Manco 495-B Fox Conquest

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Ycgoat

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I picked up a Fox Conquest and the more I work on it the more I find wrong. I have found a few manuals with part #s, but have not dug into them quite yet to see if I can verify a proper part when comparing to online availability. The diagrams I found were from posts in here but all reference 485/486 with different sub models. Is there a way to verify which diagram or sub model or even exact model if different from what I have. My concern is I would like to be able to confirm if I am buying the correct part.

Example: it lost a front wheel nut on the first shake down run (after fixing the no start problem). The other side is jammed on either glued or cross threaded, so I bought some parts from GoKart supply:
5/8" SPINDLE BUSHING 7/8 LONG
5/8" SPINDLE BUSHING 13/16 LONG
Description: LOCK NUT 5/8-18 NYLOCK

This cart is at a rural property a few hours away so I can't just walk out after work and check sizes. I believe the nut I bought is 5/8-18 but I have confirmed a typical 5/8-11 works, and the only bushing I see is inside the wheel chase. My point is How do I verify proper fitment before buying parts. My next purchase will be brakes which are completely inop. Any insight to help my buyer's remorse for not digging deep and spending of few grand on a Hammer head.
 

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Hellion

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Ycgoat said:
The diagrams I found were from posts in here but all reference 485/486 with different sub models. Is there a way to verify which diagram or sub model or even exact model if different from what I have.
Click to expand...

Does your kart have an intact model number sticker? To be honest, the different sub models don't vary too much between models because having a wildly different model in a company's lineup does not make much sense to a mass production manufacturer on a busy assembly line. Time is money and parts complexity also complicates things. Variety is the spice of life, but a manufacturer can make a lot of similar karts with the same running gear but be wildly different in terms of 1 or 2 seater, different paint schemes, different tire sizes, etc.
 
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Ycgoat

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That makes sense. I found an operators supplement for 485B-1X and 486C-1X it gives a caliper assembly part # as 9597, An operators supplement for 485B-0 and 486B-0 it gives a caliper assembly part # as 9598, and an operators supplement for 485-25, 485-26, 485-241, 485-291, 486-252, and 486-352 it gives a caliper assembly part # as 9598.
 
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Ycgoat

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That is a clear vs and lists the brake caliper assembly as 9597. I guess I need to measure all of the parts and compare any available specs once I have narrowed down based on these part #s.
 
Hellion

Hellion

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There are a few owner's manuals in cyberspace but the bulk of existing info for the now-defunct Manco/American Sportworks fun karts are the "Owner's Manual Supplements" like you mentioned which are just exploded parts manuals. The drawings are good and exact enough for product ID, luckily.

A massive amount of photos will help us help you. Most of us can ID a part with the OEM Mark 1 Eyeball with great skill.

There's basically only one version of that mechanical brake caliper but many manufacturers, a lot of them Chinese now. I think the original manufacturer is/was AirHeart now Tolomatic.

 
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Manco model 495-B "Fox Conquest" is what I was able to find and cross reference. It looks like your kart but I only have your one photo. Karts just aren't that well documented in cyberspace because people just don't photograph their stuff all that often. Guess they think it's as ubiquitous as a VW Beetle in the mid 70's and just as boring lol.

The 485-B (or any suffix) is just one number off but it is a completely different frame style. No wonder you are confused....

Model 485 Go-Cart Parts Manual

Model 485 Go-Cart Parts Manual
gokartsrus.com gokartsrus.com

The list at the link shows the progression of the 485 series. Side bars up to the edge seat back, no head rest, then a full wrap-around side bar and full safety cage (actually a brush guard). EDIT: I mentioned this off topic verbiage because I didn't want anyone saying "aha! there's some 485 karts that look wildly different so how can you positively identify a 485 from a 495?"
 
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Ycgoat

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So this was the first weekend my 11 year old grandson got to ride the gokart. He was limited to some fields and gravel driveway since his dad was in the woods hunting. About 10 minutes after opening the trails through the woods, BAM he side swipes a tree and bends the axle
 

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Welp, that didn't take long... first time out on it 😁 🤯 I say make him pay for the repairs. Chores, his allowance, etc., and he gets to learn about axles when the new one comes in and he helps you fix it.

He's a special one. :roflol: i kid, i kid.
 
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It made me think of this [see timestamp 1:08]. ....😂


These go kart axles are tough, hardened steel and all, but they are not meant to take that sort of side load or impact. Riding mowers have similar axles but they all have a differential. Anyway, we don't see who damaged John Deere because the guy at 1:08 hits around his front tire (maybe this is a second heat?) Then, later on the guy that hit John Deere himself has a bent axle at about the 2 minute mark....
 
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Hellion said:
It made me think of this [see timestamp 1:08]. ....😂


These go kart axles are tough, hardened steel and all, but they are not meant to take that sort of side load or impact. Riding mowers have similar axles but they all have a differential. Anyway, we don't see who damaged John Deere because the guy at 1:08 hits around his front tire (maybe this is a second heat?) Then, later on the guy that hit John Deere himself has a bent axle at about the 2 minute mark....
Click to expand...
Hellion you owe me 8 plus minutes of my life back!
 
Hellion

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Ycgoat said:
About 10 minutes after opening the trails through the woods, BAM he side swipes a tree and bends the axle
Click to expand...

Maybe it's your fault and the offending tree was in the middle of the "trail" and you were lax with Mister Chainsaw? I'm joking 😁

We can help you fix it, be your moral support and shoulder to cry on and so forth. *I renamed the thread because it is more descriptive and informative now that it has morphed.
 
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Just got back, he is supposed to do the bulk of the work, but did not finish taking off the plastic skid plate before getting distracted. I am sure glad I did not spend thousands on a new or newish polaris, and that he was not hurt
 
Hellion

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We are glad he wasn't hurt. A really crafty person might be able to bend that axle back into shape, some here have done it but I'm not that crafty person. I bet a good machine shop could do it using gauges and a dial indicator to check for true.

These old karts have the edge on other recreational vehicles on the ride, wreck, wrench and repeat cycle. They are made of and use inexpensive, generic parts and they are still a'plenty even though the domestic go kart industry is defunct.

Let us know how it goes.
 
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Ycgoat

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Took a while to get him back on focus, but the axle went back in this weekend with minimal double work. The brakes did not work when the kart was bought; we put a new manual caliper in but the lever actuator is backwards. I got the caliper apart, using an impact, but I need to drive the lever pivot pin out in order to flip it. Hopefully it goes well.

Are the caliper bolts torque to yield? they seem stretched
Will the lever pivot pin re-insert once driven out?
 
Hellion

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Ycgoat said:
...put a new manual caliper in but the lever actuator is backwards
Click to expand...

I think some of the calipers are modular, meaning you can choose which side to put the actuating lever on. Got a pic of yours?

This chart however, shows clockwise and counter-clockwise pull but not both:
www.tolomatic.com

MB1 Series Mechanical Caliper Disc Brake - Tolomatic

www.tolomatic.com

Ycgoat said:
Are the caliper bolts torque to yield? they seem stretched
Will the lever pivot pin re-insert once driven out?
Click to expand...

On your original caliper or the new one? I would just tighten them snug and keep in mind you are tightening steel bolts on a softer cast aluminum. They will 'smush' some.

It should re-insert. Maybe Denny knows for sure.
 
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This model appears to have an opening for the lever on the bottom side:


Image 804.jpeg
 
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Ycgoat

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T second photo looks like the one I have. I got it from Go Power Sports (9597-9598) along with the other replacement parts and it fits nicely just reverse action. Thanks for the parts link

Thanks for
 
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