Engine upgrade on a Manco Fox Conquest

[Bustabr]

Hi everybody!

I am new to the forum and this is my first post. I bought a Manco Go kart fox conquest. It comes with a 5hp Subaru 126 cc engine and belt driven with a comet 20 series clutch.

The engine is on it's last leg and I figured I could swap out the engine and upgrade if possible.

What options should I explore? I can get a brand new honda gx240 8hp engine (from my neighbor for only $125 brand New sitting in his garage collecting dust) but I think I may have to change the clutch and pulley?

Or I could pickup a clone predator engine that is 212 cc 6.5 hp. I believe no modifications are needed.

Before you answer I want to take this little buggy to a dirt course and let my son have some fun.

What engine should I go for?

I want to spend the least amount of money and minimum fabrication.

Thanks in advance for your advice!

 

[firemanjim]

Least amount of money...... You should still go for the 8hp..... And a comet 30series clutch kit. Or the cheaper tav2 off ebay. The 20 series is only gonna hold up to so much. Being that you want to play in the dirt, the 30 series will be better for you in the long run. You can get that 8hp and a tav2 for right at $250, combined..... Then bolt it up and go have fun..... Sell the complete engine/drive system you have, to recoup some of the money. Or build a small, lightweight, street kart for it. Have the best of both worlds.... Fast street kart, and a rockin rough rider kart.....
to the forum.
EDIT only reason you would HAVE to change clutches is if the 8hp has a 1" shaft versus a 3/4" shaft, like the engine you currently have.....

 

[Bustabr]

I gotcha Firemanjim, go with the horsepower upgrade and clutch upgrade.

The only issue are dimensions of a gx240 8hp wont bolt right up to existing. I am no fabricator. Not a welder. Thats my problem.

 

[firemanjim]

Redrill the holes in the plate you have now, if possible. Drill the holes on each end of the slot. Then cut the center out with a die grinder.
You can buy a new mounting plate already made fairly cheap. It would not cost you much at all, to take it to the local muffler shop and get it welded on. Like $10-$15...... If that.....
Cut off the existing one, carefully, not to cut the frame work. Grind it all down smooth and pretty. Mount the plate on to the engine, with it being in the center of the slots. Now put the engine down where it needs to be, on the frame, in order to work correctly. Now clamp down the plate with what ever you got. Just make sure it don't move. (or do this part in the parking lot of the shop) ....... You can see where I'm going with this, so I won't go on.....
You don't have to be a master fabricator with expensive fancy tools. You just need to be brave enough to let your creativity take over. Don't be afraid to think outside the box. Don't be afraid to ask for advice. That's why we are here..... We might have already done what you're trying to do, so we can give you some insight and guidance along the way.....
Something, what kind of building/wrenching history do you have. It will help us to help you, to know a little more. What kind of tools do you have or are at your disposal?........

EDIT and I would go with the 8 hp and 40 series personally. Then hop up the 8hp to put out in the 13-14 hp range....... Let's you gear it a little higher, but have the power to pull it through, with no problem......

 

[firemanjim]

http://www.ebay.com/itm/1-40-SERIES...5A-/231205667264?ssPageName=ADME:L:OC:US:3160
Check that out! Not bad.......

(I know , I know....... I double posted...... )

 

[OzFab]

Quite simply, the cheapest, simplesy option would be a new Predator (straight swap) but, think how much fun the GX240 would be; maybe you could get it for the future...

 

[landuse]

http://www.ebay.com/itm/1-40-SERIES...5A-/231205667264?ssPageName=ADME:L:OC:US:3160
Check that out! Not bad.......

(I know , I know....... I double posted...... )

That sounds like a steal....

 

[Bustabr]

Wow, thanks FiremanJim. You are really hyping me up. You are making me believe that I am really overthinking this and I could do this. By the way, I have 0 experience with metal work. Although I did take wood shop in High School.

Sounds like fun either way I go. I think there are more upgrade parts for the smaller 212cc predator engine.

But I think if I start already at 8hp and take out the governor and add the tav2 from comet or any other off brand torque converter I should get more than enough power for my son who is 12 years old and 120lbs.

Even if he takes his sister (younger about 70 lbs). He should still have enough power to go around in the dirt and some really small hills here in Florida.

FABROMAN, you are right. it is the cheapest solution to just bolt the predator engine on. So torn cause I am so cheap. If I mess up taking out the governor on a HF predator engine, I could just take it back and exchange it. But if I get my neighbors honda gx240 and messup...NO REFUNDS!!

Here is a pic of this little thing. Its not mine just for reference. Mine looks exactly the same and as you can see it doesnt really have the suspension setup of the new karts with the gy6 150cc engines.

My son will love it anyways.

THANKS EVERYBODY FOR THE ADVICE!!

 

[firemanjim]

You can do it.... Plain and simple. You just got to get past that "hump of doubt" that most people carry. It's not difficult, and we are here to help you do it. That's what we are about.....
Now first things first..... You need to see what size shaft your neighbors engine is. That's going to be the biggest factor in your decision. Ideally, it would have a 3/4" shaft, letting you use a tav2. You're looking at just over $200 ($225ish) together. If its a 1" shaft, then you're looking at $275 for engine and the 40series set. In the long run, you will be better off with the latter, for a couple reasons.... IMHO
First, we (some of y'all ) spend a $100 to get 10+hp out a $125 hf engine. Your neighbors is already at 8hp and can get 10 for next to nothing...... That's a win.... Since its only $125 to start with.....
Second, it has a lot of torque,already on tap. You can run a lot wider ratio range..... You have the power to pull it.....
If it has a 1" shaft, you're gonna need the 40series. Cool..... It's stronger, and more suited for the rigors of off road....... Didn't you say you'd be going off road with this thing?.........

 

[OzFab]

IIRC, GX240 & up are big block so, it'll be a 1" shaft but, I wouldn't hurt to check...

Jim is absolutely correct there, my biggest concern was the price of a 40 series TC...

On the subject of "you can do it", have a quick look at this thread; the cliff notes version is landuse (one of our mods) had never even cracked an engine open &, with our help & guidance, he totally rebuilt a monster of an engine...

 

[landuse]

IIRC, GX240 & up are big block so, it'll be a 1" shaft but, I wouldn't hurt to check...

Jim is absolutely correct there, my biggest concern was the price of a 40 series TC...

On the subject of "you can do it", have a quick look at this thread; the cliff notes version is landuse (one of our mods) had never even cracked an engine open &, with our help & guidance, he totally rebuilt a monster of an engine...

He he. And I sold it for 4 times what i paid for it

 

[Denny]

You could check with Supermannatorious and see what kind of deal he may give you on clutches.
( I'm not affiliated with him in any way.)

Denny