another new guy with a messed up manco

[moron88]

i finally got my gokart from my brother in law. it is a manco american challenger fox (that's what the decals say) that appears to have the original engine. he had tried to sell it before and the person never finished paying so he took it back. it has 1 front tire off a riding lawn mower, all four tires are worn, no clutch and i have no idea what else is wrong.

we picked it up from his dad's house tonight and it's too dark and cold to really look at it. i know i didnt get ripped off, mainly because it at least has a sturdy frame (although i dont have the cage yet) and all it cost me was $50 and my digital camera that they use more than i do. i have no clue the full extent of the issues.

basically, i was wondering what i should check before trying to drive this thing. also, can i put atv wheels and tires on it? i plan to drive it in my back yard and the current tires wont do. if i cant, what tires/wheels will work? what brand of clutch would be best? when this engine dies, i plan to put a stronger engine in it (maybe 8hp or so) and i dont want to have to buy a new clutch for the added power.

lots of words up there, i hope someone can help me. thanks in advance.

 

[moron88]

after a quick look over, it looks like i need to do something with the brakes and replace the brake pedal. the steering is quite difficult when i was sitting in it, but that was probably due to being stationary and rusty (not to mention weighing 230lbs). havent tried to start the engine yet, mostly because i dont know how to turn it off.

anyone have any ideas on how to convert this to 2wd? i have some, but i'm sure someone else can come up with a better idea.

 

[DS13]

can we see some pictures cause that will help a lot!

 

[moron88]

yeah, i'll try to post some up. may have to borrow the camera i traded for it

 

[OzFab]

Now that's perfect irony

 

[momoe]

Now that's perfect irony

hhahahahahah xDD

welcome to the forums man, but seriously ..... the name, its gonna attract alot of attention

 

[moron88]

thanks. many people have said the name was fitting, a few others have said i give morons a bad name, but no one forgets who i am!

 

[moron88]

got the camera and i'll be taking pics tomorrow. when my sis and BIL came to pick me up today i had him show my how to kill the engine once it started (didnt want to start it and not know how to shut it off; the kill switch isnt working) and he got it running too (it didnt want to start at first, probably more because it was 34 degrees than anything else but it had trouble none the less and i know very little about engines... for now). now that i know it runs and doesnt knock or spew black smoke, i dont have a problem buying a clutch for it. however, i dont quite know the shaft size. will a ruler work or should i use calipers to measure it?

not only did i experience irony, but now i'm in a catch 22. i have $100. i need a clutch and maybe tires as well as tools to work on it. both will cost aproximately $100. so which do i get? i could possibly get the clutch and the mandatory tools (i need a chain tool and a new 3/8" ratchet. i have a set of 3/8" sockets in a tool kit i bought at goodwill but the ratchet was broke when i bought it. i think i have another one somewhere but it's probably seized up or covered in bird crap, either way i wouldn't want to use it). i would have an additional $30 if it wasnt for the charger i had to buy for the camera (it was lost in an exchange over the past 2 years. that says something about the nikon coolpix s3100 though, no needing a charger for at least 6 months of sporadic light to moderate usage, including a baby shower and the birth of my nephew). my sister said i could call it her birthday present so it's all good.

any suggestions as to brands of clutches to look at? i dont mind paying extra if i can transfer it to future engines.

 

[DaiSan76]

Assuming you have a 40/41 pitch chain, this clutch should be the way to go. You might stick a tape measure on it and make sure it's a 3/4" shaft, will be pretty easy to see the difference between 3/4" and 1".

http://www.bmikarts.com/Hilliard-Extreme-Duty-34-Clutch-10T-4041-_p_728.html

 

[moron88]

i think we have a winner. the ones i was looking at a few months ago were running $80-$130 for the same HP rating. granted, they would probably last a lot longer or at least have a better warranty but at this price, i wont mind as much buying a new one every year (kart meant for kids+220 pound man=suicidal clutch). and thanks for linking to that website. i had come across it yesterday or the day before but i'm skeptical of these types of sites each time i start a new hobby. i figure if someone with experience links them, they cant be complete con artists.

i just looked up how to tell the chain size. i'll check tomorrow but i think it's #35. i found the same hillard clutch with a #35 sprocket and it's the same price and the chain tool is even cheaper. but supposing it's #40/41, i'm looking at less than $80 for the clutch, chain tool, key stock and a cheap helmet including shipping. that leaves $20 for a new ratchet (if needed), gas and maybe a new tire to replace the lawnmower tire. i probably wont get it running this month though, partly because of money but mostly because it's friggen cold out! i fully expect to be driving it by my birthday (july 10th), maybe even remotely

 

[landuse]

i dont quite know the shaft size. will a ruler work or should i use calipers to measure it...

I would use a set of calipers, but at a pinch a tape measure would do. If it is a 1" shaft, you are looking at some serious money (like over $100). If it is anything smaller, then you are going to be spending a whole lot less.

What do you want a chain tool for? If you just want to break chains, all you need is a grinder to grind off the pins on the link and the chain will break naturally there. I have never had a chain tool, and will never get one.

To check chain pitch, have a look at these:

The complete guide to chain and sprockets
http://en.wikipedia.org/wiki/Roller_chain#Chain_strength
http://chain-guide.com/applications/index.html
http://www.gizmology.net/sprockets.htm

 

[moron88]

there is a jack shaft and the chain that runs to the clutch had a pin removed because it runs to the inner sprocket. it's easier to just get a chain tool.

 

[moron88]

uploading a few pics and a video to photobucket right now. they'll be up in 15 or 20 minutes.

 

[moron88]

they finished uploading.

here she is. a bit dirty and rough around the edges, but it'l be fun ripping around the back yard on.
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0436.jpg.html

here is the jack shaft. as you can see, i need a chain tool to put on the main chain unless i want to remove the second chain. i'm just preparing for the future as i intend to keep this gokart for a while and get more in the future.
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0437.jpg

messed up brake pedal. dont know who twisted it or how they did it but now, the brakes dont work (although that isnt entirely the fault of the pedal, it's a band brake and the cable is slack to boot). debating if i should fix this one, buy a new one or just make one.
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0438.jpg.html

thought i'd document this. there is no air filter cover. and the filter could use a good cleaning.
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0439.jpg.html

there is a kill switch...
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0440.jpg.html

...but they only work if they are connected to the engine
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0441.jpg.html

my voice sounds funny for some reason... at the beginning i say "i believe i can get it started with one pull"
http://s1155.beta.photobucket.com/user/moron88/media/DSCN0442.mp4.html


i tried to embed them but it wasnt working.

 

[moron88]

seeing the pic of the kill switch taunting me mad me get up and go try to figure it out. in the pic, you can see 2 yellow wires wrapped around a black wire. no clue why they are there. they dont have anything to do with the kill switch (at least not now). you can see 2 black wires (the one with the green insulator in between the yellow wires and another in the back ground resting in the routing clip) which are not connected to anything. these are the kill switch wires. after a little trial and error, i got it working. now (hopefully) i will never singe my hand on the muffler trying to shut the engine off. now i'm toying with the idea of replacing the toggle switch on the wheel with an ignition key, just because i'm awesome that way. it doesnt help that bmi has a couple key switches for $20 or less and there i'm getting a gift card that i had completely forgotten about ($50 rebate from my laptop). first world problems, i tell ya

 

[OzFab]

Ok, let's see if we can't sort a few of these minor annoyances:

here is the jack shaft. as you can see, i need a chain tool to put on the main chain unless i want to remove the second chain. i'm just preparing for the future as i intend to keep this gokart for a while and get more in the future.

You will need a chain breaker to set the length of the chain but, the tension is set by moving the engine.

messed up brake pedal. dont know who twisted it or how they did it but now, the brakes dont work (although that isnt entirely the fault of the pedal, it's a band brake and the cable is slack to boot). debating if i should fix this one, buy a new one or just make one.

There's a number of ways to fix the pedal:
1. Using two adjustable spanners, place them on either side of the bend & push them againist each otheruntil the pedal is straight(ish).
2. Remove the pedal & place it in a bench vice below the bend. Tighten an adjustable spanner at the top of the bend & twist the pedal to the desired position.

Yeah, they're pretty much the same thing but, one you can do on the kart or two you need to take it off

There should be adjusters at either end of the outer cover; adjusting them should remove the slack

thought i'd document this. there is no air filter cover. and the filter could use a good cleaning.

It'll actually run better without the cover (less air restriction). it'lll be even better if you replace the whole assembly with a hi flow filter... eventually

there is a kill switch...

So you got that sorted?

...but they only work if they are connected to the engine

Wait, there's two components there; one is the kill switch, the other is the low oil sensor. The one at the top, near the red switch is the only one you need to worry about...

i tried to embed them but it wasnt working.

That's because you left them as a url, you need to change "url" at the beginning & end to "img". Other than that, follow these instructions...

 

[moron88]

thanks for the help. i'll take another look and see if i cant figure out which is the oil sensor and how it's supposed to be set up.

i just put the url's because when tried to embed them, they wouldnt show up in the preview.

 

[jamyers]

WELCOME! Looks like you've got a great kart project there, oughta be up and running in no time!

Try copy/pasting the thumbnail code straight from photobucket, like this: