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Page 5 of 13
Install and Align the Rear Drive Sprocket, Part 2 and Installing the Drive Chain, Part 1
(Continued)
Once you have the sprocket assembly installed on the rear wheel, attach the wheel to the bike. As you tighten the two rear wheel axel nuts insure that the rear wheel is turning straight with the bike. On the coaster brake models be sure to connect the coaster brake brace lever that extends from the sprocket side of the rear wheel. Flip the bike over and stand it up on the seat and handle bars. Using the bike pedals begin turning the rear wheel. As the wheel is turning insure that the rear drive sprocket is turning evenly and straight. If not slowly adjust the nine mounting bolts until the rear drive sprocket is turning without any wobble. Note: this same process is followed for the hand brake model of bike.
Installing the Motor Drive Chain
Now it’s time to install the motor drive chain. Place the bike back on its wheels with the kick stand down. Remove the three screws that cover the front drive motor sprocket. Take care to insure that the clutch shaft does not fall out. If it does be sure not to lose the ball bearing behind it. The image below shows you where the clutch cover is and point out the three screws that need to be removed.
 
Using the spark plug socket included with the kit, remove the spark plug from the motor. Remove the drive chain from the kit box and lay it out in front of you. Find the master link on the chain, remove it and open the chain up. Wrap the chain around the Rear wheel drive sprocket and feed it up to the motor drive sprocket. Using a pair of channel locks turn the motor drive sprocket around feeding the chain around it. Feed in from the top and continue to turn the drive sprocket until there is about six inches of chain sticking out the bottom. Re-install the master link making the chain one piece again. Note: Depending on the type of bike you may have to remove links in order to get the chain the proper length.
Once the drive chain is installed you need to put the clutch cover back on. One trick at this point is to take some high quality grease and put some in the clutch shaft hole and around the clutch shaft before re-installing the cover. Tighten the three screws evenly until firmly tight, insuring that the cover is flush with the engine block.
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