Inheirited an ole Manco 2-seater... any do/don'ts?

[2SlickNick]

Great work!

 

[Half-breeder]

OK... here comes another fabrication/fusion(I swear Im gonna be done w/ this kart one day...!).

I have recently acquired a 250 Bayou. Ive stripped it, and evaluated my choices(was gonna make a 'trike' w/ it)... and have come up w/ fusing it to my kart.

To alleviate mount and clearance issues, Im planning on cutting the engine 'cage, and rearend mounts off the ATV frame(1 solid piece) and fusing it to the rear of Lo-T. I would remove my current GX200 and the rear axle... cut out the area needed to weld/fuse in the 'cage' frame. By doing this, Ill have a huge HP upgrade... 5 gears and reverse... a power supplying outlet... electric start(maybe)... a drive shaft vs a chain... a differential... and rear suspension. The now current 16" wheels will be the front wheels at that time, to prevent positive 'rake'(nose points down... butt sticks up).

... the draw backs... my rear wheel base becomes narrower by 4-5"... front to rear wheel base is lengthened more... about a 75-100lbs weight gain... tires will be alot more expensive(22x10-10)... no rear bumper... 3" added to ground clearance(total of 5-6")... stepping into the realms of 'buggy' vs 'kart'...

Any COMMENTS/suggestions/recommendations are welcome...




EDIT: Oh and the last vid of it w/ the rearend...
https://www.youtube.com/watch?v=acPzcgvbwBU

 

[Half-breeder]

Here is the frame which I shall be cutting the engine cage and rearend mounts...

This is the drive train(engine/drive shaft/differential axle) that will be cleared for the fusion...

... YEAP!!!! Its gotta reverse!!!

.... I wonder if this is a gravity fed engine(yes the tank 'was' above it)?!?!? And if so... wonder if my pulse pump will work on it?..... hmmm

 

[Half-breeder]

Last day w/ the GX200 rear...




https://www.youtube.com/watch?v=CGBk98F-m7s&feature=youtu.be

 

[Half-breeder]

I got a few hrs in the shop this morning for some cutting on the ATV frame(removing the nonessentials). Gonna scale photoshop these pics and see where I stand asfar as clearance. The long upper support bar, on Lo-T, is getting relocated to the top of the ATV frame(where the 'step down' is... where one's crotch would sit).

Speaking of sitting... an popped in my head as I was cutting... why not make the kart a 2 seater?!?! I would evidently sit in the driver seat and the passenger would sit in the ATV seat w/ their feet resting next to my upper arm area. Also would have a 'cover' to hide the seat to make it more presentably surprising to someone wanting to ride(not the neighbor kids). Id install OSG's... maybe a short sissy bar. Gonna have to see when I get 'that' far... unless someone talks me out of it.

 

[OzFab]

Wait, wasn't Lo-T already a 2 seater at one point?

 

[KartFab]

Pretty soon we will be saying.. Wait, didn't Lo-T used to be a go kart? I'm interested to see what you make of this, go kart.

 

[OzFab]

 

[Half-breeder]

Wait, wasn't Lo-T already a 2 seater at one point?

Yep... but I like symmetry... so putting the passenger in the back just 'seems' better... to me

.........................................................................................

I had to install seats into my wifes car today so I didnt get all that much done to Lo-T... but got a closer look at the ending approaching (sorry bout the shatty pics/vid, took em on the spur of the moment)...

First steps to gears..."

 

[Half-breeder]

Mock up...

Got 'placement' layed out today. Still gotta cut the old motor mount area... but for the 'most' part... this is about how she's gonna 'look'...


Mockup of steps towards gears.

 

[landuse]

That is going to be a beast when its done

 

[OzFab]

...& very loooong

 

[Young One With A Manco]

Turning circle?
Pshhhhh... Nah we dont need turning where we're going.

 

[Half-breeder]

...& very loooong

... yea, I didnt 'want' to add the extra length... but had to in order to incorporate the driveshaft and differential axle into the 'muck'. I was hoping to be able to make it into a chain driven, then I wouldnt of had to have done over 70% of the fab work Im having to calculate/do. But over all Id have to say she 'looks' mean as hellina hand basket, and will be the LAST engine upgrade Ill need(... knock on wood...). I will be adding a roll cage later after I finalize the build.

Ive all but mastered Ackermann... but I too have my inclinations of its turning performance. I KNOW itll be a wider circumference... just not knowing how much more... but Im guaranteeing that if anything... Ill be able to break traction and spin her butt around to shorten the turn .

 

[OzFab]

... and will be the LAST engine upgrade Ill need(... knock on wood...).

It probably didn't "need" this upgrade; needs & wants are totally different things

Im guaranteeing that if anything... Ill be able to break traction and spin her butt around to shorten the turn .

I was thinking along those lines too...

 

[Young One With A Manco]

I have 0% belief in the fact that this is the last upgrade...
It does look MEAN though. Those back tires are like dingo tires on a kart.

 

[Half-breeder]

Tonite I did # crunching, just to possibly find out what all im in store for w/ the KLF25-A1 vs. the modded GX200 and comparatively... the #'s are alil scary(but doable).

Power...
Max Torque 7.9Nm (1.83kg-f/m) @ 5500 rpm
Max Power Output 12kw(17hp)@ 7000 rpm

Gearing... (w/ 22" wheels/tires)
Gear Ratio 1st 2.923 =~16mph
Gear Ratio 2nd 1.684 =~27mph
Gear Ratio 3rd 1.173 =~39mph
Gear Ratio 4th 0.923 =~50mph
Gear Ratio 5th 0.785 =~58mph
Gear Ratio 6th Reverse 3.115 =~15mph

Plus, im just now thinking of the pain it's gonna be to strip her down for painting... GGGrrrrrr! oh well... hoping itll be worth it.

 

[itsid]

Uhm you mean 17.xx Nm right? 7 I don't believe; should be closer to 20 even,
17.3 would be at 7000rpm considering the torque curve.. I believe it peaks at 20-21Nm ...

Do you know by chance the primary, secondary and final reduction (crank:gearbox in, gearbox out:driveshaft and driveshaft:differential)

that way we could eventually get you a better guess at the speeds

'sid

 

[Half-breeder]

pulling info off this page...

Engine
Type Air Cooled 4 Stroke SOHC Single
Bore x Stroke 69 x 61 mm
Compression Ratio 8.9 : 1
Displacement 228 cc
No. of Valves 2
Firing Order 1
Valve Train OHV with Screw and locknut adjusters
Lubrication System Forced Lubrication, Wet Sump
Starting Electric and Recoil
Carburation Mikuni VM28SS
Carburation Main Jet 115
Carburation Idle Jet 30
Fuel Minimum Octane Rating 95
Pilot Screw Setting 1.5
Transmission
Gear Ratio 1st 2.923 (38/13)
Gear Ratio 2nd 1.684 (32/19)
Gear Ratio 3rd 1.173 (27/23)
Gear Ratio 4th 0.923 (24/26)
Gear Ratio 5th 0.785 (22/28)
Gear Ratio 6th Reverse 3.115 (27/13 x 33/22)
Clutch Type Automatic, Multi Disc, Wet
Final Drive Differential
Primary Drive Gear
Primary Drive Ratio 3.450 (69/20)
Gearchange Pattern R N 1 2 3 4 5
Transmission 5 Speed plus Reverse
Misc.
Motorcycle Style ATV
Colour Options Red
Frame Tubular, Double cradle
Power
Max Torque 7.9Nm (1.83kg-f/m) @ 5500 rpm
Max Power Output 12kw(17hp)@ 7000 rpm
Tyres
Front 21/8.00-9
Rear 22/10.00-10
Wheels
Front 9 x 6
Rear 10 x 8.5


All information is to the best of the Motorbike specs knowledge at the given time, the information is intended only as a guide.
A major japanese manufacturers quote:

We reserve the right to vary our specification with or without notice and at such time and in such manner as we think fit.

 

[MancoGX390]

Looks pretty cool but i would be a bit worried, your head being that close to a angry 250cc motor reving to 7000rpm but thats just me