my semi offroad kart

[redcali]

hi everyone, thought id post up some pictures of my project.

heres pictures of my project. from start to current.
this is how i got it 6 or so years ago. buried in a parents friends backyard. getting rid of it because they were moving house.

http://byfiles.storage.live.com/y1pLo28D_FRoF8oSSUOjBsLatTUdvN060SzGVimi5qDcGUlfrJ pFY1jLddzu_AUPwR9yj4lv3MLlKk


then i painted it and got newer wheels off our boat trailer. my dad changed the axles on the trailer to suit a bigger wheel. so i got 2 new wheels with almost new tyres. the wheels are off a mini cooper. 4 stud 11" i think. also picked up a second hand fibreglass kart seat.

http://byfiles.storage.live.com/y1pLo28D_FRoF9-U_QFwsPXDtZTaHFt9ZjS10QICw-cCfgx-fA9xyt-LwVQ7beAAoV0k0PU4C7QuC4

then i bought an engine for it. found this on ebay, thought it appropriate for power-weight ratio. i was younger then..

http://byfiles.storage.live.com/y1pLo28D_FRoF_czjXxRE4d0So5xRLP2oC9bhP2-C46xqqKe_RMOHHeaxqzN7jiMwFBol92SKQFFgs

then i neglected the go kart, after mounting the engine for about 5 years. it sat in the garage doing.. nothing..

then i got back into it! bought air filters, got around to sorting out the wiring loom, cutting what was un needed and keeping what was needed. daunting at first but not hard once you start and have a basic idea of whats going on! so now the whole thing is wired up and ready to start..

http://byfiles.storage.live.com/y1pLo28D_FRoF-a1-4yqzfHzMuIJfrCmbr73G9IpGtR_F2si8DJnphe5_UlsLnbgOty tys7DA5TFD0

http://byfiles.storage.live.com/y1pLo28D_FRoF923tfv1q0VVyrKm1pPgebiDWSAfg2bIDq1nIg __fSIAS4PCLtqozmK_D5rWTl0Qvg

http://byfiles.storage.live.com/y1pLo28D_FRoF_JGy7CZUjJe_Jc1wZm3VvUmW_-u4DAQoiFMCi_dc50bgiKyuQla3UAerH5LgmrmWk

the engine is a from a *1979-85 suzuki GSX400. its a 400cc 2 cylinder engine. im aware now but wasnt so aware when i was younger that this engine is way to much twice over for this kart and power/weight and looking at others karts and the engine sizes im fully aware this is gunna kill me but thats what makes it exciting:sleeping:

i didnt start it when i bought and hadnt started it for 6 years, so you can imagine how anxious i was to start it once i re wired it and got it all sorted. thankfully it started first go and ran a little rough, Blew a crapload of smoke for about 5 minutes but now runs decently.

now my list of things to do is far smaller than it used to be!

-brakes attached to the frame, its there but not in the photos ready to be attached.
-wire up the pedals. one will be accel one will be brake.
-connect up the gear lever.
-connect up the clutch.
-find a lengthened tacho cable to connect it up to the tacho and mount the tacho/gear position light in veiw from the seat.

the rest is small. i will try to keep everyone updated


i also have a pair; but only need one of genuine recaros out of one of my calibras which i may put into the car instead of the fibreglass seat.

any feedback is appreciated.:thumbsup:

cheers all,

[ironman]

one word---- wow!!!!!!!!!!!!!!!!!!!!!!!:2guns: !!!!!!!!!

[Jblankster]

2 words

CRAZY AWESOME!

i hope its fast!

[noley99]

That thing looks like a mini sprint car without the wing. Man that thing is gonna be insane fast.:thumbsup:

[noley99]

Oh yeah, I want it!!!!!

[crazycart]

That is very similar to the engine i have in my trike(in avatar)Yamaha 400 twin.Very strong engines.

[redcali]

That thing looks like a mini sprint car without the wing. Man that thing is gonna be insane fast.:thumbsup:

this is what i was told it was originally, the suspension set up also makes me beleive it is aswell as mounting points in the 'roof' for the massive wing on top. however i couldnt find any photos of sprint cars set up like this :(

yea the engine looks pretty much exactly like yours crazycart. standard the bike came with twin exhausts aswell, this one is aftermarket 2into1.

got some photos today, working on the carbi, thing revs way to high but i think it was just up tight, still needed a clean.
installed my 'dash' but when i changed gears it didnt change in order. went from neutral to 2, 3 then nothing. so im now worried about it.

also got a video or two of it running. however it runs rough!

[crazycart]

If you were changing gears while the engine was off, thats pretty normal,when i rebuilt the tranny in my trike i noticed the gears had to be spinning a bit to shift through all gears correctly.Also, on my bike it runs ALOT better with the stock exhaust and not straight pipes haha

[redcali]

hmm that makes me feel alot better. i know i didnt wire it up wrong, the dash is from a gsx 250 but it works out the same. i jsut had to extend the wires about a metre.

right now for exhaust, uncompleted i have both mufflers (completely different ones..) coming from the extractor that come out parrallel to the ground.


heres a picture of my drivetrain set up.
http://byfiles.storage.live.com/y1pLo28D_FRoF-W52o9Xw9txUyCj9cupI7UaqUcD0yFnkZcM8s-a8XwKRH5bIbds_JPELNLsEamCB4

http://byfiles.storage.live.com/y1pLo28D_FRoF_7am8QqY905yVa3lQki7rEzKNlfN_-MAAjvEiiVUFsrHw6XBJuT1ZS1gwIZUs-kAs
brake and driver are on the same axle so no burnouts :innocent:

the caliper is off the gsx400 that the motor came with and will be bolted or welded to the frame. still works after years of not being used :D

http://byfiles.storage.live.com/y1pLo28D_FRoF9Ac7Y3hNZ5zYAFRYBt6SWH7gTCft3imwNBSRM pf8B3yOiQ2RcP6plY6sDC9Ge_xx8

heres my 'dash' currently the only thing working is the neutral light and i hope the gear position light. the tacho is there but ofcourse the original cable is about 3 times to short. and i cannot find where it plugs in on the motor:mad2:
the speedo is aswell useless so i took it out, might jsut leave the space empty incase i find something to put in there or can make a speedo work. i also need to work out where the 'oil pressure switch' is so i can connect that light up.
http://byfiles.storage.live.com/y1pLo28D_FRoF-VTBGm3De2nOlyDmv1D-blt4lHHWoyuzgTSGIre1Wz2NZ7pIkPACq3fH--C930rnE

[crazycart]

On my bike the tach cable screws in on the top of the engine by the valves idk if that helps haha

[redcali]

yea thats where i keep looking but cannot find it. i can see the speedo cable though, unless its not the speedo cable and in fact the tacho cable point.

thats probably it then, because it is really short. where abouts does your speedo cable join to the engine?

[redcali]

thank you again :P it was the tacho cable mount. so now the tacho works except the cable is still short so i need to work that out.

found the oil pressure switch, wired it into the dash so now it works aswell.

dad and i did the exhaust today. so once we tighten the extracters on it should quieten down quite alot.

here is a video. if the first link doesnt take you there the second one should. ill try to upload one of it running quieter tomorrow with the better exhaust set up and extracter tightened!
http://www.youtube.com/watch?v=LAfZzIsXvak
http://www.youtube.com/wonderbred87

[speedy_moe]

now my list of things to do is far smaller than it used to be!

-brakes attached to the frame, its there but not in the photos ready to be attached.
-wire up the pedals. one will be accel one will be brake.
-connect up the gear lever.
-connect up the clutch.
-find a lengthened tacho cable to connect it up to the tacho and mount the tacho/gear position light in veiw from the seat.


I am wanting to do the same thing when I get the time to build mine. (Hopefully this summer when I send the wife and kids on vac.) I have one question for you. How and where are you planing to place the clutch. I was thing of putting mine on the shift handle. but I still have fully thought of where to place it.

[crazycart]

On my bike the speedo cable mounted to the front tire not the engine.

[redcali]

I am wanting to do the same thing when I get the time to build mine. (Hopefully this summer when I send the wife and kids on vac.) I have one question for you. How and where are you planing to place the clutch. I was thing of putting mine on the shift handle. but I still have fully thought of where to place it.

basically, because i really only need it to change out of nuetral or when i panic, i was thinking of leaving it as the original lever or get a bicycle 'V'brake as its far smaller and mount it somewhere on the right hand side in easy reach.

i still havnt fully thought through my pedal/gear setup yet. thats today and tomorrow hopefully:idea2:

[redcali]

my dad got the exhaust set up done today.

however one of the manifold/extracter bolts has been stripped in the head of the engine, not the bolt thread.
any suggestions on what i do to fix this?

http://byfiles.storage.live.com/y1pLo28D_FRoF-KRA-vCyUvM-_0uBo-I7RDKgJjPvwjndB8F4InZTx3wJjoOmLiKXMcdhznZz7eY3E
http://byfiles.storage.live.com/y1pLo28D_FRoF_zCydf_z7YYwOhSZua3iVz_aSpW6bdzBQWq2B cfmDjg-DfehzSgGYcOXjr1ozewIQ

spent most of the day on other things that needed doing unfortunately

[kibble]

Ooh! Nice!

About the stripped part. They have stuff in auto parts stores to fix stripped threads in holes. I don't know off the top of my head what it's called though. It comes with spring like coils and I think some sort of adhesive. I believe you have to drill it out a little bit or something and then you insert the coil into the hole and then you're able to use it like there was never anything wrong with it.

[jr dragster Tyler]

JB weld a threaded stud into it and use a nut.

[rockstomper]

Ooh! Nice!

About the stripped part. They have stuff in auto parts stores to fix stripped threads in holes. I don't know off the top of my head what it's called though. It comes with spring like coils and I think some sort of adhesive. I believe you have to drill it out a little bit or something and then you insert the coil into the hole and then you're able to use it like there was never anything wrong with it.

Heli-Coil inserts,you can get these at any good auto parts store they come in standard and metric sizes you just need to know what size bolt and thread pitch,just take it with you if your not sure.You can buy a kit,Mine is from grainger.

They also come with a drill bit and a special tool to install the coil.also there is a thing called a thread insert that looks like thishttp://images.grainger.com/images/products/small/SMALL-5JK76.JPG kinda works like a rivet and you can do this with a tool made for it or a bolt 2 nuts and a washer these are made to use in a spot were there is enough space like sheet metal or square tube,drill the right size hole put the insert in pull it tight instant threads.

inerts are great if you don't have enough material for the tap and die ie you get more threads with a thread insert

[redcali]

awesome thanks guys! i will talk to me dad about which option seems best!

[redcali]

a few newer photos.
accel pedal is in and almost set up. cracked my brake fluid resevior and a new one is more then i want to spend on something so simple so trying to work something better out at the moment so brake pedal is not done yet.

got the heli coil kit and ready to do it when i can be bothered! exhaust is set up etc. dash is almost mounted. its sitting a little low in the first pic then where it will in the end.

found a new tach cable, needs to be cut to length.
http://byfiles.storage.live.com/y1pLo28D_FRoF-gfL7QRvf21Gr3VdZb_hyAh6D9CRlcAufRIyBUMg7j5RVzYfgrd IGxaTMFlRkUoJg

this is the steering setup. its almost rack and pinion i guess. kind of cheap. needs a bit of a sand and re oil to make it a bit smoother.
http://byfiles.storage.live.com/y1pLo28D_FRoF_fGBlp2cSOdwPvcIvDm1QJV8r5fe9LEL9T2-0YoBrDhxFTbXVunNFvM_aV460mhbA
http://byfiles.storage.live.com/y1pLo28D_FRoF_uMsmXjsFSHqD45LNX1mcmPE8bH6DGwDM4kkY EkMQTOCfq_XtF5A6FaswQYcozjFM
http://byfiles.storage.live.com/y1pLo28D_FRoF_Pn0mPcdkehnv8VrskpGM2Pp2rZKetMsWcaSS MRrE0AzdB5wleTHatBBfKZQJA5eg

fuel tank does the job, shouldnt really need much bigger but might look for bigger in the future.

[robertdjung]

man that thing is cool. Can't wait to see vids!

[2or3wheels]

its gonna scream, does the motor still turn over?

[redcali]

yea mate kicks over easily now, idles really well. ill get a better vid later sometime.

[2or3wheels]

sweet

[redcali]

bit of a new look, 'bonnet' and sides covers.
and a video of it running


*Video of it running here!
its electric, push button start.

http://www.youtube.com/watch?v=p0Pv5ys6a3o

http://byfiles.storage.live.com/y1pLo28D_FRoF_hQBEe3oQ3uRi81u6Gad_AbqHsbxJPSqN17hV qz9_fxRvTRF7yMdHf4QRYtpf0r3c

[kibble]

Sounds Mean! Get a video of it going! :thumbsup:

[redcali]

man still need to attach the brake pedal and gear knob to actually change gears. and the steering wheel. hopefully this weekend!

[redcali]

bit of an update. stupid crap keeps taking longer than it should, but aiming for complete by this weekend. dunno if ill be able to get a video then but atleast ill get to drive it!

got lights, was aiming for nice ones but then i found some at my house so free is good for now! two smaller are wide angle. single at the top is a spot light for distance.
http://byfiles.storage.live.com/y1pLo28D_FRoF-gNqkDupbCYknNrisnnsojxf5pff0F_O8VBJQ2taLaYTM8D3fUZ ExGBvjX_IppUe4

http://byfiles.storage.live.com/y1pLo28D_FRoF9mtpB-8GeLPpOnMeIiYGOwYIhVOc873291MomVP_8TDPdeGG-CHS3ViujuJYEzOl0

http://byfiles.storage.live.com/y1pLo28D_FRoF8FHZkwupSVwATNZH8wzi6TSZkuvWE3K8MmRRV 0rgU8JO4zUx0CScllFYLTBzH4u8k

wired the dash so that, when the lights are on the high beam indicator is on and the dash lights too.
in the top right of the photo the lights are on, top light is high beam, bottom is neutral indicator and the light off is the oil pressure light.

http://byfiles.storage.live.com/y1pLo28D_FRoF8Xv-fnv5RF9KiyNm9EXPUpNmZYwD8dOYK2BZlcytNn0lU_yxUua41y BMw-ZwV5ED0

also got the steering wheel in. the kart inside is tight and getting in is difficult and almost impossible for anyone of a decent size with the steering wheel in, so we fashioned a 'boss kit' so it can be removed for easier in/out.

http://byfiles.storage.live.com/y1pLo28D_FRoF_wrkfUf1Nxsa5DmkPJR6k63yvLrXl_zckMyLV XvVH4uqCZQPplJxuIgSz_o6Hd0JU
http://byfiles.storage.live.com/y1pLo28D_FRoF_8yav3AZriU5Yt7tWy1uKE8fDTkzdC_92udaN xSMDIylKwrvJAC38BZN6JAknJT0A

[kibble]

Just my .02, but wouldn't it have looked a little more even if you had put the top light in the middle?

[redcali]

hah yea but the top bar is round and think and drilling through was to much effort.

in between the other 2 lights and it is in the way. with it mounted there, if i buy a set of lights ill remove it and put the pair there and on the opposite sides. right now aesthetics is not a priority :P the mufflers are two diff colours and shapes :D

[kibble]

LOL I hear you.

[redcali]

well today took alot longer to sort out the gear setup then expected. its hard to get a bit of metal to go that far and not flex with the push to gear up/down.

also having alot of trouble deciphering how the gearing actually works.

also, having heaps on trouble finding a sealant that is brake fluid proof. found loctite 3 is supposably brake fluid proof but it has been setting for 2 days and is still sticky and can be wiped off with turps.

anyway with this days from completion im already looking at gokart frames:idea2: looking at proper track kart frames though and looking into keepng it somewhat track viable.

[kibble]

What is Loctite 3? :confused:

[redcali]

well loctite is just the company brand, a branch of 'henkel' it appears and loctite is the aus face of it.
http://www.loctite.com.au/int_henkel/loctite_au/index.cfm

i cant find any info on it for loctite 3 though which is one of there many products.

[kibble]

Well, yeah, I know what Loctite is, I was wondering about the "3".

All I could find was "Loctite 3-ounce" but nothing about just what "3" was. What is it for? Is it like a threadlocker?

[ironman]

that is the maximun strengh

[redcali]

oh right. yea it is the maximum one, it is more a gasket sealant i think. ill get a photo of the label.

[I like karts]

im aware now but wasnt so aware when i was younger that this engine is way to much twice over for this kart and power/weight and looking at others karts and the engine sizes im fully aware this is gunna kill me but thats what makes it exciting


There is no such thing as too much power.