3540 Mini Bike Kit, 5 in. Aluminum Wheels

3540 Minibike Kit, 5 in. Aluminum Wheels
3540 Minibike Kit, 5 in. Aluminum Wheels3540 Minibike Kit, 5 in. Aluminum Wheels
Part No: A3540
MFG: Kits
LIST PRICE: $495.00
Product Options

* denotes required field

Chain Guard*
Clutch Options*

Quantity Discounts

2 to 3$357.00
4 to 6$352.00
7 to 9$350.00
10 to 999$349.00
  MADE-IN-USA Since 1960
  5" Aluminum Tri-Star Wheels
Everything you need except Engine and Clutch is included in this kit.
You can add a Clutch in Product Options above. click Add-to-Cart, then
  scroll down to select an Engine

the video is not of this kit! It's shown as a great example of what you can do with our minibike parts and kits.  Good Job!

Painting and Assembly Required           Assembly Manual
This is the original Mini Bike made since 1960
Remember the Old School Minibikes of the 60s? Like Taco, Bonanza and Rupp? MINIBIKE WARNING
Those of you who grew up in the 60’s remember Minibikes as a wonderful part of childhood. Boy's who were fortunate enough to own one couldn't wait to get out of school and go down to the local field to ride.
This is one of the only Old School Mini Bikes still manufactured today!


  • Will accept a 2 to 6hp Engine
  • 4 1/2" Internal Expanding Brake
  • 60T Sprocket / Brake Drum Combo
  • 5" Aluminum Split Rim Mag style Wheels
  • 4 Bearings, 2 each wheel
  • Front tire: 4.10 x 3.50 x 5" - Sawtooth
  • Rear tire: 4.10 x 3.50 x 5" - Knobby
  • Front and Rear Innertubes
  • Front & Rear Axles
  • #35 chain with master link
  • Deluxe Throttle Control, Grips and Cable
  • Brake Lever and Cable  
  • Deluxe Padded Seat
  • Hardware Kit
  • Low cost, High Quality, MADE-IN-USA
  • Rugged Construction
  • Ready to paint and assemble with basic hand tools
You will need to select a Clutch for your Mini Bike in Product Options above.
The 12 tooth clutch will give you a faster take off and lower gearing for climbing hills. The 13 tooth clutch will give you more top end speed
Engine Sold Separately. The Mini Bike Kit does not include an Engine unless you add one.

After adding this Mini Bike Kit to your cart, you must scroll down to add an engine.
All of the engines shown below fit this frame and have a throttle cable adapter setup for minibikes. Not just any engine will work on a Mini Bike

Note: California customers must use Stock engines only
Add a Chain Guard, Strongly Advised, in Product Options above
Add a Kickstand with weldable Mounting Bracket in Product Options above
add a kickstand   
Add Fenders in Product Options above. Select Plated or Paint Ready finish. installation requires drilling of the fenders. mounting screws not included
add fenders to your minibike  
GAS TANK: Most of the newer engines now have a larger gas tank and a much taller gas cap due to EPA requirements. On a Minibike, this can make it difficult or impossible to remove the gas cap. If you are ordering one of our minibike kits, the plasic top on the gas cap on the Titan engine can be removed for easier re-fueling. You may also install an external Minibike Gas Tank. Our 7 and 11" Cylindrical gas tanks can be mounted on the minibike or directly on the engine. The stock gas tank can be relocated and mounted on the frame in front of the seat using heavy duty zip ties. When using a Honda Engine, we recommend ordering the Low Profile Gas Cap if your going to use the stock Tank. The Predator Engine does not have a low profile gas cap. This is not an issue on a Gokart
 shown with a Titan engine, stage 1 with clone pipe, angled air filter and top plate.
Has everything you need. Easy-to-follow Instructions included.
No Welding, just basic tools. it's Fun!   Assembly Manual
This is an excellent project for you or your family. Not only does it help teach mechanical basics, but you can also have the fun of riding it after you have said
"I built it myself!"
The kit includes everything you need except an engine and clutch. Add a Clutch and other add-ons in Product Options above. Then scroll down to add an engine if you need one.
 No welding is required! Everything simply bolts together. The Frame & Forks come completely welded and are not painted, are made from thick-wall mild steel tubing.
 The engines shown below fit this frame and have throttle cable adapter setup for minibikes.
ENGINE INFO: Not just any engine can be used on a Go Kart or Minibike. The engines shown below are factory designed to be used on Go Karts or Minibikes
Lawn Mower and Utility Engines from other suppliers may cause you to have unwanted problems such as these:
  • They may not have the proper spring-loaded throttle return for the throttle cable
  • The crankshaft may be the wrong length and a standard clutch will not fit
  • The side cover may not have a standard bolt pattern for adding chain guards, Torque Converter kits, etc.
  • It may also be completely under-powered because of the RPM range of the engine
 add this minibike kit to your shopping cart above,
  then scroll down to add an Engine shown below (engine sold separately)

*minibike parts are sold as a novelty items, not for use on public roadways

THESE ARE PARTS ONLY. No representation is made regarding use of these parts for a specific purpose. Customer Assumes All Risk associated from using these parts or operating any device using these parts. Customer is responsible for any and all final design of application and use of these parts. Only persons with proper mechanical training should use these parts



Mini-bikes must be operated in accordance with all applicable laws and regulations and riders must comply with all require­ments regarding head, eye and body protection. Please check with appropriate government agencies before operating your mini-bike. Prior to any operation, all riders must be properly trained in, and fully knowledgeable of all mini-bike functions and safe operation and procedure. Full compliance with this with all information set forth in these guidelines is mandatory.FAILURE TO FULLY COMPLY IS UNSAFE AND COULD POSSIBLY RESULT IN SERIOUS INJURY OR DEATH.




Assembly should be performed by knowledgeable individuals using appropriate tools. Please consult with your retailer or a Kart or Mini-Bike shop or your local, knowledgeable mechanic if you experience problems with, or have questions about any portion of the assembly process, individual or overall function or operation whatsoever.

CAUTION! COMPRESSED AIR CAN BE DANGEROUS! ­Containment guards and eye protection should be used when inflating tires. Assemble tires and wheels with care. Never force a tire onto a wheel by prying against the wheel rim. A properly assembled tire will seat itself onto the wheel rim with less than 15 pounds per square inch (psi) of air pressure.



EVERYTHING INCLUDED: Frame, Fork, 5 in. Aluminum Wheels, Tires, Innertubes, Drum Brake , Brake Lever, Brake Cable, 60T Sprocket, #35 Chain, Throttle Controls, Padded Seat and all Hardware. Add Engine and Clutch to complete kit

Product Reviews

(11 Ratings, 5 Reviews) Average Rating:
great mini bike kit
Mark Gorman (GA) 5/2/2017 6:15 PM
I wanted to share the mini bike experience with my son. I had his attention from the moment the kit arrived. I had a few questions during the build, I called and spoke with Mario who was very knowledgeable. Instructions good but no photos.
great mini bike
Scott (Shingle Springs, CA) 8/6/2014 5:30 PM
great mini bike kite very easy to put togeather would recomend to every one thanks scott
Just wanted to express my appreciation to Lilly
Mark M (Hillsboro, OR) 8/6/2014 5:08 PM
Just wanted to express my appreciation to Lilly in the sales dept. I ordered a mini bike kit for my son, and am completely ignorant re: most things mechanical. (I'm likely to learn far more than he, as we assemble this!!) She was very patient and greatly helpful in walking me thru the on line ordering process. Thanks so much. Best regards, Mark
Hello! I'm from Russia
Dmitry (Russia) 8/6/2014 4:41 PM
Hello! I'm from Russia want to buy you doodlebug tell me how much shipping will cost and how long it will last. Dmitry, Order online and use PayPal, w will ship it FedEx no problem
We love this minibike
Rick Martin (Santa Monica, CA) 6/25/2013 4:18 PM
I bought one of those cheap minibikes from pep boys. It broke the first day and we could not get any parts. I returned it and bought this kit with an engine. It took us about 3 days to put together and ir runs and rides great. I had the full attention of both of my boys during the build and also when we ride. I just ordered another one so that 2 of us can ride together. This time I ordered the road rocket model with the larger wheels. These bikes are so much fun to ride we just love them. I had a minibike when I was a kid and now I'm re-living those years with my boys. Get this minibike!! Thanks


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Starter Package, Go Kart, Buggy, ATV, Pit Bike, Mini Bike
Part No:
LIST PRICE: $54.95
ENGINE OIL, ALL THE THINGS YOU WILL NEED TO SETUP A GO KART, PIT BIKE, UTV | Buy it here, or GET IT FREE with ENDURO Bike. (1) Add this Package to your cart. (2) Add the Vehicle to your Cart. (3) Enter Coupon Code STARTER at checkout to GET IT FREE!!
View Starter Package, Go Kart, Buggy, ATV, Pit Bike, Mini Bike
Stage 1 Kit, for Stock Carb, for Honda GX120/160/200, Titan & Predator
Part No:
LIST PRICE: $149.00
for Mini Bike or Go Kart, for STOCK CARBURETOR on your Honda GX120/160/200, Titan or Predator engine. Kit includes: Thru-the-Frame Fatty Exhaust Header, K&N Angled High Flow Air Filter, K&N Pre-Filter, Billet aluminum Intake Adapter, Decals MADE-IN-USA
View Stage 1 Kit, for Stock Carb, for Honda GX120/160/200, Titan & Predator
GX200 Hop-Up Kit, bolt-on Engine Upgrade for Honda GX160/200
Part No:
LIST PRICE: $249.95
Bolt-on Engine Upgrade Kit, bump-up to 11hp for your Honda GX120/160/200 (stock carb) engine including Titan and Predator Engines. Choose your Exhaust, Air Filter, K&N or Standard Angled High Flow Air Filter, K&N Pre-Filter, Intake Adapter + more
View GX200 Hop-Up Kit, bolt-on Engine Upgrade for Honda GX160/200
Spark Plug, AR3910X Honda GX120/160/200
Part No: GAR3910X
LIST PRICE: $12.00
The AR3910X spark plug is longer. This increases compression and can add as much as 3/4hp. A must have for your Honda GX120/160/200, Titan and Predator. Works great on our Titan Engines
View Spark Plug, AR3910X Honda GX120/160/200
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