My Off-Road Kart Project

[Marks Kart]

This kart started out as a concession kart from a local track that went out of business. When I purchased the kart it was not running and needed the tires replaced, seat recovered and tank/carb cleaned. The motor was a GX160 with a wet clutch gearbox and single wheel belt drive. After the repairs my kids ran it that way for a few years, it was OK for street and yard use but not trail use. Well after rebuilding a basket case all-terrain kart and installing a Comet CVT clutch (TAV2) I found that the at-kart could pull some large hills and had plenty of torque. My thoughts were to convert the concession kart to an off road kart. After kart swap meets and searching kart web sites I found all the parts needed for the conversion. The pictures I posted tell the story, but the GX160 needed a rework that involved turning the crank down and welding an extension on to accept the TAV2 converter. A complete rear end with disk brakes and new tires and roll cage/brush bar were installed. You can see from the pic's the finished kart with the GX160. I ran it that way for about a year, running alot of ATV trails and the kart ran and pulled great. But I wanted electric start type setup, so the GX160 was replaced with a tuned Tecumseh 12 HP and adapted the TAV2 onto it. I know that the TAV2 is not rated for motors larger than 8 HP, but it runs great with the original belt. The kart has alot of low end torque and a top speed approaching 50 mph. I'm presently 3D modeling a complete new kart with full suspension, molded type seat, steering dampening and the list goes on. I will post those pic's in the future. :thumbsup:

[kibble]

W...O...W!!!

That machine is awesome! Oh BTW, welcome to the site! That's the kinda stuff we like to see!:thumbsup:

So you welded onto the crank and machined it to make it longer? That's some great work you did there!

[gocartkid]

COOL KART THERE!!! Nice work!!! :drool5:

[ironman]

very nice setup like the cart and can see you have a nice garage setup ......

[THE_REAL_RAT_FINK]

I love those wheels! Great Kart man!

[2or3wheels]

speechless

[Pa and Corby]

Nice kart, I have a 3203 Yerf dog with a series 30 Tav, and was looking at replaecing the 6.5 tec with a larger motor! just wandered how your tav is holding up to that many ponies? have u made any adjustments to the tav? dif.spring or spring setting?

[Marks Kart]

Thanks for all the nice comments, I'll post pic's when I start building my new kart. Pa and Corby, I changed only the "driven" pully spring tension to the next higher number which came set on #1. By increasing the spring tension the unit stays in a lower range for pulling hilly terrain conditions. The pully belt seams to be holding up very well but I do clean and relube the "driver" pully with comet dry lube GP-730A after two runs..... Mark

[kibble]

Thanks for all the nice comments, I'll post pic's when I start building my new kart.

Well, come on dude! You came in with your guns blazing. :2guns: What else what we supposed to do? Insult you? :furious2:

LOL, jk. That is a really nice kart though.

[robertdjung]

yup, that's a nice setup. when you've got the time I'd like to know a little more about the rear end source, and maybe some more pics of the front end / steering. Looks really great.

[Sam.s.94]

wow thats a nice machine, where can i find some wheels like that , or can wheels be painted to give that finish ?

[landy mad luke]

Well, i wish my kart looked like that!! you have built a cracker :drool5: :thumbsup:

[jr dragster Tyler]

Well it's good to hear from somone that a TAV2 30 can handle some good pony's. So it should hold up to my racing clone engine I just built.

[plankton]

nice work men!
i like the dashboard

[g racer]

hey what size sroket u got on thoes wheels

[Marks Kart]

The Comet Torq-A-Verter has a 10 tooth (#41 chain) to 54 tooth on axle. The rear tire rolling dia. is 54" and the motor approx top end is 4600 rpm (tach reading). The Comet Torq-A-Verter produces a overdrive condition at top rpm so the approx. speed is 45 mph. Thanks again for the comments..............Mark

[r_chez_08]

your kart is sooooo nice.... im jealous.

[r_chez_08]

what size wheels are they.

[Marks Kart]

Added hyd. rear brake caliper assembly from Kawasaki 636R..........Mark