In this episode of Weekend Mechanic, host Bruce Bonebrake continues the go-kart project begun in the previous episode. With the wheels, tires, steering components and braking components already installed, the second phase of this project includes installation of the engine, clutch, chain, throttle assembly and seat. DIY Difficulty Rating for Repair: Provided that you're starting with a kit, ssembling a go-kart is not a difficult project for the novice mechanic, but it can be time consuming. Because there are a number of stages to the project, and to ensure that we do a good job, we allotted two weekends for this project, working about 12 hours per weekend. We give the job a difficulty rating of 2 on a 5-point intermediate-level scale. Important: Included below are the steps in this mechanical project as shown in the episode. These steps are general guidelines that are applicable to most go-kart assemblies. With any particular model, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. Always consult your owner's manual when undertaking a project of this type. In addition to standard auto-mechanic's tools, specialty tools that will be helpful for this project include an air compressor and a set of air ratchets and sockets. If you don't own air tools, you can rent them from most equipment-rental centers. Go-kart kits vary in terms of complexity and how much of the work you may be required to do yourself. With some kits, you may even be required to weld the frame. The go-kart kit we selected for our project comes with a pre-made, pre-painted frame, engine, clutch and all of the other elements needed for assembly. This particular kit costs around $1000.
Installing the Engine and Clutch
- There were several available engine modelss that were suitable for this particular kart. We opted for a 5-horsepower engine, capable of powering the kart at speeds up to about 30 mph. This engine comes without a clutch already installed. The clutch is purchased and installed separately. Installing the clutch yourself will save you money in the go-kart project.
- The engine rests on the engine mounting plate (figure A), and is bolted in position through four slotted mounting holes in the plate. The holes are slotted so that the engine position can be shifted forward or backward to adjust the tension on the chain, which will be installed in a later step.
- Secure the engine to the mount using the provided mounting bolts and nylon lock-nuts. The bolts extend up through the bottom of the plate and engine. When installing the nuts, make certain that the nylon side of the nut is facing away from the threads of the bolt (figure B). Install all four bolts and nuts, but don't tighten the nuts down yet. The engine will need to slide forward and backward for chain adjustment.
- The next step is to install the clutch. Note that the clutch assembly has a front and back that are not interchangeable. The front side (figure C) has clutch-sprockets while the back (figure D) has key that installs in slot and holds the clutch in position on the engine Two set-screws help secure the clutch to the crankshaft.
- Align the key on the clutch with the key-way on the crankshaft, and make sure that the clutch is seated firmly against the crankshaft plate (figure E).
- Fasten the clutch using the provided bolt and flat-washer (figure F).
- Tighten the bolt securely using the appropriate socket.
- Tip: It's a good idea to oil the clutch after each use.
Installing the Chain
- The chain installs on the sprocket and comes already cut to length. It is formed into a complete loop using a master link.
- Place the chain on the lower sprocket, and bring the end up over the clutch sprocket.
- Where the two ends of the chain (figure G), the ends are fastened using a master link which is secured using a tiny link-washer and link-clip (figure H).
- Fasten the two ends together at the master link, install the washer, and the clip. Use needle-nose pliers to make sure that the clips snaps completely into place (figure I) to secure the master link.
- This competes the installation of the chain (figure J). If the chain ever needs to be removed from the kart, the clip can be removed so that the two ends can be disconnected.
- With the chain installed, check to make certain that the top and bottom sprockets are aligned with each other (figure K).
- Once the sprockets line up, and the chain is straight up-and-down, mark the location of the lower sprocket on the axle, then install the key provided to secure the lower sprocket to the axle shaft (figure L). Use a hammer and pin to tap the key in as far as it will go.
In the segment that follows, the chain and rear axle are adjusted.
RESOURCES :
The Haynes Small Engine Repair Manual
ISBN: 1850106665
Author: Curt Choate, John H. Haynes
Haynes Publishing Group
Chilton's Small Engine Repair Up to 20 Hp
Model: 0801983258
Author: Kerry A. Freeman
Nichols Publishing
Small Gas Engine Repair
Model: 0830641424
Author: Paul "How to Troubleshoot" Dempsey
Go-Kart Racing Chassis Setup
Model: 0960506845
Author: Brian Martin
Martin Motorsports Pub. Co.
International Karting Industry Buyer's Guide
Model: 0966146743
Author: Darrell E. Sitarz
Kart Marketing Association of America
Gokartparts.com
gokartparts.com
Dorchester, WI 54425
Fax: 800-294-4144
Email: sales@mfgsupply.com
Website: www.gokartparts.com
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