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Old 09-17-2012, 09:31 PM
Kshannon17 Kshannon17 is offline
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Default 1996 YZ125 into KGB Shifter kart

Hey everyone.
A couple weeks ago my friend wrecked his 96 yz 125 and caused the cases to crack right at the swing arm motor mount. No fluid was leaking, and in the diagram, that mount is separated from any internal parts. Since I had been letting him store the bike in my garage, I told him that if he let me have the motor, I would sell the rest of the bike.
I replaced the base gasket, piston ring, head gaskets, and clutch and power valve gaskets and now I'm in the process of designing a motor mount.
I picked up a KGB 32mm shifter kart the other day, with a hand clutch, shifter, and brakes and it's all ready to go beside a motor mount and a fuel pump.
Any suggestions on the design? Any experience with this same motor? Please feel free to help out and give any suggestion, I would greatly Appreciate it!
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Old 09-18-2012, 03:47 AM
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First up, welcome to the forum.

Second, pics, pics & more pics It's gonna make it easier if we know exactly what we're looking at.

The simplest way is to cut the cradle out of the frame, your second option being copy the cradle while you still have it. Correct me if I'm wrong but, it's just 4 tabs welded to the frame is it not? If so, it should be simple enough to fab something up...
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Old 09-18-2012, 04:08 AM
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Welcome to the forum
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Old 09-18-2012, 09:01 AM
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Thank you for the welcomes and also the quick replies! I have a ton of pictures but I am always on this site through an iPad so it's difficult, I think? I will try to do it more later. Yes the mounting to the frame is just 4 tabs welded, 1 mount going through the swing arm, and another connected to the cylinder head underneath the gas tank. I bought some steel and have a design of how it might work and will post some pictures later.
I don't know much about these karts. I am not even sure if I paid a decent price for it? I did a lot of research but prices varied so much it's hard to tell. The kart looks like it has a lot high-quality parts on it like anodized EVERYTHING, black rims that have never been used, and an ITALKART hydraulic disc brake. I paid $500 for the kart, kart stand, extra sprockets, and a chain.
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Old 09-18-2012, 09:21 AM
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Quote:
Originally Posted by Kshannon17 View Post
Yes the mounting to the frame is just 4 tabs welded, 1 mount going through the swing arm, and another connected to the cylinder head underneath the gas tank.
Ewww, that means an overhead cage mount; that's gonna be fun . Why couldn't it have been an easy one with both mounts on the bottom of the engine

Quote:
Originally Posted by Kshannon17 View Post
I bought some steel and have a design of how it might work and will post some pictures later.
I don't know much about these karts. I am not even sure if I paid a decent price for it? I did a lot of research but prices varied so much it's hard to tell. The kart looks like it has a lot high-quality parts on it like anodized EVERYTHING, black rims that have never been used, and an ITALKART hydraulic disc brake. I paid $500 for the kart, kart stand, extra sprockets, and a chain.
It sure sound like you got a decent deal, won't really know until we see it... :biggrin5:
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Old 09-18-2012, 12:14 PM
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http://i1153.photobucket.com/albums/...905C62F648.jpg
http://i1153.photobucket.com/albums/...902DE4A07D.jpg
http://i1153.photobucket.com/albums/...90187B11BF.jpg
http://i1153.photobucket.com/albums/...90748CA3A7.jpg
Hope this works
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Old 09-18-2012, 02:22 PM
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I apologize if these appear more than once, im
trying to do all of this through mobile but this is the first time through a desktop.

Fabroman- What i meant was that there are a total of 4 motor mounts. 1 in the front of the engine under the exhaust, one in the middle of the engine on bottom, one that goes through the swingarm, and one that connects to the head. I was planning on only using the one in front, and the swingarm mount and leaving the other two empty.
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Old 09-18-2012, 04:37 PM
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I can't get pictures to appear on actual thread
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Old 09-18-2012, 05:02 PM
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Quote:
Originally Posted by Kshannon17 View Post
I can't get pictures to appear on actual thread
http://www.diygokarts.com/vb/showthread.php?t=736

here are instructions

welcome
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Old 09-18-2012, 10:04 PM
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Here is the kart along with the motor, the shifter is bent a little, but it was like that on the bike while it was running and we never had a problem with it shifting. Thank you for the uploading pictures advice though, I think it worked.
Attached Thumbnails
31AFBDF7-60E3-4137-8F02-F8EB1B01BADF-2259-000002FF1B08B2C7_zps7ad048d1.jpg   339A291A-F8C9-4B3E-9D37-4C8F42C5013D-2218-0000028FCA5A5405.jpg  

5AB75DFC-8BCA-45B7-9DE8-3B87C2B21EA4-2218-000002902DE4A07D.jpg   61240D37-7176-4CDE-89B3-1977EEF86483-2218-0000029039028D65.jpg  

EA7839C0-C1CC-4368-A111-88C6D388CEFF-2218-00000290187B11BF.jpg   46533BBA-4200-4043-B5ED-145103631D4B-2259-000002FF11E02BFC_zps13b25bbe.jpg  

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Old 09-18-2012, 11:43 PM
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Welcome to the forum Kshannon17!

Heres some YZ125 motor mounts made for racekarts like yours:
http://www.ebay.com/itm/125cc-Shifte...-/150707038673
http://sharkshifter.com/zc/index.php...index&cPath=76
Those say they're made to fit 97 and newer YZ125's, but you could prolly mod one or just build your own to fit.

You'll find all kinds of trick shifterkart parts avalible here:
http://sharkshifter.com/zc/index.php...index&cPath=76


There's some really good pics of a YZ125 bolted to a racekart style motor mount at this link:
http://www.ekartingnews.com/viewtopi...d46e5aaf5edc6d



Most shifter racekarts use a J-shaped shift levers like this pic below, but you might be able to just reinstall your stock shifter pointing upward, and then mod it so you could attach a shift linkage rod.:

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Old 09-19-2012, 06:36 AM
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I was thinking about that motor mount for a 97 but i can find any for less than $200.. I found a mount for a 2 stroke with 2 Burris clamps and a mounting plate. It was made of Steel I think so I could just weld onto that? As long as it was straight. I wonder how different 97 is from 96.. I've never seen anyone use anything pre 97 but I've also only been researching for the past 2 weeks or so. Thank you for the links tho. I've never seen that J shifter before. It's smart
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Old 09-19-2012, 06:53 PM
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@Fabroman, what do you think?
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Old 09-19-2012, 10:33 PM
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Quote:
Originally Posted by Kshannon17 View Post

I was thinking about that motor mount for a 97 but i can find any for less than $200.. I found a mount for a 2 stroke with 2 Burris clamps and a mounting plate. It was made of Steel I think so I could just weld onto that? As long as it was straight.

I wonder how different 97 is from 96.. I've never seen anyone use anything pre 97 but I've also only been researching for the past 2 weeks or so.

Thank you for the links tho.

I've never seen that J shifter before. It's smart
Yeah if you can get that steel mount for a good price, modding it to fit your engine might be the best solution.
Just make sure it fits your karts frame-rail spacing, here's some info about that:

What is the difference between International and American Rail?
The distance center to center between the two engine rails.
International Measures 3 5/8" and American Measures 3".
Almost all race karts are International whether they are made in the US or not.


Yeah I'm not sure what the mounting diference is between 96 & 97 either.

yer welcome.

Yeah those J-shifters are cool!
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Old 09-21-2012, 09:27 PM
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What is the best gear ratio to have on these? I think i have a 20 tooth sprocket on the rear right now. It doesnt matter whether its geared for top speed or for acceleration, im just more concerned with having it go and work for right now.
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Old 09-22-2012, 09:37 AM
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Quote:
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@Fabroman, what do you think?
I'm wondering what the two bars are on the front of the engine? If they're mouted to the engine securely, they can be used as mounting pints to the frame.

My best advice to you right now is listen to anderkart, He knows what he's talking about...
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Old 09-22-2012, 12:53 PM
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Those two bars are the start of my motor mount design lol
They are 1/4" steel from fleet farm. They are real stable though. I got the motor mount and the case welded where it was cracked. I'll put up some pictures later. Aluminum welding isn't cheap.. The guy at the shop up the street wanted $90 and kept saying he doesn't guarantee it will hold. The guy that did it knew what he was doing though. And was a lot cheaper
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Old 09-22-2012, 05:57 PM
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Those two bars are the start of my motor mount design lol
Awesome, That makes life a bit easier Now you just need to sort out the rear mount & you're almost there
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Old 09-22-2012, 08:26 PM
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What is th difference between a pump around system and a single inlet?
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Old 09-23-2012, 01:21 AM
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Quote:
Originally Posted by Kshannon17 View Post
What is the best gear ratio to have on these? I think i have a 20 tooth sprocket on the rear right now. It doesnt matter whether its geared for top speed or for acceleration, im just more concerned with having it go and work for right now.

Carefully count the teeth on your axle sprocket again, and let me know for sure.

I'll also need to know exactly how many teeth your engine-sprocket has?


_____________


You'll find Pump around system info here:--> http://sharkshifter.com/zc/index.php...roducts_id=108

With a single inlet fuel system you could save money and just use your stock carb with just 1 pulse fuel pump. This usually works out fine and costs much less. The only problem you might run into is a possible flooding issues from too much fuel pressure, because your carbs needle and seat valve is designed for the much lower fuel pressure of gravity-flow from the motorcycles fuel tank.

But If you did have flooding issues, you could always instal a return line from your fuel pump back to the fuel tank. This will lower the pressure reaching your carb and solve most flooding issues.


_______________


Heres a pic of my karts fuel return system:

I installed this:--> http://www.lawnmowerpros.com/detail....FQXhQgodVCAAKQ) fuel shut off valve In my return line, so I could adjust how much fuel returns, and regulate how much pressure reaches my carb.

I also installed a Marine primer bulb In my fuel pickup line so I could manually pump fuel through the pump and to the carb. This option was just added for easier starting:

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