LONG one
First as you said the bike is the wrong type of bike try and find a BEACH CRUSER you do not need all those gears and the coaster break is a lot better than the hand breaks esp when you do a panic stop. You will need at least 16 inches for the motor to mount.
It looks like your engine is going to be at to sharp of an angle for the chain drive to work properly.
There is a type of gas tank that sets on the back of the bike you can take and put a rack on the back of the seat and have the tank mounted there that way avoiding the crimps and possibility of burning your fuel line
.1. After connecting the throttle to the carburator, it can now twist 360
degrees in both directions. However, it does seem to have a "lock pick" feel where you can tell it has extended all the way in a direction (although I'm not sure which). Does this mean I set it up wrong? ..YUP something is not right check how you wrapped the line
2. The muffler doesn't fit correctly on my bike. Before I spend the 40 or so dollars it takes to bend it to fit, I must ask, is it required (i.e. is it dangerous if I dont have it, or will it just not run if I dont have it)?
It is not dangerous but it will be loud and might make the engine run funny but I took and drilled a hole though the body of mine and it runs a lot better now and make some new gaskets the ones that come with the kits are glorified match books and blow out within the break in period.
3. I took my setup to a welder to get it to fit on my frame. He did a fine
job welding a mounting plate to the frame so that the motor would fit, and then welded an extension to the air intake so that it would fit without
having to turn the carburator sideways. Is this perfectly ok (i.e. safe)? The only difference is that its slightly longer and is turned so that it is
no longer centered underneath the bike frame. From what I can tell it is
safe.
4. The kill switch is supposed to be "tied to the blue wire", but I'm not
sure how this is done. It doesnt seem to normally fit on its own. Is the white wire for, say a light I wanted to connect to the bike?
My kill switch kept killing the bike at the wrong time so I ripped it off and do not use them it was a major pain in the rump trying to track down Y the bike stopped and then to find out after all that work it was the kill switch ARRRRRG!! and that has happened on 4 of the bikes I have built so now I just throw the switch away
5. I dont understand how the clutch works. It seems to be just a brake for the drive sprocket / gear (and not a very good one since the little gold thing will snap off if squeezed too hard). Based on my understanding, pedalling while its engaged would probably ruin something, so it would be nice if I could get some reassurance that wont happen.
once you get that thing set right (it will take 4 hands) it will surprise you these bikes are like push starting an old stick shift car except you are peddling once the motor gets broken in and your skill grows you will be able to pump the pedal 3 or 4 times and start the motor.
6. Is it possible I could get a clearer picture of how the chain guard is set up? Does the front connect to the right side of the engine (somehow...) while the rear connects to inside of the frame (with a zip tie?)
the chain guard in my mind is a pain where a pill will not reach...they make a lot of noise and have a tendency to break loose at the wrong time as a matter of fact I know of only one guy that has one on his bike but I do not know how much he rides his bike either
7. How hot does the motor get? I can guess your not supposed to touch it but if a piece of clothing just touches it a little will it catch on fire?
It gets HOT I have burned my leg by resting it on the motor for a second as far a pc of cloth bursting into flames NO but nilon will melt.
8. What are some warning signs of a improperly set up rig? Is it possible
for it to catch on fire or explode? Is there a way to test the motor without actually mounting it? What if I smell smoke of some sort?
Your ears are the best monitor for when something is not right you will hear a different rattle check it out !!! when you have ridden you bike some where befor you start back home check your screws nuts and bolts be sure you have used lock tight on all the nuts and bolts.
I have had an argument with a SUV and if my bike was going to explode it would have done it that day these are safe little engines and you would have to do something really dumb like dropping a match in the tank to see if it had any gas in it LOL.
If you find a way to start the motor with out mounting it let me know
.
9. The black cap that goes over the spark plug seems to have some wiggle room, is this correct?
I cut mine off as it had wiggled itself lose and was not making contact so I soldered a eye to the wire and screwed the wire onto the plug and have not had any problem since
10. I mixed the gas with 10w-30 synthetic, does that sound good? 2 cycle oil !!!
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