Need setup advice

[BrownStainRacing]

Here's another 1, it doesnt say how far it moves side to side. I'm liking this idea better. You might have to mock up the axel, sprocket, and turn the clutch around and see how far outta wack the sprockets are.

Universal Engine Mount Plate For Mini Bike Go Kart Doodlebug DB30 Coleman KT196 | eBay

Custom light weight aluminum engine mount made out of 6061-T6 aluminum alloy. The center plate bolt pattern lines up with Doodlebug DB30 and Coleman 100 mini bike bolt pattern to allow for an upgrade to a larger engine using the original bolt pattern without having to drill holes.

www.ebay.com

 

[Thepartsguy]

not for the purpose you would be using it for but to make a massive block bolt to the 5hp mount I used a toro plate from a wheelhorse. just drilled holes into the slides... then welded the plate down.

 

[joshw0000]

The torque converter bolts to the motor. If I turn it backwards, what would it bolt to? I like the idea as it should keep me from cutting the frame. I'm just not sure how I'd apply it.

Edit - I think I'm remembering an extra bolt that isn't there. I should be able to simply put it on backwards. I think that'll work and I should have room to do it this way.

 

[joshw0000]

I was about to pull the trigger this morning and realized the #40 sprocket I posted is actually a 428 sprocket. This is frustrating.

 

[Denny]

It will be fine.

 

[joshw0000]

It will be fine.

Can a 40 chain be used on a 428 sprocket? If so I can simply use the 43T that's currently on the cart and I know I won't have clearance issues.

 

[BaconBitRacing]

It is so nice to work with someone who listens to advice! Thank you!

 

[BrownStainRacing]

Can a 40 chain be used on a 428 sprocket? If so I can simply use the 43T that's currently on the cart and I know I won't have clearance issues.

No. Stay with 41, 40, or 420 chains and sprockets.
The 428 has a larger roller, so mixing it with a 40 chain will not have full contact with the 428 sprocket, causing the chain to jump, broken teeth, and wore out chain.

 

[joshw0000]

No. Stay with 41, 40, or 420 chains and sprockets.
The 428 has a larger roller, so mixing it with a 40 chain will not have full contact with the 428 sprocket, causing the chain to jump, broken teeth, and wore out chain.

Ok thanks, that's what I thought. I found a 48T that seems to have the same bolt pattern but the bore is slightly too small. I may be able to grind it out some or simply put the 428 sprocket back on and bolt this to it since it's bigger. I do worry that it'll hit the frame but it's not the end of the world if I have to notch it.

If that one works it'll put me right in the sweet spot of 6/1 ratio.

MWMNUN Go Kart Drive Sprocket 48Tooth Rear Sprocket Compatible with 40/41/420 Chain Sprocket for Go Karts Mini Bikes and Quad ATV https://a.co/d/4Z4l4wa

 

[BrownStainRacing]

Ok thanks, that's what I thought. I found a 48T that seems to have the same bolt pattern but the bore is slightly too small. I may be able to grind it out some or simply put the 428 sprocket back on and bolt this to it since it's bigger. I do worry that it'll hit the frame but it's not the end of the world if I have to notch it.

If that one works it'll put me right in the sweet spot of 6/1 ratio.

MWMNUN Go Kart Drive Sprocket 48Tooth Rear Sprocket Compatible with 40/41/420 Chain Sprocket for Go Karts Mini Bikes and Quad ATV https://a.co/d/4Z4l4wa

What's the bolt pattern and bore diameter??? I must have over looked it some where.

 

[joshw0000]

What's the bolt pattern and bore diameter??? I must have over looked it some where.

These are my measurements. 58mm bore and 2.25" hole spacing.

And now that I look back at the link, the hole spacing is off. So I'd need an adapter or to drill out to make it work.

 

[joshw0000]

I've been going about this all wrong...why try to change everything I have to work with weaker materials? I just need to find a way to make the 428 chain and sprockets work. This is a good start. It'll probably take a while to come in so I have time to get everything else ready.

I may try this out with my 43T sprocket and a torque converter. According to an online calculator that'll make the cart capable of nearly 40 MPH. If it's too slow off the line I can swap for a 45T off Amazon that appears to be a good fit. I also found a 50T that may fit (likely with some frame cutting).

 

[BrownStainRacing]

These are my measurements. 58mm bore and 2.25" hole spacing.

And now that I look back at the link, the hole spacing is off. So I'd need an adapter or to drill out to make it work.

Heres what I would do.

Find the biggest sprocket 40/41/420 that will fit inside the frame, and mount to the hub. It might be smaller then the 43t now.

Buy the 30 series tav

Buy one of those plate adapters. So you can move engine side to side for chain alignment, and front to back for chain tension.

Buy that engine riser, you may not need it, but it would be nice to have jus incase. You can always sell it or send it back.

Buy a 8t and 9t sprocket for tav, jus incase the 8t jumps the chain. Idk, I've never had to use a 8t on a 5/8" shaft.

You will also need 4) 5/16"-24 bolts, 3/4" or maybe 1" to mount the tav backing plate to the engine. The bolts that come with the tav don't fit.

You need 5/16"-24 bolts 1 each 2.5" , 2.75" and 3" long, to bolt the driver to the crankshaft. A 2.5" might be long enough, you jus never know.

Some 3/4" i.d. shims or washers 5 or 6 should be plenty. Use these to line the driver up with driven, it's a must to keep the belt straight as possible.

2 white driver springs. These will help the tav pull the "not so great gear".

The smaller axle sprocket is not idea, but we can tune the tav to help. By installing 1 or both of the white springs, I'm thinkin both. Also can move the driven spring over a notch and help the tav stay in low a little bit longer, allowing the engine to build power before shifting.

It can work, and I think this is the cheapest way to get it going.

See how this works 1st, and if not happy, then change out the 6" driven for a 7" driven and belt to match, I know the 7" will pull better outta the hole, and help the engine get up in rpm, that's all I use.

If not sure, keep asking questions.

 

[BrownStainRacing]

I've been going about this all wrong...why try to change everything I have to work with weaker materials? I just need to find a way to make the 428 chain and sprockets work. This is a good start. It'll probably take a while to come in so I have time to get everything else ready.

I may try this out with my 43T sprocket and a torque converter. According to an online calculator that'll make the cart capable of nearly 40 MPH. If it's too slow off the line I can swap for a 45T off Amazon that appears to be a good fit. I also found a 50T that may fit (likely with some frame cutting).

Lol, you found the missing part!!!!! And nobody could help???
It won't be the perfect gear, but that tav will work better for you.
Don't worry too much about 40 mph, you gotta get it to move 1st.

 

[BrownStainRacing]

I've been going about this all wrong...why try to change everything I have to work with weaker materials? I just need to find a way to make the 428 chain and sprockets work. This is a good start. It'll probably take a while to come in so I have time to get everything else ready.

I may try this out with my 43T sprocket and a torque converter. According to an online calculator that'll make the cart capable of nearly 40 MPH. If it's too slow off the line I can swap for a 45T off Amazon that appears to be a good fit. I also found a 50T that may fit (likely with some frame cutting).

I hate to give you the bad news, but you will only be gaining .57 gear when that tav goes into high. That's not enough of a gain to do anything different then you have now with the clutch.

Let's look at the math:
You have now,
13t clutch and 43t sprocket.

43/13 = 3.30:1 gear ratio

With the tav, a 6" driven(.90 overdrive in high), 10t and 43t sprockets.

43/10= 4.3.
4.3 x .90 = 3.87:1 gear ratio

Sorry bud, it's still not gonna work. It'll pull off the line alot better, but gonna burn up belts when it gets into high. Jus too much weight, not enough gear.

 

[joshw0000]

I hate to give you the bad news, but you will only be gaining .57 gear when that tav goes into high. That's not enough of a gain to do anything different then you have now with the clutch.

Let's look at the math:
You have now,
13t clutch and 43t sprocket.

43/13 = 3.30:1 gear ratio

With the tav, a 6" driven(.90 overdrive in high), 10t and 43t sprockets.

43/10= 4.3.
4.3 x .90 = 3.87:1 gear ratio

Sorry bud, it's still not gonna work. It'll pull off the line alot better, but gonna burn up belts when it gets into high. Jus too much weight, not enough gear.

Where does the x .9 come from?

I've studied this cart for hours and spent three times as many online searching for parts. I don't know any other way to get this thing going without throwing away everything and starting over. There's no combo of sprockets for 35 or 40 that will fit my setup and provide any benefit over what I have.

Looking at my axle more yesterday and the threads are smaller than 0.75 on the end and the the center of it is thicker than 1-1/8". I didn't have enough washers on hand to check against. But that's just one more complication to face if I decided to replace the axle. It's a 35" inch axle. Nothing about it seems standard.

 

[Denny]

When it’s all said and done you’ll end up at least buying a new axle, brake disc, 60 tooth axle sprocket, 30 series TAV II CVT, Genuine Comet Belt for it, And you’ll end up notching the frame to clear the sprocket.

 

[joshw0000]

I understand that 6:1 is ideal but what's the missing piece to the equation? From the factory, most carts don't come with tiny front sprockets and huge rear sprockets. This cart once pulled well on a smaller motor with 43/13 sprockets.

I'm not trying to be a smart @$$. I'm generally curious. I know, on a car 4.10 gears are great for the track but you'll cruise on the highway at super high RPM's (reduced top speed).

So what's the in between ratio? One that won't smoke the tires but still takes off reasonably well, cruises fast enough, and doesn't each up belts?

The one video you sent, the guy swapped his red spring for the yellow. If I did that, it would allow the engine to spool up more before engaging, right? So essentially faking a higher ratio?

 

[joshw0000]

When it’s all said and done you’ll end up at least buying a new axle, brake disc, 60 tooth axle sprocket, 30 series TAV II CVT, Genuine Comet Belt for it, And you’ll end up notching the frame to clear the sprocket.

I promise I won't. I'll sell it and buy a new one before I get to that point. I've almost posted it more than once already.

I did order a TAV2 and 10T front sprocket. The axle is staying on it. I MAY buy a slightly larger rear sprocket but that's it.

 

[Denny]

Well then put it up for sale because that is what you’ll have to do! Some genius cut off the stuff for a jack shaft and really screwed up the kart in the process. Fix it right or don’t I don’t care. My nephews and nieces karts run good and are reliable, what do I know?