A few pics of the kart

[Jean Luc Picard]

Hi all, I got this kart about three months ago and only got it as an add on to all of my other toys, little did I know that it would become a full on project.

First the tecumseh 6.0hp just never ran right, so I ditched that and got a predator 420cc and removed the governor and added some 32lb springs to avoid valve float and piston to valve contact. I plan to get a header and air filter-adapter-jet to go along with it. Also have an arc billet rod as well.

After welding the engine plate to the original swing arm and getting the engine installed and everything lined up, I took it for a spin. To my surprise every time I took a turn or gave it any gas the chain would fall off, so I then fabricated a sprocket guard out of 1/8" plate and installed that and took it for a spin.

Well needless to say the chain kept getting loose. I made sure to make a mark on the engine plate to see if it was moving and it wasn't. So I started looking over the swing arm and that's when I discovered the swing arm had bent dramatically.

From there I decided instead of giving up I was going to get this done. So I fabed a completely new swing arm from 1.5x3x1/8" chromoly. Then fabed some shock mounts and modded the frame and added shock mounts to that so I could fit a pair of yfz450 rear shocks.

I then fabed up a different pivot setup for the swing arm seeing the original was just garbage and had no bushings nor bearings. So I welded extensions off of a custom piece of 1.5x3x1/8" chromoly that I welded to the bottom of the frame. I then welded a 1 1/4" racing kart axle to the extensions. Off of the swing arm I welded some brackets to house race kart axle bearings, yeah I know a little over done but keep in mind, the rear of this kart weighs about 220lbs so I wasn't taking any risks.

After this I added a mcp hydraulic brake set up with a yz250 brake rotor and custom made rotor hub. After the rear was all said and done I moved onto the front. There I just welded in some box steel to the frame for extensions to compensate for the much longer banshee shocks.

Of course after all of this more issues arise. I then had play in the steering shaft, so I welded in brackets to the frame so that I could mount a aluminum steering block with bearing then welded the steering shaft solid. After that I added a race seat with cover and a light bar.

I must say, for a kart that only cost me a total of about $1300 when all was said and done is not to bad. So far all has held up to everything I can throw at it. I plan to finish up the fully welded cage and add some alloy wheels and aggressive tires oh and of course a double a-arm setup.

 

[GearHeadGarage]

Good job

 

[Jean Luc Picard]

Thanks, yeah I'm adding things every day. When I get it close to done I will post some new pics of it.

 

[cornerman11]

Nice! The kart's lookin' good!

 

[Jean Luc Picard]

Thanks bud, just finished up the pedals and more of the cage. More pics to come.

 

[OzFab]

First the tecumseh 6.0hp just never ran right, so I ditched that and got a predator 420cc and removed the governor and added some 32lb springs to avoid valve float and piston to valve contact. I plan to get a header and air filter-adapter-jet to go along with it.

Not a very good or safe idea there; with the governor removed, valve float protects the conrod from shattering; I strongly recommend you fit a billet conrod IMMEDIATELY!

 

[Hellion]

No, no, don't bother with a billet or aftermarket con-rod. Raise the rear wheels off the ground and just rev the snot out of it. That's a great way to break-in the engine.

I trust you Jean Luc Picard. You're a talented starship captain.

 

[Jean Luc Picard]

Already got an arc rod, I forgot to mention that. The one concern I have as of right now is the flywheel. I want a billet one but I want e-start and recoil started as well. I noticed a few billet flywheels with the e-start gear but no recoil cup? Instead they have adjustable timing which I’m not concerned with.

Today I got the choke assembly mounted in the kart, which was a big pain in the rump. I had to make a custom bracket for the cable at both the engine and chassis, then making a lever took a bit of thought too.

I will update my first post with the rod. I will also be adding a filter, pipe and jet here soon but like I said, I’m concerned with the flywheel.

@Hellion You should trust me, I’m the captain. But I’m no engineer and I’m not into pushing warp for to long, the warp core could destabilize leaving me no alternative but to eject the warp core, leaving me stranded in Q knows where.

 

[Hellion]

E-start and recoil? What do you want, egg in your beer?

I can understand being a 110 pound weakling, but why would you want recoil start too? That's for big boys.

You're going to need the services of a skilled engineer. I'd ask Geordi.

 

[Jean Luc Picard]

Well for one, I’m 6’ 185 so trust me a recoil starter is no issues for me.

I want to retain the recoil because it would be nice to have a backup on long trail rides. When I was in the market for a 450 mx bike me and every one of my friends said the same thing, get a bike with both e-start and kicker and if you can’t get both then get one with a kicker. I have come to learn that you can never rely on just the e-start, not to mention a china e-start to boot.

If I have to make a decision, I suppose I will have to go with the e-start flywheel. I really wish arc would make one with the e-start gear and some bolt holes for the recoil cup. Not to mention they cost $200 plus.

I’m only hitting about 4700 rpm max right now and that’s going slightly down hill. Do you think I could get away with the stocker and do you think I will really gain anymore rpm with the pipe and clamp on filter?