G.W
Well-known member
It looks like that engine has seen better days
Cheap quick refurb
- Thread starter Thelegg
- Start date
Thelegg
Active member
G.W
Well-known member
Ah, I see. If you look past the dirt and grime it does look pretty new.
Thelegg
Active member
Bit of time wasted on this unfortunately, my plan was to use the old sprocket and weld it to a new carrier but turns out it's an alloy sprocket which I can't weld so I decided to bolt it to a modified bearing carrier which worked really well. Only issue was my hole saw snagged and broke when cutting out the centre of the sprocket so I had to resort to drilling and grinding the centre bigger which ended up looking awful.
Looks fine with the carrier hiding it tho lol
Got the torque converter bolted on and trialed everything on the kart to check fitment.
Everything fits really nice and there is plenty of room the other side for the brake setup
hopefully next time I work on it I'll have enough time to get the welder out and get everything mounted properly
Looks fine with the carrier hiding it tho lol
Got the torque converter bolted on and trialed everything on the kart to check fitment.
Everything fits really nice and there is plenty of room the other side for the brake setup
hopefully next time I work on it I'll have enough time to get the welder out and get everything mounted properly
Thelegg
Active member
The welder did indeed come out! Engine mount plate made and welded in
Engine bolted on with new chain fitted
More updates tomorrow hopefully
Engine bolted on with new chain fitted
More updates tomorrow hopefully
G.W
Well-known member
That's an interesting take on an engine plate. I've never seen someone make one that way
panchothedog
Well-known member
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Lots of room for fore and aft adjustment.
Thelegg
Active member
Trialed the design years ago on another kart and it worked really well so now I use it all the time
Denny
Canned Monster
Are you sure it is going to be strong enough?
Thelegg
Active member
It's like 6mm angle iron with extra supports welded in both ends so yeah I'd like to think it's strong enough lol
G.W
Well-known member
For that size engine it should be more than enough. I'd be concerned if you where putting a 420 on it.
Thelegg
Active member
So spent most of the day working on this, first job was to hook up a throttle cable.
Should of been a 5 min job but the cable was to short, made an extension which solved the issue. Operated the pedal a couple times and the original bit of cable snapped haha so spent hours hunting for a new cable in my workshop and eventually found a new clutch cable from a car and it was perfect length no pics sorry.
Next step.
Old fuel drained and carb off for a quick clean (surprisingly clean) all back together and after a few pulls it fired.
Now I've fiddled with the carb abit and got it running pretty good mainly just had to adjust the idle as it was set at high revs for the old pressure washer.
I can't say it runs amazing tho but I may be able to increase the idle slightly just didn't want it running away from me every time I start it lol the only issue is that it take alot of throttle travel for it only to rev up right at the end and then it feels like it's got way more but the govnor is holding it back. Am I right in thinking there is no way to alter this without physically removing the govnor?
Anyway on all 4 wheels again
Thought I'd take it for a first run but can't go very far as the roll bars are only bolted in finger tight and theres no brakes haha
Goes pretty well definitely picks up and gets to top speed quicker than before but then govnor steps in :/
Should of been a 5 min job but the cable was to short, made an extension which solved the issue. Operated the pedal a couple times and the original bit of cable snapped haha so spent hours hunting for a new cable in my workshop and eventually found a new clutch cable from a car and it was perfect length
no pics sorry.Next step.
Old fuel drained and carb off for a quick clean (surprisingly clean) all back together and after a few pulls it fired.
Now I've fiddled with the carb abit and got it running pretty good mainly just had to adjust the idle as it was set at high revs for the old pressure washer.
I can't say it runs amazing tho but I may be able to increase the idle slightly just didn't want it running away from me every time I start it lol the only issue is that it take alot of throttle travel for it only to rev up right at the end and then it feels like it's got way more but the govnor is holding it back. Am I right in thinking there is no way to alter this without physically removing the govnor?
Anyway on all 4 wheels again
Thought I'd take it for a first run but can't go very far as the roll bars are only bolted in finger tight and theres no brakes haha
Goes pretty well definitely picks up and gets to top speed quicker than before but then govnor steps in :/
Thelegg
Active member
Little update, mainly waiting on brake parts as the caliper, master cylinder and hoses I got given free with the axle don't match each other which is abit annoying but with the extra bits I've ordered I should be able to make two brake kits so I can use one on another kart 
Soooooo whilst I wait, engine off again and oil drained
Goodbye govnor! Not many pics as I was to covered in oil to get my phone out lol
Treated it to a new fuel pipe whilst it was all in pieces
That's all for now
Soooooo whilst I wait, engine off again and oil drained
Goodbye govnor! Not many pics as I was to covered in oil to get my phone out lol
Treated it to a new fuel pipe whilst it was all in pieces
That's all for now
Thelegg
Active member
Small update, brakes haven't arrived yet not sure why
Engine cleaned, back together and onto the kart.
Started it up and it didn't want to run on anything less than half choke no matter what I did to it. Concluded that it can't be getting fuel when trying to run on the idle jet/pilot jet. Popped it out and found it clogged solid which was odd seeing as I cleaned it the other day.
Back together fired straight up and ran perfectly, got the carb setup perfectly now and it certainly likes to rev! Couldn't rev it too much tho as it vibrated and tried to jump off the axle stands haha.
Throttle cable hooked up and that's all I can do now until the brakes arive as I really don't want to ride it without being able to stop lol
Engine cleaned, back together and onto the kart.
Started it up and it didn't want to run on anything less than half choke no matter what I did to it. Concluded that it can't be getting fuel when trying to run on the idle jet/pilot jet. Popped it out and found it clogged solid which was odd seeing as I cleaned it the other day.
Back together fired straight up and ran perfectly, got the carb setup perfectly now and it certainly likes to rev! Couldn't rev it too much tho as it vibrated and tried to jump off the axle stands haha.
Throttle cable hooked up and that's all I can do now until the brakes arive as I really don't want to ride it without being able to stop lol
ezcome-ezgo
G'me sumthin to write on
Did anyone else see this?:
Thelegg
Active member
Few brake parts have arrived so made a start on fitting bits together and making mounts on the kart.
Caliper mount
The old fixed axle came in handy here as a good place to mount it
Made up a pipe for the brake set up so now I have everything together and working (bench test for now)
Now it works but the pistons don't travel very far in the caliper so I'm wondering if the rubber hose expands to much when under pressure from the master cylinder? I know the caliper and master work together as I have the same 2 on my other kart only difference is there joined via a braided hose
Still waiting on a new brake disc to arrive as the one I have is very thin so I've ordered a thicker 1 which should fill out the caliper better
Caliper mount
The old fixed axle came in handy here as a good place to mount it
Made up a pipe for the brake set up so now I have everything together and working (bench test for now)
Now it works but the pistons don't travel very far in the caliper so I'm wondering if the rubber hose expands to much when under pressure from the master cylinder? I know the caliper and master work together as I have the same 2 on my other kart only difference is there joined via a braided hose
Still waiting on a new brake disc to arrive as the one I have is very thin so I've ordered a thicker 1 which should fill out the caliper better
Thelegg
Active member
Decided to change the brake pipe to a hard line which removed loads of flex and gained more travel of the brake pads Brake disc arrived so fitted that
master cylinder also fitted and old linkages connected up with just a little bend required so nice easy install for once!
Inflated the tyres and thought I'd take it for a spin 
unfortunately I made it 2 feet and the chain came off lol easy fix... Nope of course not.
Turns out the sprocket holder I made from an old bearing carrier was twisting when the chain put tension on it so everytime you rev the engine everything moves and goes way out of line so now Ive got to wait ages for a proper carrier to come in the post.
Kart now parked back up with the rest of the gang lol
Brake disc arrived so fitted thatmaster cylinder also fitted and old linkages connected up with just a little bend required so nice easy install for once!Inflated the tyres and thought I'd take it for a spin
unfortunately I made it 2 feet and the chain came off lol easy fix... Nope of course not.Turns out the sprocket holder I made from an old bearing carrier was twisting when the chain put tension on it so everytime you rev the engine everything moves and goes way out of line
so now Ive got to wait ages for a proper carrier to come in the post.Kart now parked back up with the rest of the gang lol
Denny
Canned Monster
If that is your brake line with hard lines and fuel hose and clamps it will never work or be safe! Get the correct nylon tubing kits or go to a band brake.
Thelegg
Active member
Lol it's working fine at the moment and I did try to find a braided hose but I couldn't identify the thread in the caliper
it's not metric, it's not imperial, it's not pipe thread I can't identify it at all. All the lines were pressure tested with no leaks so I don't really see what the problem is?Denny
Canned Monster
You will.