Cheap quick refurb

[G.W]

It looks like that engine has seen better days

 

[Thelegg]

It looks like that engine has seen better days

Nah lol it's a good engine, came off a pressure washer which someone decided to fit a new honda engine onto because they didn't like Loncin engines. It's only done a few hours work but been sat in my barn gathering dust for about a year.

 

[G.W]

Nah lol it's a good engine, came off a pressure washer which someone decided to fit a new honda engine onto because they didn't like Loncin engines. It's only done a few hours work but been sat in my barn gathering dust for about a year.

Ah, I see. If you look past the dirt and grime it does look pretty new.

 

[Thelegg]

Bit of time wasted on this unfortunately, my plan was to use the old sprocket and weld it to a new carrier but turns out it's an alloy sprocket which I can't weld so I decided to bolt it to a modified bearing carrier which worked really well. Only issue was my hole saw snagged and broke when cutting out the centre of the sprocket so I had to resort to drilling and grinding the centre bigger which ended up looking awful.

Looks fine with the carrier hiding it tho lol

Got the torque converter bolted on and trialed everything on the kart to check fitment.

Everything fits really nice and there is plenty of room the other side for the brake setup hopefully next time I work on it I'll have enough time to get the welder out and get everything mounted properly

 

[Thelegg]

The welder did indeed come out! Engine mount plate made and welded in


Engine bolted on with new chain fitted

More updates tomorrow hopefully

 

[G.W]

That's an interesting take on an engine plate. I've never seen someone make one that way

 

[panchothedog]

Lots of room for fore and aft adjustment.

 

[Thelegg]

Trialed the design years ago on another kart and it worked really well so now I use it all the time

 

[Denny]

Are you sure it is going to be strong enough?

 

[Thelegg]

Are you sure it is going to be strong enough?

It's like 6mm angle iron with extra supports welded in both ends so yeah I'd like to think it's strong enough lol

 

[G.W]

It's like 6mm angle iron with extra supports welded in both ends so yeah I'd like to think it's strong enough lol

For that size engine it should be more than enough. I'd be concerned if you where putting a 420 on it.

 

[Thelegg]

So spent most of the day working on this, first job was to hook up a throttle cable.
Should of been a 5 min job but the cable was to short, made an extension which solved the issue. Operated the pedal a couple times and the original bit of cable snapped haha so spent hours hunting for a new cable in my workshop and eventually found a new clutch cable from a car and it was perfect length no pics sorry.

Next step.
Old fuel drained and carb off for a quick clean (surprisingly clean) all back together and after a few pulls it fired.

Now I've fiddled with the carb abit and got it running pretty good mainly just had to adjust the idle as it was set at high revs for the old pressure washer.

I can't say it runs amazing tho but I may be able to increase the idle slightly just didn't want it running away from me every time I start it lol the only issue is that it take alot of throttle travel for it only to rev up right at the end and then it feels like it's got way more but the govnor is holding it back. Am I right in thinking there is no way to alter this without physically removing the govnor?

Anyway on all 4 wheels again

Thought I'd take it for a first run but can't go very far as the roll bars are only bolted in finger tight and theres no brakes haha
Goes pretty well definitely picks up and gets to top speed quicker than before but then govnor steps in :/

 

[Thelegg]

Little update, mainly waiting on brake parts as the caliper, master cylinder and hoses I got given free with the axle don't match each other which is abit annoying but with the extra bits I've ordered I should be able to make two brake kits so I can use one on another kart

Soooooo whilst I wait, engine off again and oil drained

Goodbye govnor! Not many pics as I was to covered in oil to get my phone out lol

Treated it to a new fuel pipe whilst it was all in pieces

That's all for now

 

[Thelegg]

Small update, brakes haven't arrived yet not sure why

Engine cleaned, back together and onto the kart.

Started it up and it didn't want to run on anything less than half choke no matter what I did to it. Concluded that it can't be getting fuel when trying to run on the idle jet/pilot jet. Popped it out and found it clogged solid which was odd seeing as I cleaned it the other day.

Back together fired straight up and ran perfectly, got the carb setup perfectly now and it certainly likes to rev! Couldn't rev it too much tho as it vibrated and tried to jump off the axle stands haha.

Throttle cable hooked up and that's all I can do now until the brakes arive as I really don't want to ride it without being able to stop lol

 

[ezcome-ezgo]

Did anyone else see this?:

 

[Thelegg]

Few brake parts have arrived so made a start on fitting bits together and making mounts on the kart.
Caliper mount

The old fixed axle came in handy here as a good place to mount it
Made up a pipe for the brake set up so now I have everything together and working (bench test for now)

Now it works but the pistons don't travel very far in the caliper so I'm wondering if the rubber hose expands to much when under pressure from the master cylinder? I know the caliper and master work together as I have the same 2 on my other kart only difference is there joined via a braided hose

Still waiting on a new brake disc to arrive as the one I have is very thin so I've ordered a thicker 1 which should fill out the caliper better

 

[Thelegg]

Decided to change the brake pipe to a hard line which removed loads of flex and gained more travel of the brake pads Brake disc arrived so fitted that

master cylinder also fitted and old linkages connected up with just a little bend required so nice easy install for once!



Inflated the tyres and thought I'd take it for a spin unfortunately I made it 2 feet and the chain came off lol easy fix... Nope of course not.
Turns out the sprocket holder I made from an old bearing carrier was twisting when the chain put tension on it so everytime you rev the engine everything moves and goes way out of line so now Ive got to wait ages for a proper carrier to come in the post.

Kart now parked back up with the rest of the gang lol

 

[Denny]

If that is your brake line with hard lines and fuel hose and clamps it will never work or be safe! Get the correct nylon tubing kits or go to a band brake.

 

[Thelegg]

If that is your brake line with hard lines and fuel hose and clamps it will never work or be safe! Get the correct nylon tubing kits or go to a band brake.

Lol it's working fine at the moment and I did try to find a braided hose but I couldn't identify the thread in the caliper it's not metric, it's not imperial, it's not pipe thread I can't identify it at all. All the lines were pressure tested with no leaks so I don't really see what the problem is?

 

[Denny]

You will.