left, brake side on right)
          • Second symmetrical spacer
        2. Align everything and tap the axle through with a mallet
        3. Thread on the locking axle nut
        4. Tighten using a 17mm wrench and 14mm socket
        5. Critical checks:
          • No wheel wobble
          • No axle play or slack
          • Wheel spins freely without drag
          • Brake disc runs true

    Pro Tips:

        • The brake side is ALWAYS on the right side of the bike
        • Cross-pattern tightening prevents warping
        • Proper axle tension is crucial for safety

    Step 6: Handlebar and Riser Installation

    Time Required: 20-25 minutes

    Components Needed:

        • 12" vintage handlebars
        • 2 handlebar risers (top and bottom sections)
        • 4 riser bolts
        • 4 nylon locking nuts (13mm)

    Instructions:

        1. Preparation:

          • Disassemble both risers (separate top and bottom sections)
          • Note the handlebar contour (curves toward the front)

        2. First Riser Installation:

          • Place bottom section of first riser in fork clamp
          • Position handlebars with contour facing forward
          • Place top section over handlebars
          • Insert bolts through top section
          • Thread on 13mm nylon locking nuts from bottom
          • Do not fully tighten yet

        3. Second Riser Installation:

          • Lift handlebars slightly to access second fork leg
          • Install bottom section of second riser
          • Position top section and insert bolts
          • Thread on remaining nuts

        4. Alignment and Tightening:

          • Center the handlebars
          • Set desired handlebar angle (slight forward rake recommended)
          • Using 10mm socket (top) and 13mm wrench (bottom):
            • Alternate tightening between both risers
            • Keep gaps even on both sides of each riser
            • Gradually tighten to maintain equal gaps

        5. Final Check:

          • Handlebars should be centered and secure
          • No excessive play or movement
          • Comfortable riding position

    Pro Tips:

        • Having a helper makes this step much easier
        • If working alone, lay handlebars down between installations
        • Equal gaps on risers ensure proper clamping force
        • Don't rush the alignment process

    Step 7: Kickstand Installation

    Time Required: 10-15 minutes

    Components Needed:

        • Kickstand
        • Kickstand spring
        • Kickstand pin
        • Cotter pin
        • Needle-nose pliers

    Note: Your kit may include an extra weld-on kickstand mount - this is for future projects and not needed for this build.

    Instructions:

        1. Disassembly:

          • Remove cotter pin from kickstand assembly
          • Keep cotter pin straight for easier reassembly
          • Separate spring and kickstand (be careful - it's spring loaded)

        2. Spring Installation:

          • Hook the spring's hooked end around the pin on the kickstand
          • Connect the other end to the small pin behind the kickstand mount on the frame

        3. Kickstand Installation:

          • Pull down on the kickstand to align the holes
          • Line up frame holes on both sides of the kickstand mount
          • Insert the kickstand pin through the assembly

        4. Securing:

          • Turn the pin so you can see the hole for the cotter pin
          • Insert the cotter pin through the hole (this is a snug fit)
          • Using needle-nose pliers, bend the cotter pin to prevent it from backing out
          • Important: Ensure the bent cotter pin doesn't interfere with the spring

        5. Testing:

          • Test kickstand operation
          • Should spring up and down smoothly
          • Bike should stand securely when kickstand is deployed

    Pro Tips:

        • Keep the cotter pin straight during disassembly
        • The spring provides the return action for the kickstand
        • Don't over-bend the cotter pin - just enough to prevent removal

    Step 8: Engine Installation

    Time Required: 15-20 minutes

    Components Needed:

        • 98cc gasoline engine
        • 4 M8 bolts (labeled "Rascal Lite EM")
        • 4 M8 serrated nuts
        • 4 5/16" lock split washers

    Important: The engine's clutch side (jackshaft) goes on the LEFT side of the bike.

    Instructions:

        1. Engine Positioning:

          • Place engine on the frame with clutch side facing left
          • Push engine to its furthest rearward position in the mounting slots
          • This provides maximum chain adjustment range

        2. Hardware Installation:

          • Place lock split washers on M8 bolts
          • Insert bolts through frame and into engine mounting points
          • Thread on M8 serrated nuts from underneath
          • Hand tighten only at this stage - final positioning comes later

        3. Purpose of Hand Tightening:

          • Allows for chain length adjustment
          • Permits engine repositioning during chain installation
          • Final tightening occurs after chain setup

    Pro Tips:

        • The split washers serve dual purposes: protection and anti-loosening
        • Serrated nuts provide additional security against backing out
        • Don't fully tighten until chain is properly adjusted

    Step 9: Clutch Installation

    Time Required: 10-15 minutes

    Components Needed:

        • 12T #35 pitch clutch (5/8" bore)
        • M6 clutch bolt
        • M6 split lock washer
        • M6 flat washer

    Instructions:

      1. Clutch Orientation:

        • Install clutch with gear facing INBOARD (toward the engine)
        • The clutch already has a key installed - no additional key needed

      2. Hardware Installation Order:

        • M6 split lock washer (first, against clutch)
        • M6 flat washer (second, against split washer)
        • M6 clutch bolt

      3. Installation Process:

        • Slide clutch onto engine crankshaft
        • Ensure key aligns with keyway
        • Install washers and bolt in correct order
        • Start bolt by hand to prevent cross-threading

      4. Tightening:

        • Use 7/16" socket or 11mm socket
        • Do not use impact driver at full power
        • Give a few light impacts or tighten by hand
        • Ensure split washer is completely flattened
        • Check for clutch play - should be none when properly tightened

        Pro Tips:

        • Cross-threading the crankshaft can be catastrophic
        • The split washer must be completely flat when properly tightened
        • Clutch should have no play but crankshaft should still turn freely

        Step 10: Chain Tensioner Assembly

        Time Required: 10-15 minutes

        Components Needed:

        • Chain tensioner roller
        • Chain tensioner bolt
        • 2 flat washers
        • 2 lock washers
        • Nylon locking nut

        Instructions:

        1. Washer Order (from bolt head to nut):

          • Flat washer
          • Lock washer
          • Tensioner roller
          • Lock washer
          • Flat washer
          • Nylon locking nut

        2. Critical Assembly Note:

          • The lock washer against the roller should contact the INNER RACE only
          • Do not let washers contact the outer race (causes drag)
          • Smaller diameter washer should be against the bearing

        3. Installation:

          • Thread assembly into frame tensioner mount
          • Use 13mm socket and 1/2" box wrench
          • Tighten until snug but roller still turns freely
          • Some drag is acceptable, but roller shouldn't be locked

        4. Adjustment Options:

          • If too much drag: Remove one flat washer from nut side
          • This provides more threads for fine adjustment
          • For 98cc engine, moderate drag is acceptable

        Pro Tips:

        • Proper washer placement is critical for roller function
        • The tensioner will be adjusted multiple times during chain setup
        • Start with tensioner in most forward position

        Step 11: Chain Installation and Adjustment

        Time Required: 20-25 minutes

        Components Needed:

        • #35 chain
        • Master link (3 pieces: main link, side plate, clip)

        Instructions:

        1. Initial Chain Routing:

          • Let rear of chain hang loose initially
          • Route chain over the tensioner roller
          • Under the front clutch
          • Around the top of the clutch
          • Ensure chain engages rear sprocket properly

        2. Chain Length Check:

          • Pull chain ends together
          • Chain may appear slightly too long initially
          • Do not cut chain - engine position will be adjusted instead

        3. Master Link Installation:

          • Connect chain ends with master link
          • Install in this order: main piece, retaining plate, retaining clip
          • CRITICAL: Install retaining clip correctly

        4. "Pac-Man Rule" for Retaining Clip:

          • Imagine Pac-Man on the clip opening
          • Pac-Man should "run backwards" relative to chain rotation
          • This prevents the clip from being knocked off during operation
          • Use needle-nose pliers to install clip properly

        5. Engine Position Adjustment:

          • With chain connected, move engine forward to remove slack
          • Aim for approximately 1 inch of chain play
          • This allows for chain stretch over time

        6. Chain Tensioner Adjustment:

          • Position tensioner at most forward position initially
          • This provides maximum future adjustment range
          • Loosen tensioner mounting bolt
          • Move tensioner to achieve proper chain tension
          • Retighten tensioner bolt

        7. Final Engine Mounting:

          • With proper chain tension achieved, fully tighten engine mounting bolts
          • Use appropriate wrenches (not impact tools in tight spaces)
          • Double-check chain tension after engine bolts are tight
          • Readjust tensioner if necessary

        Pro Tips:

        • Never cut the chain - always adjust with engine position
        • The "Pac-Man rule" is critical for safety
        • Chain will stretch during break-in period
        • Maintain about 1 inch of play in the chain

        Step 12: Clutch Cover Installation

        Time Required: 10-15 minutes

        Components Needed:

        • Clutch cover
        • Clutch cover bracket
        • 4 M8 bolts (10mm heads)

        Instructions:

        1. Bracket Installation:

          • Locate the two uppermost M8 bolts on the engine side cover
          • These bolts have factory Loctite applied
          • Remove these bolts and install the clutch cover bracket
          • Use 10mm socket to tighten securely
          • Note: Bolts won't thread in completely due to Loctite

        2. Cover Installation:

          • Position clutch cover over the clutch assembly
          • Align top hole with bracket
          • Align bottom hole with engine block
          • Install remaining two M8 bolts
          • Tighten all bolts securely with 10mm socket

        3. Final Check:

          • Ensure cover doesn't interfere with clutch operation
          • Cover should be secure with no rattling
          • All bolts should be properly tightened

        Pro Tips:

        • The bracket provides proper mounting alignment
        • Factory Loctite prevents bolts from backing out
        • Cover protects clutch from debris and provides safety

        Step 13: Brake Caliper and Bracket Installation

        Time Required: 20-25 minutes

        Components Needed:

        • Brake caliper bracket
        • Brake caliper
        • 2 M6 bolts (for bracket to frame)
        • 2 M6 serrated nuts (for bracket)
        • 2 M6 bolts (for caliper to bracket)
        • 2 M6 split washers
        • T30 Torx bit

        Instructions:

        1. Bracket Installation:

          • Position bracket on inside of frame
          • Bracket follows the flow/curve of the bike frame
          • Identify larger holes (for frame mounting) and smaller holes (for caliper)
          • Install bracket using larger holes with M6 serrated nuts
          • Start nuts by hand, then tighten with appropriate tools
          • Keep nuts smooth - don't damage serrations

        2. Caliper Installation:

          • Place M6 split washers between caliper and bracket
          • Install M6 bolts through caliper, washers, and into bracket
          • Start bolts by hand to ensure proper threading
          • Use 10mm socket and 10mm box wrench to tighten

        3. Caliper Alignment:

          • Initial alignment may not be perfect
          • Use T30 Torx bit to adjust alignment bolts on caliper
          • Adjust until brake disc runs centered in caliper
          • Test wheel spin - some drag is normal and desirable
          • Continue adjusting until wheel spins reasonably freely

        4. Final Brake Check:

          • Wheel should have slight drag (this is normal for disc brakes)
          • No grinding or excessive resistance
          • Brake disc should not rub heavily on one side

        Pro Tips:

        • Take time with caliper alignment - it affects braking performance
        • Some brake drag is normal and actually desirable for safety
        • T30 adjustment allows fine-tuning of caliper position

        Step 14: Kill Switch Installation

        Time Required: 5-10 minutes

        Components Needed:

        • Handlebar-style kill switch
        • Phillips head screws

        Instructions:

        1. Positioning:

          • Install kill switch FIRST before other handlebar components
          • Position with "RUN" button at the bottom (personal preference)
          • Place as close to handlebar bend radius as possible (innermost position)

        2. Installation:

          • Slide kill switch onto right handlebar
          • Position for easy thumb access while riding
          • Tighten Phillips head screws securely
          • Ensure switch doesn't rotate on handlebar

        Pro Tips:

        • Install kill switch first - it's harder to install after other components
        • Position for natural thumb operation
        • "RUN" button down is recommended but not mandatory

        Step 15: Brake Lever and Cable Installation

        Time Required: 15-20 minutes

        Components Needed:

        • Brake lever
        • Brake cable
        • 5/16" or 8mm bolts

        Instructions:

        1. Cable and Lever Assembly:

          • Connect brake cable to lever before installation
          • Align gaps in lever with cable barrel
          • Insert cable barrel into lever
          • Ensure cable seats properly in lever mechanism

        2. Lever Installation:

          • Position brake lever on left handlebar
          • Use 5/16" or 8mm socket to install mounting bolts
          • Leave bolts loose for now - final positioning comes later
          • Ensure lever is accessible and comfortable

        3. Cable Routing:

          • Route cable down through frame
          • Keep cable routing neat and organized
          • Avoid sharp bends or kinks in cable
          • Leave slack for final adjustment

        Pro Tips:

        • Pre-assembling cable and lever makes installation easier
        • Proper cable routing prevents binding
        • Final lever position adjusted after throttle installation

        Step 16: Throttle Assembly Installation

        Time Required: 15-20 minutes

        Components Needed:

        • Throttle housing (2 pieces)
        • Twist throttle grip
        • Throttle cable
        • Wedge guide piece
        • Allen head screws

        Instructions:

        1. Throttle Disassembly:

          • Separate throttle housing into top and bottom pieces
          • Locate small wedge piece inside bottom housing
          • Set wedge piece aside temporarily

        2. Cable and Grip Assembly:

          • Thread throttle cable through bottom housing
          • Connect cable to twist throttle grip
          • Ensure proper cable engagement with grip mechanism

        3. Housing Assembly:

          • Pull slack out of cable
          • Position wedge piece to guide cable properly
          • Install top housing section
          • Ensure housing sits flush but not against handlebar
          • Leave small gap between housing and handlebar

        4. Final Adjustment:

          • Tighten Allen head screws securely
          • Test throttle operation - should return to closed position
          • Ensure smooth throttle action without binding

        Pro Tips:

        • Remove all slack from cable before final assembly
        • Small gap prevents housing from binding on handlebar
        • Throttle should snap back to closed position when released

        Step 17: Dummy Grip Installation

        Time Required: 5 minutes

        Components Needed:

        • Dummy grip (left handlebar)
        • WD-40 (optional)
        • Rubber mallet

        Instructions:

        1. Preparation:

          • WD-40 can help with installation but isn't always necessary
          • Try dry installation first

        2. Installation:

          • Start grip by hand, pushing as far as possible
          • Use rubber mallet to tap grip fully onto handlebar
          • Ensure grip is fully seated and secure

        Pro Tips:

        • Rubber mallet prevents damage to grip
        • Grip should be fully seated against handlebar controls

        Step 18: Cable Routing and Management

        Time Required: 15-20 minutes

        Components Needed:

        • Zip ties
        • Wire cutters/snips

        Instructions:

        1. Cable Organization:

          • Group throttle and brake cables together
          • Use zip ties at strategic points:
            • Upper handlebar radius
            • Lower handlebar radius
            • Top of frame spine
            • Bottom of frame spine

        2. Zip Tie Installation:

          • Leave some slack in cables
          • Don't over-tighten zip ties
          • Ensure cables can move freely
          • Cut zip tie tails flush - this is important for appearance

        3. Professional Appearance:

          • Keep cable runs neat and parallel
          • Avoid crossing cables unnecessarily
          • Maintain consistent spacing

        Pro Tips:

        • Cut zip tie tails for professional appearance
        • Proper cable management prevents wear and damage
        • Leave slight slack for handlebar movement

        Step 19: Kill Switch Wiring

        Time Required: 5-10 minutes

        Components Needed:

        • Ground wire from kill switch
        • 5/16" socket

        Instructions:

        1. Ground Connection:

          • Locate tank bolt on frame
          • Remove bolt temporarily
          • Install ground wire under bolt
          • Retighten bolt securely

        2. Switch Connection:

          • Connect male end from kill switch to female connector on engine coil
          • Ensure connection is secure and snug
          • Test connection by gently tugging

        Pro Tips:

        • Secure ground connection is essential for kill switch operation
        • Connectors should fit snugly without forcing

        Step 20: Throttle Cable Connection

        Time Required: 10-15 minutes

        Components Needed:

        • Throttle cable
        • Phillips head screwdriver
        • Allen wrench
        • 10mm box wrench

        Instructions:

        1. Engine Preparation:

          • Locate throttle cable connections on engine
          • Loosen both Phillips head screws:
            • First screw: cable sleeve holder
            • Second screw: cable holder

        2. Cable Installation:

          • Route cable sleeve under sleeve holder
          • Feed cable into cable holder
          • Position metal eyelet in sleeve holder
          • Tighten sleeve holder screw

        3. Cable Adjustment:

          • Pull all slack out of throttle cable
          • Ensure no slack remains in system
          • Tighten cable holder screw
          • Use Allen wrench and 10mm box wrench for final tightening

        4. Testing:

          • Test throttle operation
          • Should open and close smoothly
          • No binding or sticking

        Pro Tips:

        • Remove ALL slack from throttle cable
        • Proper adjustment ensures responsive throttle control
        • Test operation before final tightening

        Step 21: Brake Cable Connection

        Time Required: 10-15 minutes

        Components Needed:

        • Brake cable
        • 10mm wrench

        Instructions:

        1. Cable Routing:

          • Route brake cable through same path as throttle cable
          • Keep cables organized and parallel
          • Route behind frame bar for clean appearance

        2. Caliper Connection:

          • Locate 10mm nut on brake caliper
          • Loosen nut to access cable connection point
          • Thread cable through connection hole
          • Pull all slack out of cable while tightening nut

        3. Final Adjustment:

          • Pull cable tight while tightening connection
          • Tighten by hand to prevent over-torquing
          • Test brake lever operation
          • Should have firm feel with stopping power

        Pro Tips:

        • Remove all slack for proper brake feel
        • Hand tightening prevents damage to cable
        • Test brake operation before riding

        Step 22: Foot Peg Installation

        Time Required: 5 minutes

        Components Needed:

        • 2 foot peg grips

        Instructions:

        1. Installation:

          • Foot pegs slide directly onto frame-mounted foot peg brackets
          • Push firmly until fully seated
          • Much easier installation than hand grips

        2. Verification:

          • Ensure both foot pegs are secure
          • Test by applying pressure
          • Should not slide or rotate

        Pro Tips:

        • Installation is straightforward
        • Ensure full engagement for safety

        Final Setup & Testing

        Step 23: Engine Oil Fill

        Time Required: 10 minutes

        Components Needed:

        • 12 oz of 4-stroke engine oil (Tillotson recommended)
        • Measuring funnel
        • Oil dipstick

        Instructions:

        1. Oil Measurement:

          • Measure exactly 12 oz of 4-stroke oil
          • Note: 98cc engines require 12 oz (212cc engines require 16 oz)

        2. Oil Fill Process:

          • Remove oil filler cap
          • Lean bike slightly to one side during filling (prevents overflow)
          • Pour oil slowly using measuring funnel
          • Oil may seem to overflow - this is normal
          • Replace oil cap quickly after filling

        3. Oil Level Check:

          • Set bike upright
          • Remove dipstick completely
          • Reinsert dipstick fully
          • Remove and check oil level
          • Oil should be at proper level on dipstick

        Pro Tips:

        • Leaning bike during fill prevents mess
        • 12 oz is correct amount even if it seems like too much
        • Always check oil level with bike upright

        Step 24: Fuel Fill and First Start

        Time Required: 10-15 minutes

        Components Needed:

        • Fresh gasoline
        • Fuel funnel

        Instructions:

        1. Fuel Fill:

          • Add fresh gasoline to fuel tank
          • Use funnel to prevent spills
          • Fill to appropriate level (don't overfill)
          • Replace fuel cap securely

          1. Pre-Start Checklist:

            • Verify fuel valve is in "ON" position
            • Check that kill switch is in "RUN" position
            • Ensure throttle moves freely
            • Check that brake lever has proper feel
            • Verify all bolts are properly tightened
            • Check chain tension one final time

          2. First Start Procedure:

            • Move bike to well-ventilated outdoor area
            • Ensure area is clear of obstacles
            • Set bike on level ground
            • Pull recoil starter cord with firm, steady pulls
            • Engine should start within several pulls

          3. Initial Run Check:

            • Let engine warm up for 2-3 minutes
            • Check for any unusual noises or vibrations
            • Test kill switch operation (engine should stop immediately)
            • Check for any fuel or oil leaks
            • Verify throttle response

          Pro Tips:

          • Always start engine outdoors with good ventilation
          • Don't over-choke if engine is warm
          • Kill switch test is critical for safety

          Step 25: Final Safety Inspection and Test Ride

          Time Required: 15-20 minutes

          Pre-Ride Safety Checklist:

          Frame and Structure:

          • All frame bolts properly tightened
          • Seat securely mounted
          • Kickstand operates properly
          • No loose or missing hardware

          Wheels and Brakes:

          • Front wheel spins freely
          • Rear wheel spins with slight drag (normal)
          • Brake lever has firm feel
          • Brake stops rear wheel effectively
          • No wheel wobble or play

          Engine and Drive System:

          • Engine runs smoothly at idle
          • Throttle responds properly
          • Kill switch stops engine immediately
          • Chain has proper tension (1" play)
          • Clutch engages smoothly
          • No unusual noises or vibrations

          Controls:

          • Handlebars turn smoothly
          • All cables routed properly
          • Foot pegs secure
          • Grips properly installed

          Test Ride Procedure:

          1. Initial Test:

            • Start with very slow, short ride
            • Test throttle response gradually
            • Check brake effectiveness at low speed
            • Verify steering and handling

          2. Break-In Period:

            • Keep speeds moderate for first hour of operation
            • Avoid full throttle operation initially
            • Check chain tension after first ride
            • Monitor for any loose bolts or components

          Pro Tips:

          • Always wear appropriate safety gear
          • Start with slow, careful operation
          • Check all systems after first ride
          • Follow break-in procedures for longevity

          Maintenance & Troubleshooting

          Regular Maintenance Schedule

          After First Ride:

          • Check all bolt torques
          • Verify chain tension
          • Check brake adjustment
          • Look for any loose components

          Every 5 Hours of Operation:

          • Check engine oil level
          • Inspect chain tension and lubrication
          • Check brake operation
          • Inspect all bolts and fasteners

          Every 10 Hours of Operation:

          • Change engine oil
          • Clean air filter
          • Lubricate chain
          • Check spark plug condition

          Monthly (or 20 hours):

          • Complete safety inspection
          • Check tire condition and pressure
          • Inspect brake pads/disc
          • Clean and inspect entire bike

          Common Issues and Solutions

          Engine Won't Start:

          • Check fuel level and fuel valve position
          • Verify kill switch is in "RUN" position
          • Check spark plug connection
          • Ensure throttle isn't stuck open
          • Check for flooded engine (wait 5 minutes if flooded)

          Poor Throttle Response:

          • Check throttle cable adjustment
          • Verify cable isn't kinked or binding
          • Check air filter condition
          • Inspect carburetor for debris

          Chain Issues:

          • Too loose: Adjust tensioner or move engine forward
          • Too tight: Move engine backward or adjust tensioner
          • Chain jumps: Check sprocket alignment and wear
          • Noisy chain: Lubricate and check tension

          Brake Problems:

          • Soft lever: Check cable adjustment and connection
          • Dragging brake: Adjust caliper alignment
          • No braking: Check cable connection and brake pad contact

          Handling Issues:

          • Loose steering: Check fork bearing adjustment
          • Wobbling: Check wheel bearing tightness
          • Poor tracking: Verify wheel alignment

          Storage and Winterization

          Short-term Storage (1-30 days):

          • Fill fuel tank to prevent condensation
          • Store in dry location
          • Check tire pressure

          Long-term Storage (30+ days):

          • Add fuel stabilizer or drain fuel system
          • Change engine oil
          • Remove battery if equipped
          • Store in dry, covered location
          • Lubricate chain and exposed metal parts

          Parts and Service Information

          Replacement Parts:

          • Contact GoPowerSports at 866-846-5278
          • Visit gopowersports.com for parts diagrams
          • Ask for Flacco for personalized assistance

          Warranty Information:

          • Keep all documentation
          • Register product if required
          • Follow maintenance schedule to maintain warranty

          Technical Support:

          • GoPowerSports customer service: 866-846-5278
          • Email: sales@gopowersports.com
          • Online resources at gopowersports.com

          Conclusion

          Congratulations! You have successfully assembled your Rascal Lite Mini Bike. This build represents a quality entry point into the mini bike hobby with excellent potential for customization and upgrades.

          Key Accomplishments:

          • Complete mechanical assembly from kit components
          • Proper engine installation and setup
          • Brake and throttle system installation
          • Safety system integration
          • Professional cable management

          Next Steps:

          • Customization: The raw steel frame is ready for powder coating, painting, or other custom finishes
          • Upgrades: Consider performance modifications as you gain experience
          • Maintenance: Follow the maintenance schedule for reliable operation
          • Safety: Always wear appropriate protective gear and follow local regulations

          Final Reminders:

          • This mini bike is designed for off-road use only
          • Always check local laws and regulations before operating
          • Wear appropriate safety gear including helmet, gloves, and protective clothing
          • Supervise minors during operation
          • Perform regular maintenance for safe, reliable operation

          Enjoy your new Rascal Lite Mini Bike and ride safely!

          For additional support, parts, or questions, contact GoPowerSports:

          Thank you for choosing GoPowerSports for your mini bike needs!