1996 YZ125 into KGB Shifter kart

[Kshannon17]

Hello!
Sorry for not replying as often as i should have, I have been pretty busy with school and work. BUT i did do a little work on the cart this last week and got the motor mount taken care of!
I welded a plate to the bottom of my motor mount, and then bought some Burris clamps on line. I set the motor in the kart, got the chain straight, then drill holes in the plate so that it would all line up. I then ran a bolt through the clamps and tightened her down, and it works!
I started her up, let her run for a while without the radiator cap and when the motor started to heat up, the coolant went down and the radiator started to burp. I let it run til some vapor came out of the radiator and shut it tight so i think all the bubbles are out.
I will be able to ride it soon, just need to put air in the wheels, brake fluid in the lines, figure something else out for the ignition system, and get a throttle cable!

 

[Olyptorius]

Awesome stuff!! Can't wait to see this thing ripping around. Just picked up a shifter kart roller myself! Throwing a rm125 engine in it. Hopefully i get it done before winter arrives.. Check out my build log if you have time!

 

[Kshannon17]

Brakes are bled, throttle cable is installed, motor mount is done, chain is tight, and everything is ready to go, BESIDES one thing.
Is there any way to increase the length of spark plug wire? The wire is like 6 inches long and doesn't give me any room to mount the ignition or the ground wire.
There are two pieces of metal sticking out of the ignition, do these need to be grounded also? I attached a couple of pictures with this so you can have a better look.
Just a couple more days and i will be able to ride this thing
Ill post a video once i get to take it for a spin

 

[Olyptorius]

Can't wait to see this man! Mind if you take a few photos of your mount setup so i can get a general idea for mine?

As for the magneto, you can definitely extend that ground wire and mount it anywhere on the frame.. The spark plug issue is quite a head scratcher, i will have the same issue as well... You can probably buy a longer boot for it but idk if that will decrease the output to the plug..:S

 

[landuse]

The cable coming from the coil just screws into the coil where I have circled in red. You can buy a longer one and just replace it.

 

[anderkart]

Ksh,
landuse had a good suggestion there, but you could always rig-up a DIY extension spark plug wire to simply plug-in for extra length too. All you'd really need is another plug wire conected to the tip (cut off ) from an old spark plug... So you'd simply be plugging 2 plug wires In-line, just make sure the conections are sucure/tight and well insulated using the rubber boots.

 

[Kshannon17]

to be honest i was worried to take the wire out, i didnt know that it came out so easily lol does the distance make the spark less powerful or does that even matter? should i get the shortest one that will work or can i give myself some room? also anderkart, if i extend it does that make the spark any more weak?

Also, in the picture that landuse circled for me, you can see the two posts coming out of each side of that ignition piece. Are these to be grounded to the frame with the ground wire itself? Or do these even matter<

 

[Kshannon17]

Got her started, got everything off my checklist and rode it around the block a couple times! I'm not sure if its possible, but this motor felt WAY faster on th kart than on the bike. I couldn't even believe how easy it was to spin the rear wheels and slide corners... I was only in 3rd gear and it was still too fast! I love it though, it's a nice smooth ride, doesn't rattle as much as I thought it would. Thank you for all your help. With your help I made my goal of getting it done before winter
I'm still going to work on it and perfect it though, I'll post pictures and videos of it later on.
Thank you.

 

[Olyptorius]

Got her started, got everything off my checklist and rode it around the block a couple times! I'm not sure if its possible, but this motor felt WAY faster on th kart than on the bike. I couldn't even believe how easy it was to spin the rear wheels and slide corners... I was only in 3rd gear and it was still too fast! I love it though, it's a nice smooth ride, doesn't rattle as much as I thought it would. Thank you for all your help. With your help I made my goal of getting it done before winter
I'm still going to work on it and perfect it though, I'll post pictures and videos of it later on.
Thank you.

Awesome! Looking forward to seeing the video of it running and ripping!

 

[ia-turtleboy]

inspiration for my yz125 build!nice work

 

[Kshannon17]

Well worth it! So much fun. I've spent only 20 minutes actually riding it and its well worth it! What year motor are you using?

 

[Olyptorius]

Could you possibly post close-ups of your motor mount? I'd like to get a general idea what you've done!

 

[Kshannon17]

Its hard to get a picture that shows exactly what is going on. Ill try and draw something that you might be able to understand. What do you need to see? How the mount is connected to the motor, or how the mount is connected to the frame?

 

[Olyptorius]

Its hard to get a picture that shows exactly what is going on. Ill try and draw something that you might be able to understand. What do you need to see? How the mount is connected to the motor, or how the mount is connected to the frame?

How the mount is connected to the frame. I've checked online and mounts are around 150-200$.. I rather make one out of scrap metal foe quarter of the price.

 

[Kshannon17]

See if this helps at all. Motor mounts are too expensive and one for an RM125(depending on the year) might be hard to find. There is a difference between TAG motor mounts and 2stroke shifter motor mounts. I think you are better off making your own mount if you want to save money. It might add a little more stress on you and will take a lot of thinking about how you want it. If i were you, I would do it the same way as mine but instead of having the vertical steel piece connected to the horizontal steel mount base i would weld the vertical pieces right to a 1/4" steel plate the width of your frame at the length of the motor.
Burris Clamps are what clamps the mount to the frame. You can order them at a lot of different places, but i found some cheap ones at one of the sites anderkart gave me a couple pages ago. They are kind of expensive but they really do a good job of holding it together. Let me know if you need anything else, and remember, anderkart, fabroman and landuse are a lot of help and their names seem to appear pretty often so i think they would be able to respond fastest. Im always here for questions tho if you need, but im new at this so my advice isnt backed with much experience

 

[ia-turtleboy]

im confused on the clutch system on these. i have a clutch lever behind my steering wheel but how does that system hook up properly?

 

[Olyptorius]

See if this helps at all. Motor mounts are too expensive and one for an RM125(depending on the year) might be hard to find. There is a difference between TAG motor mounts and 2stroke shifter motor mounts. I think you are better off making your own mount if you want to save money. It might add a little more stress on you and will take a lot of thinking about how you want it. If i were you, I would do it the same way as mine but instead of having the vertical steel piece connected to the horizontal steel mount base i would weld the vertical pieces right to a 1/4" steel plate the width of your frame at the length of the motor.
Burris Clamps are what clamps the mount to the frame. You can order them at a lot of different places, but i found some cheap ones at one of the sites anderkart gave me a couple pages ago. They are kind of expensive but they really do a good job of holding it together. Let me know if you need anything else, and remember, anderkart, fabroman and landuse are a lot of help and their names seem to appear pretty often so i think they would be able to respond fastest. Im always here for questions tho if you need, but im new at this so my advice isnt backed with much experience

Thanks for the info and advice!that diagram will definitely come in good hand! Yes they've been helping me a lot through my build as well, though considering we have similar karts, it is easier for me to look at yours and get rough ideas! If you plan on making another video showing off the kart, try explaining what you've done and get a few close ups for me! Must appreciate it. Can't wait to get mine going, picking up my engine tonight

 

[Kshannon17]

The clutch hooks up to the handle just like on a dirtbike handle. The metal wire inside the cable itself is connected to the handle, and the rubber housing is connected to a stop on the steering column. If you have a handle, you should have everything you need to make it work

 

[anderkart]

im confused on the clutch system on these. i have a clutch lever behind my steering wheel but how does that system hook up properly?

You'd just need a strong bracket to hold the cables housing in place.
Here's a pic of a home-made/DIY setup that Rickracer built:

You'll find LOTS more good info/pics on his shifterkart build thread here
at this link:--> http://www.diygokarts.com/vb/showthread.php?t=4742

 

[fourtogo]

A piece of Alum plate heavy enough to support the cable is all you need . Punch a hole in it the same size as steering shaft . Cut a slot in it so you can through bolt as to clamp it to shaft .