Got a kart, but with a few problems.

[Nodroz]

Hello guys,

Yesterday I got a kart which I bought for $75. It has a 100cc engine from Ital System, 2 stroke. I have never heard of that engine before. It's also quite hard to find any information about it.

The kart is direct drive; there is no clutch involved. A friend pulls you in the kart and then when you're lucky, the engine will start up. Once you completely stop, the engine will shutdown.

Ok so at first I look at the engine. I removed the air filter and the carb looked really clean inside. Looks like people took care of this kart.

Things I did:

1.
Got the spark plug out and checked it for a spark. When cranking the engine a few times I saw a bright spark - that's ok.

2.
There is no fuel tank connected yet, (that was the only thing mission) so I just put a few drops of fuel directly into the combustion chamber.

3.
Raised the kart off the ground and got a rope around the rear tire. Pulled as hard as I can to get any movement, but the compression was too hard, I couldn't get any smooth movement in it.

4.
Got my dad to push me whilst I'm in the kart. Even my dad had it hard to puch me forward because the compression is way too much.

5.
Got another friend to push me, together with my dad. Finally we overwon the compression and I got some speed, yet the engine didn't want to start for a few secs.

Is it normal that's it's so hard to get the kart running? The compression seems VERY high.


Next problem:
The brake; I opened one of the hydrauli lines, but there wasn't any fluid coming out. How do I refill it again? And with what? Also, the 2 brakes are locked together. Is it normal that when there's no fluid in the lines, the brakes automatically lock the axle?


Here are a few pics:

I hope somebody can answer my questions.
Nodroz

 

[fourtogo]

On the brakes the cap need to be on while bleeding system, you will get zero peddle build up . For starting it's ether a quick snap over of the rear tire off the ground . Or A run and jump start deal . It takes two to do the run and jump start. One in front steering and on in back lefting bumper off ground all the while running and then drop to pavement and Wala it starts or you just run out of pushing gas. Or your dad has a heart attack LoL . and it can be done with nylon strap rapped around tire also. DO NOT USE A TIE DOWN . STRAP, USE A BEAR STRAP ONLY NO HOOKS NO RATCHET. Question where you burning rubber away from sellers house after you handed him the cash!!! . On the brakes they sell a tank and valve set up that screws on top on Master Cylinder for brake bleeds. Dry brakes is very normal, brake fluid evaporate while kart sits . You my friend got heck of a lot of racing Kart for just $75 . I would get it running smooth, and then do a full clean up. Take the master cylinder apart for a clean up reassem do the same on rear all so . Then do brake bleed .

 

[fourtogo]

PS this kart has had a water cooled engine on it at one time > see alum pulley in middle of axle<. That is for water pump drive belt.

 

[fourtogo]

Fuel tanks are cheap check with seventh/gear/karting for used stuff . Or go on Bobs4cycle.com for used stuff all so. and Ekarting news

 

[fourtogo]

I reread your post a few drops of gas is not going to get it pop or start. you need a fuel tank.That type of carb has a fuel pump built in to it and it works on vacuum and engine pulses

 

[Nodroz]

Thanks for your replied, fourtogo.

I will get a fuel tank. I will try to open up the master cilinder cap and see how everything looks there. Is there anything I need to know before doing that? I have zero experience with these fluid brakes.

Btw, why can't I use a rope?

 

[fourtogo]

Starting

Thanks for your replied, fourtogo.

I will get a fuel tank. I will try to open up the master cilinder cap and see how everything looks there. Is there anything I need to know before doing that? I have zero experience with these fluid brakes.

Btw, why can't I use a rope?

A rope will work . A strap has more surface area >more grip< . Thing is with Kart brakes are a bit different the car brakes . You can't pressurize brake system with out Master Cylinder being capped . And it will drain quickly during bleed cycle . A pump and half or so and empty . That is why the tank and valve set up work great . A spent three days messing with the brakes >four wheel set up< before I bought bleed tank system . Any racers around your area would have this tool . No snakes are going to jump out from under the cap LoL Bahaha . To help with bleed lift the rear of the kart higher the master cylinder . this help air pocket/bubbles flow to bleeder on caliper. if it mushy the next day i tear down the brakes and look for galling and Corrosion In side of caliper and master cylinder. And believe me once you get it running you will say just a little nip around the block . And before you know it brake peddle will be on the floor and >NO BRAKES< on MR TOADS WILD RIDE. Done it didn't like it, but got real close look at moving cars bumper. and still made it back to drive way. Brakes first power second . You still got a >STEAL< even with having to spend a couple bucks getting it running

 

[mysteryboy28]

are those unopened bottles of beer?

 

[Nodroz]

are those unopened bottles of beer?

Hehe, you got it right. There nothing better than a little beer while working on your gokart.

I'll look at the brakes tomorrow. I'll post some more detailed photos also.

 

[Nodroz]

Hello guys,

I opened the caliper today. I think the "pistons?" are locked. They don't want to move at all? Is this normal? How to repair this?
Here are some pictures:

Regards,
Nodroz

 

[Doc Sprocket]

You should be able to press those pistons back into the bores with a large C-clamp. If the pistons refuse to engage the rotor even after bleeding properly, then you'll have to disassemble them.

To do so, remove the caliper again, remove the pads, and place a rag between the pistons. Use compressed air in the fluid inlet fitting to drive the pistons out. If the air doesn't do it, you may have to use the hydraulic pressure to do it. Just be careful- there's a lot of force involved.

 

[Nodroz]

You should be able to press those pistons back into the bores with a large C-clamp. If the pistons refuse to engage the rotor even after bleeding properly, then you'll have to disassemble them.

To do so, remove the caliper again, remove the pads, and place a rag between the pistons. Use compressed air in the fluid inlet fitting to drive the pistons out. If the air doesn't do it, you may have to use the hydraulic pressure to do it. Just be careful- there's a lot of force involved.

Thanks for your answer.
I got the pistons back in their normal position using a C-clamp. I've disconnected the 2 lines from the calipers. I looked inside and there was a lot of dirt / rust / particles inside.
The calipers are being soaked in gasoline at the moment. I'll also soak the pistons in some WD-40, to get them loss because once I pressed them back in, they don't want to come back out.

 

[anderkart]

If you need any parts for your caliper, this shop is the Mach 1 kart dealer in Belgium:

Wullus Racing
Jeff Wullus
Moeskroenstraat 659
8930 Rekkem
Tel. +32 (0) 56 / 415868
jeffwullusracing@telenet.be


I think your engine might be one of the older PCR reed valve models.
Does it have any other letters or numbers to help us Identify it?

This site has some pics/info that might help:
http://www.agskartparts.com.au/historic-kart-engines

 

[Nodroz]

If you need any parts for your caliper, this shop is the Mach 1 kart dealer in Belgium:

Wullus Racing
Jeff Wullus
Moeskroenstraat 659
8930 Rekkem
Tel. +32 (0) 56 / 415868
jeffwullusracing@telenet.be


I think your engine might be one of the older PCR reed valve models.
Does it have any other letters or numbers to help us Identify it?

This site has some pics/info that might help:
http://www.agskartparts.com.au/historic-kart-engines

Rekkem is like almost a 2 hour drive. A bit far...

On the side of the engine, on the cooling fins it says: Ital System. I'll see if I can find some more information.

 

[Nodroz]

Alright guys!

I soaked the pistons of the caliper in WD-40 for a whole night. The next day only 1 came lose. Then with a special product (which I don't know the name of) my neighbour got the other one lose.

When installing the caliper again, I noticed the piston from the master cilinder was blocked. I put it in an ultra high Hz bath. The spring and the piston came lose without doing anything

Installed everything again, filled with oil and got the air out (I hope). Called my brother and dad and we were ready for a drive. We lifted the kart and walked 100 meter to some flat nice asphalt road where nobody lives, except a little museum.

My brother and dad started pushing me, meanwhile I was choking a bit to get the fuel into the carburetor. Suddenly, the engine startede right away! And gone I was!

50 meters later, whilst I was passing the museum, the guy shouted out his window that he will call the police... end of the story. We went back home. On Sunday, all shops are closed, so we're going to some nice parking lot.

 

[Doc Sprocket]

I put it in an ultra high Hz bath. The spring and the piston came lose without doing anything

You have access to an ultrasonic tank? Nice!

 

[OzFab]

Install everything again, filled with oil and got the air out (I hope).

By "oil" I hope you mean brake fluid.

 

[landuse]

Suddenly, the engine started right away! And gone I was!

Yes you were!! I am glad you got the brakes sorted out. I assume that you bled the brakes well enough if you were confident to ride the kart? Did the brakes work OK?

I hate it when people spoil your innocent fun. I have a lady a few doors down that glares at us when we bring any of our toys out the gate

 

[Nodroz]

You have access to an ultrasonic tank? Nice!

Yeap. That thing is just awesome for cleaning carbs and stuff like this!

By "oil" I hope you mean brake fluid.

Yeah, brake fluid.

Yes you were!! I am glad you got the brakes sorted out. I assume that you bled the brakes well enough if you were confident to ride the kart? Did the brakes work OK?

I hate it when people spoil your innocent fun. I have a lady a few doors down that glares at us when we bring any of our toys out the gate

I bled the brakes good enough. As soon the engine started I tested the brakes. Pressed my foot on the pedal and the tires inmediatelly locked and I was slipping along the road.

 

[Nodroz]

Could somebody help me finding more information about this engine?
On the side it says Ital System. Can't find much more information on the engine itself.