DIY Frame or Ready Built

[fresh101]

I would consider a clutch in the $70 range.

I forgot to ask you, how would I mount the rear caliper? Do I need to buy a bracket for it?

 

[anderkart]

I'll keep looking, but used bumpers and nerfbars are hard to find for Birel karts.
I found this Birel rear bumper on ebay: http://www.ebay.com/itm/Birel-Rear-...pt=Race_Car_Parts&vxp=mtr&hash=item4ab52062b6

We could probably find a lower price on a rear bumper made for another brand kart. But first you'll need to measure/post the distance between your 2 rear frame rails where the bumper mounts. You'll need to measure from center to center points of those 2 frame rails, post this measurement in Inches. I'd also need to know how many millimeters the inside diamiter of those 2 frame rails are.

I'd suggest this Part# 'NARC11' Noram 11T GE Clutch with Light Shoes: http://www.out2win.com/catalog/noram_ge.html

Yeah that caliper bolts right on the frame without a bracket.

 

[fresh101]

I will be buying the clutch right now.

EDIT: Already purchased the clutch. Thanks

 

[anderkart]

I found some Birel rear bumpers here: http://store.cambriangokarts.com/store/category/3/44/Nerf-Bars-and-Bumpers/
But you'd need to conform their width and buy a mounting kit.

Their site lists your floor pan too but its exspencive: http://store.cambriangokarts.com/store/category/3/249/Floor-Pan/
Maybe you could build one out of sheet aluminum to save $$$

 

[fresh101]

I really need the front bumper first. **** the floor pan is pretty expensive but I already had it, I got mine for $20.

NOTE: The parts has been shipped this morning, already have a tracking number.

 

[anderkart]

Yeah I've been looking at your pics but I cant seem to figure out how your front bumper bolts on. I cant tell if the mounting holes/tabs are missing or what... Try to post some new pics showing that area and we'll try to find a bumper that fits.

 

[fresh101]

If I need to drill new holes to add the front bumper, I don't mind doing it. Can we use the same thing used for the seat, like the brackets?

 

[anderkart]

Yeah you might be able to clamp a bumper on there. Or buy most any bumper and have mounting brackets welded on the frame.

I think the Freeline Front Bumper ($92.03) here is like your kart originally had: http://store.cambriangokarts.com/store/category/3/44/Nerf-Bars-and-Bumpers/
(those 2 up-rights would bolt on through holes in your front hoop)



I think your original front bumper was wrecked, and it tore off Its rear mounting brackets from the frame, and then maybe they welded the 2 holes in your front hoop closed, and then ground everything down smooth and repainted the frame. I think your original bumper looked like this pic:

 

[fresh101]

Before and after sand blasting brake rotor and hubs.

 

[fresh101]

final product, painted

 

[anderkart]

Looking good man

 

[fresh101]

Thanks buddy,

I got in today the engine mount, keys for the axle, clutch un-assembled & tie rods.

QUESTION: How do I assemble this clutch, I thought it came assembled?

 

[anderkart]

You'll need to carefully tap that bushing into the drum until its level with the outer part of the gear. Use a piece of wood between the bushing and your hammer, and make sure the bushing is going in straight.

Then instal the key, and slide clutch hub assembly on, (it can go either way)
then the fiber washer goes on first, metal washer second.
Then use your finger to work 2 drops of motor oil into the bushing, and slide the drum on.

Then you'll need to buy a Grade-8, 5/16"-24 x 1" long bolt, plus a 5/16" lock washer and fender washer to hold the clutch on. It'll screw into a threaded hole you'll find at the very end of your crankshaft.

When you try to tighten this bolt, the engine will just start spinning. To stop the engine from spinning, you'll need to simply remove the spark plug and feed a few inches of clean rope down inside. This will stop the piston from going up so you can tighten the clutch bolt.

I just noticed your clutch didnt come with a key, you could order one online or most hardware stores stock the 3/16" keys that you'll need.

But before you instal the clutch, we need to figure if we want its drive gear facing the engine, or away. (that's called mounting your clutch inboard or outboard) I prefer inboard facing the engine when I have a choice, but depending on how everything fits on your kart you may have only 1 possibility so the chain will line up.

So I'd suggest you instal the axle with the sprocket first, then bolt the motor mount and engine on, and see how the chain lines up. This is the only way you can tell for sure in you need to mount the clutch inboard or outboard.

If you dont have a #35 chain yet, I recommend the 106 link, RLV gold on gold here: http://www.out2win.com/catalog/chain_35.html

You should order a #35 chain breaker tool: http://www.out2win.com/catalog/toolcb.html

And you should get a chain guard for safety: http://www.out2win.com/catalog/chain_guards.html
Any of those Briggs Guards will bolt on your clone engine.

Plus you could just order a key for your clutch here too: http://www.out2win.com/catalog/noram_ge.html

 

[fresh101]

Thanks for the info. I was checking this site Gear Ratio Calculator and it tells me using a 55 tooth on axle I will be going 7.5mph but the calculator from this site it says 24mph. Which one is true?

 

[anderkart]

You have to enter tire Circumference into that calculator, not diameter...
11" tall tires = around 34" circumference.

 

[fresh101]

Ok, I have removed the top cover and blow and the air just come out from the rear where the fitting for the tubing goes.

The rear axle, I can't figure out how it's installed? I got Freeline cassettes as shown in the image with the bearing also installed. NEED HELP INSTALLING

Does the bearing need to be removed, if so, how can I remove it?

 

[fresh101]

More pictures of cassettes and holder on the frame.

 

[anderkart]

This Birel has the new style caliper, but your cassettes bolt to the inside like these pics:

 

[fresh101]

I can't get the cassettes in, do I need to remove the bearing? or do I have the wrong cassettes?

 

[anderkart]

Yeah that's the wrong cassette. We'll figure it out tomorrow.