First Go Kart - Father Son Restoration

[moe214]

Hello,

This is my first post and go kart. First and foremost I want to say thank you to this community for all of the valuable knowledge in its threads.

Thought I'd start a build thread. I have zero experience with go karts but do consider myself comfortable with a wrench.

A few weeks ago my son (11) and I picked up an old and abused Yerf Dog 3002 with the intention of restoring it. I found the kart on CG and immediately thought it was a steal... not the case. From the picture (below) I honestly thought it needed minimal work and I'd have it running in no time. After "inspecting" it in person - it had 4 wheels and tires, motor, and the wheels turned with the steering wheel! It's a winner!! Didn't think twice and loaded it up.

After further review,I noticed the kart needed:

-New tires all the way around - one of four tires held air
-TAV2 torque converter
-chain
-repair weld - drivers side upper bar
-Paint

So... we picked up:
-Tires
-TAV2
-Chain
-Paint

We took it apart sanded it down, removed rust with a wire wheel, primed and painted it. We put it back together, installed the shocks. and ran into major issues when attempting to install the TAV 2.

I immediately noticed chain clearance issues with the tav 2 mounting plate. I tried all possible mounting variations and all had issues. I know I'll catch grief for this but... I took a grinder to the plate and "corrected" the clearance issue. Put the plate and chain back on and gave the rear wheel a spin. It was obvious that something wasn't right, the chain was rubbing hard on something and was making a clunk sound - would not spin freely. The jackshaft and axle sprockets seemed aligned. I took the Tav2 plate off and watched the axle shaft as I spun the tires - should've done this to begin with. I noticed the axle sprocket wobbles pretty bad. DOPE!

By the way, It took more than a week to dismount the rear rims from the axle. Tried ALL of great suggestions on this forum and finally got them off. Feels like a right of passage lol

With the tires off I proceeded to trying to remove the axle to replace the sprocket. I'm thinking the bent sprocket is what's causing the chain to shift and therefore gives off the impression that it's rubbing somewhere.

I proceeded to removing all of the bolts on the bearing brackets and no luck. The bearings seem to be seized to the axle as well. Here we go again... I'm going to try everything possible to salvage the axle and save $$.

The BAD - I completely underestimated the scope of this project. The GOOD - my son smiles ear to ear every time we enter the garage to work on it.

Ive gotten this far Thanks to this wonderful forum. All items purchased from Go Power Ports - Im in Dallas so I drove up there, great folks!)

I'll keep you guys posted on the axle sprocket replacement.

 

[Texan]

Good progress so far. Really cool to get your son involved and start wrenching at an early age

 

[moe214]

Thank you Texan. Figure every minute away from the PS4 is a win.

Forgot to mention - I removed the bearing retainer screws on the 2 closest to the wheels. The inside of screws on the middle bearing are rounded. This will a challenge as well.

 

[Ebrownie]

Welcome! Thanks for the pics, most times we have to ask for them
And about the torque converter mounting plate, clearance isssues are fairly common and there isn't any problem with grinding a bit

 

[Hellion]

Good thread--hit the ground running here.

...Figure every minute away from the PS4 is a win.

I'd quietly confiscate that nonsense. Those are adult toys anyway but for youngsters, they devour brains IMHO.

You are going to get another kart right, for you? Two seater go karts or buggies with both seats occupied are just...slow.

Two is better.

 

[Gear_head]

I have two recent threads about karts I have bought to restore for my daughter. While I got good deals on them, both had bent axles among other issues.

One brake hub I likely would have never have gotten off, so I used the cutting wheel carefully to remove it. These are skills your son will take with him forever. I can't tell you how many helpless males I work with...

 

[moe214]

Does anyone know if Yerf Dogs came with eccentric locking collar bearings? Wonder if this is what's causing the bearings to stay in place and may have to turn the bearing before trying to remove it.

I'll try posting pics of the bearings later today.

---------- Post added at 05:32 PM ---------- Previous post was at 05:23 PM ----------

Thanks to all for the warm welcome and input... Please keep it coming

 

[moe214]

Good thread--hit the ground running here.



I'd quietly confiscate that nonsense. Those are adult toys anyway but for youngsters, they devour brains IMHO.

You are going to get another kart right, for you? Two seater go karts or buggies with both seats occupied are just...slow.

Two is better.

Hellion - that's the plan. I've been looking at CL for an actual good deal. I'll be prepared this time around. I'd like to pick up a street kart next (non off road). That'll be Dads ride!

 

[moe214]

Here are some pics of the bearings that refuse to come let go. Removing the axle is proving to be difficult. Suggestions anyone?

Here are some pics of the Tav2 plate modifications as well.

 

[Gear_head]

If you are trying to save the axle, lots of heat. Lots of heat and a big hammer

 

[OzFab]

Removing that axle will take time & patience; first, remove the rust from around the bearings using a file or emery cloth (or coarse sand paper), then try to move the bearings in one direction, even if only 1/8", repeat the rust removal process, then move the bearings in the opposite direction, repeat the rust removal process again; keep repeating this process until the bearings move freely...

 

[moe214]

New Axle

Hello,

We ended up cutting the axle off. Stopped by GoPowerSports again today and picked up a few items. Great guys, world class customer service.

Picked up:

Axel
Sprocket
Bearings
Lock Collar
Drum

Began installing the Tav2. Got everything on, last step, and noticed a washer is missing. After some research I found it's called a pilot washer, pictured below from a you tube video. I'll give GPS a call Monday to see what they can do.

 

[moe214]

Here'a a pic of the missing washer.

 

[ezcome-ezgo]

That cut axle just makes me sad.

 

[mckutzy]

The bearings aren't eccentric in any way.... If anything they would have eccentric locking collars...but those are just plain with setscrews...

That wasnt badly rusted at all... No need to cut the axle...

 

[moe214]

Believe me... I tried. It hurt me too LOL I'm the one who had to cut it.

Honestly, it came down to time/effort/tools needed to get it done. Without a torch, I was looking at many long nights with a sledge. I think the peace of mind of new bearings and a straight axle sprocket was well worth it.

I'm now dealing with another issue.

Got all put back together and found the chain is rubbing the TV2 backplate near the jackshaft. I'm starting to think the chain is too thick? It's a #40 chain.

 

[moe214]

Here's a pic

 

[Hellion]

I dunno. How about a spacer--a washer of the appropriate size?

Is there room to slide that small sprocket out and away from the plate?

 

[MTNSleder]

Try using #41 chain... That should stop chain rubbing against the backplate... You'll need a new sprocket on the axle though...

#41 chain will fit on your torque converter, #41 chain is narrower than #40 chain..

Heres a chart...

 

[Hellion]

I read the account of how you brutalized your axle and I wept inside.

There's really no excuse for not having one of these. I've removed otherwise permanently rusted-on axle hubs and fixed stuck, corroded valves in a Briggs flatty with this simple tool. Other challenges await...