Alignment issues

[Thib]

My son worked for a neighbor doing yard work and this kango yard star was what he wanted for payment. Immediately he and I got to work painting and getting it ready. I went to harbor freight and purchased a predator 212 and bolted it on. The clutch is left from our racing days and is a max torque with a 10t sprocket. The drive sprocket is a stub axle 61t and #41 chain. Problem is the motor won't move over far enough to line up the sprockets. I'm completely lost and can't for the life of me figure out how to resolve this problem.

 

[chancer]

could you swap the brake and the sprocket?

 

[Russ2251]

Can you not weld on a new wider mounting plate to the existing plate and drill new slots?
It's what I would do.

 

[Thib]

There is some sort of bracket holding the break setup that is in the way of moving the motor over if I was to weld another bracket on top the old one.

 

[Thib]

Maybe this helps

 

[Thib]

Another without the motor

 

[Russ2251]

Crap...that sucks!

 

[Thib]

Man my little dude is upset. Until now ole dad can fix anything or so he thinks and I've been standing here scratching my head for a week

 

[mckutzy]

(I know this has been said) If you can weld on new extensions, grind a relief for the more inboard holes. This would be the easiest way of doing the swap.

Edit: on second thought, if you can, mount straps long enough to span the motor plate holes but in the offset pattern.
The new holes will overhang but allow you to have something to bolt to. Use longer bolts for the overhanging part.

 

[Russ2251]

Do you know if previous engine had a longer output shaft?

 

[Thib]

Have no idea about the other engine it was already removed when we got the kart. Most of the info I'm finding show the yard star kart with a 5 hp tucumseh

 

[Thib]

This is how far past the end of the shaft the clutch hangs out.

 

[Half-breeder]

A jackshaft maybe?

 

[chancer]

Can you move the brake mounts. Down and forward, and shorten the rod. Then you can move the engine over. Also wow the clutch bell is awful close to the axle sprocket. hmmm.

 

[Russ2251]

Also wow the clutch bell is awful close to the axle sprocket. hmmm.

No problem with that as long as there is no contact between the two.
One of my karts misses by about ¼".

 

[Iron John]

This is how far past the end of the shaft the clutch hangs out.

You should be able to space that out. How much do you need? 1/2" or so?

 

[Denny]

Looks like the easiest solution would be to go up with the engine. If you made a spacer that was a inch or two taller would the engine clear all that brake junk?

Denny

 

[OzFab]

This issue is more common than you think (I'm surprised no one has mentioned it); the shaft on a Predator is shorter than most engines but, there is a simple solution...

What you need is two spacers, one that fits over the engine shaft to keep the clutch at the desired position so that the sprockets line up, & a second spacer that fits inside the clutch which the bolt can travel through; use the pics below as a reference...

 

[Thib]

That looks perfect! Now I ask the dumb question, what are the spacers made of?

 

[OzFab]

Turned steel...