Group 11 - Beginner Dirt Bike

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Wikipedia Encyclopedia

Group 11 - Gate 1

Group 11 - Gate 2

Group 11 - gate 3

Gate 4: Critical Project Review

Product Reassembly Plan

Completed bike picture with parts located

Bikeleft11.jpg Bikeright11.jpg

Part Instructions Photo
Steering Shaft
  1. Reassemble bearing at the top of the shaft of frame with the original steel balls.
  2. Slide the bottom of the steering shaft, with attached shaft, through frame
  3. Place top of steering assembly on top of shaft over the bearing
  4. Tighten bolt to secure assembly, but assembly must have ability to rotate
  5. Slide front shock absorbers into assembly. The shock absorber with the nubs on the end must be on the right to allow for brake system to be assembled correctly


Handle Bar
  1. Place handle bars on top of steering assembly in the groves provided
  2. Place handle bar cover over handle bars, with the rounded top towards the rider
  3. Place and tighten 4 bolts through cover into steering assembly
Rear shock
  1. Attach the rear frame using the one original long bolt. Place so that linkage on the swing arm is on the bottom right to allow for rear wheel attachment
  2. Place rear shock absorber between rear frame arm and body frame. The end closest to the spring should be attached to the rear frame in provided slot. Other end should attach to the part where the seat is bolted on to the frame.
  3. Attach rear shock with two provided factory bolts, with reinforcement pins and castle nuts.


Handle Bar Components
  1. Attach throttle cable to the right hand grip.
  2. Slide the grip onto the handle bar and secure with two screws.
  3. Attach kill switch to handlebars using another two screws.
  4. Attach front break cable to the front hand brake and attach front hand brake to handle bars using another two screws.
  5. Connect the other ends of components to their corresponding locations, kill switch to the spark plug, brake cable to front brake, and throttle cable to carburetor.
Front wheel assembly
  1. Place internal drum brake into front wheel.
  2. Secure front wheel to front shock absorbers.
  3. Attach brake line from handlebars to drum brake using the welded on supports found on frame and shocks.
Back Wheel Assembly
  1. Place rail slide chain tensioners into rear frame assembly
  2. Place drum brake on right side of wheel, and place chain sprocket on left side of wheel
  3. Bushing goes between sprocket and rear frame
  4. Slide axle through rear frame, rail slide wheel assembly and through other side of rear frame
  5. Attach rear frame swing arm to bottom of rear drum brake

Backwheelassembly211.jpg Backwheelassembly311.jpg

Rear Brake Assembly
  1. Place rear brake pedal on right side on the bike frame. Secure with pin.
  2. Connect brake rod to brake pedal through hole.
  3. On other end, threaded end, place spring onto cable then slide through holding on back drum brake.
  4. Secure with nut.
  1. Attach engine block to underside of frame. (Please see group 17’s page for instructions on assembling the engine block)
  2. First attachment in found on the top back of the engine block and bottom of frame underneath rear shock. Slide bolt through attachment and tighten
  3. Second attachment is found on the back underside of the engine, and the bottom of the frame below the rear frame connection. Slide bolt through slot and tighten.
Engine Attachments
  1. Attach kick lever to right side of engine
  2. Attach gearshift to left side of engine. Connection is near the front and bottom on left side.


Gas Tank
  1. Place gas tank to top of frame near handle bars. Placement should have gas tank side slanting towards rider.
  2. Attach gas tank with two bolts on the front and back into holes on frame
  1. Using master link, separate chain
  2. Place right end of chain on the rear sprocket. Take left end of chain and feed it into the engine block. Use the gearshift to work chain through gears in engine block and back out. Reattach chain together.
  3. Adjust rail slide chain tensioners to move the tire forward or back to create desired tension in chain.
  4. Attach plastic chain guard onto connections on rear frame with two washers and bolts
Kick Stand
  1. Attach kickstand assembly to the bottom on the engine. With four bolts This assembly also included the foot rest pedals. Place assembly so that kickstand is on the left hand side of the bike
  1. Attach muffler to engine exhaust outlet and attach to bikes right side to attachment point on frame
no picture available
  1. Connect electrical wiring from the handle bars to the extension from the engine and the electrical box (little black and green box)
  2. Route wiring under welded holders on the frame to the back of the bike, under the seat
Plastic Covers
  1. Attach Frame cover to bike with six bolts. Four of the bolts are placed on the gas tank, two on front and two on the side. The last two are attached on the rear of the cover beneath the seat
  2. Attach number plate (plastic white shield) to the front with one bolt. Wrap Plastic support around handle bars for extra support
  3. Attach front fender


Dirt Bike Reassembly Instructions

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Product Assembly Questions

Does your product run the same as it did before you disassembled it?

Because our product was split between two groups, group 17 and us, group 11, we did not have time to test our product because group 17 was missing pieces to complete the engine.

The frame that we assembled though does function. We tested out each component after we assembled it. We tested each of the brakes by spinning the wheel, and then stopping it with the brake. We tested the shocks, by forcing the bike up and down. Everything that we reassembled worked, but we could not test the overall capabilities of the bike because of the engine.

What were the differences between the disassembly/reassembly processes?

The disassembly of our dirt bike was in the same order as the reassembly of our dirt bike. We started with the front end and worked our way to the rear sub frame, or swing arm.

Were the same sets of tools used?

The same set of tools used to take the dirt bike apart were used to reassemble the dirt bike. Because we recorded the tools required from disassembly, we knew what tools we would need for reassembly. The only problem we had then was fighting with other groups for the tools we needed.

Were you able to reassemble the entire product?

Yes. We assembled all of the components that we had disassembled.

Are there any additional recommendations your group would make at the product level (operation, manufacturing, assembly, design, configuration, etc.)?

If the factory used standardized bolts that required only one type of socket and one size of that socket to assemble, they would reduce the production cost because bulk buy parts cost less with the more amount purchased. It would also require less tools and would decrease assembly costs as well as the amount of steps in assembly, and assembly time due to the fact that you wouldn’t have to look for different tools between steps.