Introduction Go-karts have been around since the 1950s providing a source of fun for the young, and for kids of all ages. In this episode of Weekend Mechanic, host Bruce Bonebrake shows you how to assemble a go-kart from a kit. Building a go-kart from a kit is a relatively straightforward project for the weekend mechanic. There are racing go-karts that can reach speeds of 100 mph. For our project, we undertake a more modest variation on these mini-vehicles: a "yard kart" built for top speeds of around 30 mph.
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 (figure A). 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 (figure B) 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.
Wheels and Tires
- We begin working on the front end. The first step is to install the spindles. Our kit came with nylon bushings that slip into the housing to prevent metal-to-metal contact. Install the spindle with the bolt pointing down (figure C), as a safety measure in case the retaining nuts should ever come loose.
- Assemble the wheels and tires. The front tires on this model are less knobby than the ones for the rear. Insert the tube into the tire (figure D).
- Next, install the split wheel making certain that the half with the valve-stem notch is installed so that the stem can pass through it (figure E).
- Bolt the two halves of the wheel together.
Important: Use caution not to pinch the tube when you install the two halves of the wheel.
- Repeat the steps for the other wheels.
- With the wheels assembled, inflate the tires (figure F). This is a two step process. Begin by putting in just enough air to remove any wrinkles. Check the inflation specs in your manual for the proper tire inflation, and fill the tires accordingly. For ours, the proper pressure is 15 psi.
- To prepare for installing the tire on the kart frame, install the spindle spacer onto the spindles (figure G). The spacers separate the wheel assembly from the spindle's knuckle to prevent wearing. The front wheels of this cart have sealed bearings built in, so they never need to be greased.
- The bearings ride on the spindle. Install the wheel so that the inside bearing rests against the spacer (figure H).
- Secure the wheel with the lock-nut provided (figure I). Lock-nuts have nylon rings that hold secure against the threads once tightened. Lock-nuts are used on much of the go-kart assembly since they are less prone to come loose under vibration. For this nut, the nut is tightened all the way, then backed off 1/8 of a turn to properly set the threads.
In the segment that follows, the steering components and rear-axle bearings are installed.
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
| 
)
)
)
)
)
)
)
)
)
)
