1996 YZ125 into KGB Shifter kart

[Kshannon17]

I got the pump off of sharkshifter for like $35. It's called a mikuni round pulse pump. Real easy to install

 

[jdmkid]

cool thanks! and goodluck

 

[anderkart]

Ksh,
Your kart is looking really good man!

jdm,
You could prolly find a bargain by posting a 'wanted ad' here: http://karting.4cycle.com/forumdisplay.php?f=57

 

[Kshannon17]

Hello!
I need to run the radiator hose coming off of the head at a 90 degree angle, but i the 90 degree i had isnt strong enough to hold up the hose, and just bends not allowing any flow. Does anyone know of any fitting i could install to run the hose this way?
Also, when the radiator was installed on the bike, the water pump was connected to the bottom of the radiator and the head was connected to the top. Should it stay this way or should it be the other way around?

 

[fowler]

same way

this applys to every cooling system on any engine

hot water comes into the rad and as it cools it sinks to the bottom

as the water enters the block it absorbs heat and rises to the top


go to an auto store where they usually sell rdiator hoses for cars and bikes

those hoses come pre bent
find one with the desired ange and join it to your current hose with a stort peice of metal pipe
ally is best

 

[Papa P]

It will also keep pumping coolant if the level drops.
Craig

 

[Kshannon17]

http://s1153.photobucket.com/albums/p511/kshannon199/?action=view&current=IMG_1150.mp4

Here is a link to a video of it starting and running.

 

[Kshannon17]

nevermind the exhaust falling off and the rattling sound, had a couple wrenches on laying by the brake pedal

 

[jdmkid]

nice sounds good!

 

[anderkart]

I agree with Fowler, but another solution could be to slide a spring over that bend in your hose. Might be dificult finding the right size/type of spring, most Ace hardware stores usualy stock a nice selection.

 

[qtband]

You could use a copper elbow and use a piece of hose with clamps to make that bend.

 

[Kshannon17]

I tried a copper pipe, but 3/4" outer diameter copper piping was too big to fit into the 3/4" inner diameter heater hose(schocking i know) lol. So what i did was buy a piece of 1" inner diameter PVC Elbow and lubed it up and forced the heater hose to follow the elbow while retaining its circular shape ( for the most part) and connected it to the head. It should hold, and heat against the pipe shouldnt matter because it will mostly be contained inside the tube.
The lower radiator male connector was bent into an awful triangle shape somehow. I worked with it for a while and tried to get it back to its circular shape without damaging anything. I worked with it for a while and installed the hose with a hose clamp and tightened it down but it still leaked pretty bad out of that spot and i think its because the misshaped port isnt sealing to the circular hose very well. I tried some plumbers tape wrapped around the port and put the hose back on, but i was a little nervous to try it without consulting anybody first. Is plumbers tape safe to run in a heated/pressurized system or is it guaranteed to fail? Any other solutions to this? Any idea on how to get the port back to its original shape?
Thank you guys, I really am appreciative of your replies and i am thankful for the attention this project is getting, nobody around the house seems to care.. lol
Have a good day. I will post more pictures as i do more work

 

[OzFab]

I tried a copper pipe, but 3/4" outer diameter copper piping was too big to fit into the 3/4" inner diameter heater hose(schocking i know) lol. So what i did was buy a piece of 1" inner diameter PVC Elbow and lubed it up and forced the heater hose to follow the elbow while retaining its circular shape ( for the most part) and connected it to the head. It should hold, and heat against the pipe shouldnt matter because it will mostly be contained inside the tube.
The lower radiator male connector was bent into an awful triangle shape somehow. I worked with it for a while and tried to get it back to its circular shape without damaging anything. I worked with it for a while and installed the hose with a hose clamp and tightened it down but it still leaked pretty bad out of that spot and i think its because the misshaped port isnt sealing to the circular hose very well. I tried some plumbers tape wrapped around the port and put the hose back on, but i was a little nervous to try it without consulting anybody first. Is plumbers tape safe to run in a heated/pressurized system or is it guaranteed to fail? Any other solutions to this? Any idea on how to get the port back to its original shape?
Thank you guys, I really am appreciative of your replies and i am thankful for the attention this project is getting, nobody around the house seems to care.. lol
Have a good day. I will post more pictures as i do more work

Plumbers tape is made for high pressure applications, not sure about heat though. I would assume it can handle some heat but I don't know how much.

What I do know is PVC won't handle the heat...

 

[Kshannon17]

I found some heater hose at the hardware store that was a lot thicker and less bendable. I think this will work for the head, until i can find a sufficent way to bend it. How does one bleed the radiator? and what is the best way to put in brake fluid? I have done it before on motorcycles and stuff but what is the best way for these karts? What is the process? I gave google a shot at both but wasnt impressed at the results.
I started it up, dropped it into second, and the entire motor shifter towards the axle about 4". I dont think my motor mount is sufficient enough and might soon have to suck it up and by Burris Clamps for the thing.. but at $16 a piece, i dont know if its worth it.

 

[andyjones]

You are joking about the cost of brackets being $16 arent you?? ive just spent $200 on a correct mount from sharkshifter for my 250 build!Whats the reason for the rads being mounted so high? would look 100% better sat low down! also theres gonna be alot of vibration surely sat that high on brackets! nice build though kshannon just waiting to finish my 10x10 workshop so i can make a start on mine!

 

[Kshannon17]

Because if the radiator was any lower I couldn't make the bend from the bottom because the ports are facing the wrong direction, and the side panel wouldn't fit on. And no, it doesn't vibrate too bad. As long as its tight, and you don't allow for any movement. Just the brackets for the bottom of the mount are $16 for a piece 92mm wide and 12mm tall.. It's just expensive to think that a little piece is so much money. Motor mounts are expensive also, that and not being able to find one for my motor I decided to make one myself which only costs $10 for the steel and $35 to weld it together.

 

[anderkart]

You can buy butterfly motormount clamps for $3.50 here: http://www.out2win.com/catalog/mount_chassis.html#clamps

Your heater hose wont kink if you simply slide a spring over it. You'll want a fairly light-duty spring that fits snug. You could swipe one off a garden hose or prolly buy one at an Ace hardware store for just a couple bucks...

 

[anderkart]

I found quite a few guys with YZ125 powered shifterkarts at this forum: http://ekartingnews.com/forum.php
Just type YZ125 into the search window there. Those guys prolly already figured out/posted the best way to bleed your cooling system, plus you'll find a bunch of other cool info to help your build too

Its exspencive, but I found your motormount here: http://www.ebay.com/itm/YZ125-Go-Ka...332&pid=100033&prg=1011&rk=4&sd=251150237195&

 

[Kshannon17]

Thank you, I will reply more tomorrow night!

 

[Kshannon17]

Sorry, my garage door is getting impossible to shut and lock. i finally got it shut and locked the other night but im afraid i cant do it again if i open it. Youd be surprised at how bad my neighbors want a shifter for themselves
It will be replaced sometime this week, plus I'm waiting for some parts to come in the mail also.
I assure you, i have not given up