a Crossfire kart RestoMod

[firemanjim]

Hi guys, I just found this great site, and am ready to dig in.... Let me tell ya about my newest project. I picked up a thrashed Crossfire rolling chassis, then picked up a Honda 200cc atc motor with 5 high and 5 LOW gearbox. I started making a rear motor mount today while I was at work. Tomorrow I'm hoping to have the front one done. Because of how the P/O had rigged it up, I'm stuck with 2 different pitch chains, so i will be setting up a jackshaft to get me where I need to be. I have a TON of work ahead of me as the frame was wrecked and someone did a half a"_ job of fixing/ messing it all up. Gonna post pics of what I got now,and more as I go along.... thanks for looking,and suggestions are welcome! Will post pics as soon as i figure it out.... lol

 

[Doc Sprocket]

Fantastic- Can't wait to see!

 

[firemanjim]

ok its only gonna let me do one at a time for some reason. Everytime i switch from page to page,it erases the image i previously linked...

 

[firemanjim]

 

[firemanjim]

 

[firemanjim]

 

[firemanjim]

i have more pics but thisis taking too long this way. Will figure something out tomorrow. ... These tell ya what I'm up against. ... lol

 

[firemanjim]

Ok , I hate "technology" ...... stupid smart phone is annoying sometimes. ...... sorry

 

[OzFab]

Could the pics be any smaller? Even on photobucket, all I get is thumbnail size pics...

 

[firemanjim]

Could the pics be any smaller? Even on photobucket, all I get is thumbnail size pics...

Im using photobucket and this is how it came out. Something is wrong because when I post pics to my dune buggy site,they come out just fine....

 

[souperman000]

Its an anti spam filter, you should be fine in a few more posts.

Posting pics: http://www.diygokarts.com/vb/showthread.php?t=736

 

[firemanjim]

Well, no real progress today. I did how ever put a carb on a 4hp tech and then onto my daughters kart. Gotta figure out the governor and throttle. Its not the right type carb for this application i assume...
Anyway, Ive been trying to figure out the mounts on my sons buggy,its been kinda frustrating. I WISH I had a pipe bender. Maybe i can talk my boss into buying one for the shop. Another thing I've been trying to figure out is the gear ratios to use. Since this motor already has a hi/lo gearbox and i dont want REAL slow low gears, I was thinking my sprocket sizes would go something like this.... motor has 13 th to say a 17+-1 or 2 t on jack shaft. That will drive a 19-23t sprocket driving my axle sprocket that has like 36 or 38 ,i forget. .... Does my thinking sound right? I'll figure out exact sprocket teeth counts soon and I need the specs for the atv the motor came from. The guy I got it from said in low range,it topped out at like 35-40 mph and low first was a REAL granny gear. With this in mind and knowing how we will use this thing,I dont want a real low first. I want to change ratio so low one is a little faster and that will also make my high range, well, a lot of fun being that its a 5 speed.... So does this sound realistic or I'm I at least on the right page? Sorry so long.....

 

[landuse]

Well, no real progress today. I did how ever put a carb on a 4hp tech and then onto my daughters kart. Gotta figure out the governor and throttle. Its not the right type carb for this application i assume...
Anyway, Ive been trying to figure out the mounts on my sons buggy,its been kinda frustrating. I WISH I had a pipe bender. Maybe i can talk my boss into buying one for the shop. Another thing I've been trying to figure out is the gear ratios to use. Since this motor already has a hi/lo gearbox and i dont want REAL slow low gears, I was thinking my sprocket sizes would go something like this.... motor has 13 th to say a 17+-1 or 2 t on jack shaft. That will drive a 19-23t sprocket driving my axle sprocket that has like 36 or 38 ,i forget. .... Does my thinking sound right? I'll figure out exact sprocket teeth counts soon and I need the specs for the atv the motor came from. The guy I got it from said in low range,it topped out at like 35-40 mph and low first was a REAL granny gear. With this in mind and knowing how we will use this thing,I dont want a real low first. I want to change ratio so low one is a little faster and that will also make my high range, well, a lot of fun being that its a 5 speed.... So does this sound realistic or I'm I at least on the right page? Sorry so long.....

If I use some of your figures, I get

(18/13)*(38/19) = 1.384*2 = 2.768:1

That is EXTREMELY low, and your kart won't even budge, and your clutch would be Kentuck Fried Clutch

I am not too sure what engine you have, but that ratio is waaay to high for anything. You generally need a 6:1 at least

This is all for a standard industrial engine, so for your ATV engine I am not too sure.

 

[firemanjim]

The engine is a 200cc Honda with 5 high and 5 low using a gear reduction box . I'm not good with that gear ratio math stuff , so when i get the numbers on the stock gearing from Honda, maybe you can help me figure out what sprockets i want to use. As i said, i do not want a granny gear first in low range. I'd rather have a little more speed out of the low range than than when on the 4wheeler it came from.
I got my motor mounts built and 90% installed today, in the rain. I'm waiting on the pics to upload to pBucket so i can post them up. I think its looks pretty good, for now. Gonna add some support to the front mount. I ran out of wire for welder so fabrication comes to a halt till later on in the week when i get some time to go .....

 

[OzFab]

Actually, in low range, that's exactly what you want: High range is meant for speed, low range is meant for hillclimbing & getting out of trouble. If low range is geared too high, high range 1st will be too high & acceleration will suffer.

 

[firemanjim]

Thats a good point Fabroman. ...

 

[firemanjim]

Today after work, I wired up the ATV engine wire harness, put on the carb ,rigged up a gas tank,and tried test running engine on the kart. After changing a couple wires around,it finally sputtered to life. Couldn't get it to stay running. Then, I broke one of the twists of the 2twist rope pull. Cut it off and kept at it,till the pull start hung up. Had to remove, reset, and get some rope. As I text this, I realize my carb is on hand tight with NO rubber o ring seal......

 

[firemanjim]

Well ,last night i fixed the pull string and it broke again on the first pull. I replaced it again, with paracord this time and no problems. I got motor to run, its a BEAST.with only half the exhaust on, it shoots fire ... lol I think its running a little rich, too much back fire when you rev up and then let off the gas. And it puffs a little bit of white smoke. I will video it running tonight after work and post it up. Still trying to figure out the shifting linkage. Its a little more complex than the last time i used an ATV engine for a kart....

 

[firemanjim]

No progress as of yet. Been raining and I'm currently working on it at home,outside. Too busy at the shop right now to take it there . Going to go get some wire tomorrow and maybe I'll push the cart to the shop and tinker a little. (I live directly across the street from work) Ordering all the bearings, sprockets, and chain to make the jackshaft. What size stub axle should I use? It will be 6-8 inches long. I'm thinking 3/4 or 1".... leaning towards the latter because the 4wheeler motor will have lotsa torque in the LOW gear set. What do you guys think?

 

[DRUCIFER]

WOW DUDE!!! Looks good man... mine probably wont get me out of a lot of trouble seeing as how I dont have the High/Low gear box but I still plan on having plenty of fun in it.

I know my next MUD BUGGY needs to start with 4 wheel drive 4 wheeler

THANKS DUDE