Manco XTK Resto-Mod

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ShapeShifter

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Last night I repaired the cross member on the frame that the previous owner had removed. Also built a pipe and exhaust.

At first I thought this setup was too rich, but now I think it is running too lean. Anybody ever messed with the hidden air/fuel screw on one of these carbs?

 

ShapeShifter

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I dont have a .042 drill bit but I do have a .040 and slides through with lots of slop so its probably .042.

I dunno, the exhaust header just seems to get hotter than I expect.
 

ShapeShifter

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not all but these karts do, ive had 3 and they all steel like crap, but the is due to there design. these should have had dual a arms not singles

You say you had three like this? You mean three Manco 7xx?

Any idea where the VIN is stamped on the frame? I wanna try to get it registered....
 

ShapeShifter

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I got the predator starter key switch off of the engine and in to the Manco factory console. The actual key switch held the whole electrical box with the circuit breaker and diode together so I found a bolt to put in its' place. Without this bolt, the whole thing falls apart.

I'm using the existing factory wiring as jumpers for the predator key switch.





I also installed a remote choke knob below the key switch and made a simple connection to the choke lever on the carb. I removed a tiny amount of plastic from the black choke bellcrank to make it open and close smoothly without detents at either end.

The toggle switch below the choke knob on the console is for the headlights that aren't installed yet.





---------- Post added at 04:45 PM ---------- Previous post was at 04:29 PM ----------

I also tackled the crappy steering. I tightened and in some cases shimmed every linkage and ball joint. That made it better.

Everything about the spindles is junk. Even though all fasteners were tight, there was crazy amount of slop and none of it appears to be from use, it looks like it came from the factory with all this slop. I cant stand slop. So I drilled out the knuckles and fit some oil tight bronze bushings in them. I used washers on the top to shim it all and now it is MUCH better. You can actually steer this thing now.



 

Hellion

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...Should I just go abuse it, or should I completely strip it down to bare frame then paint and restore it...

Cosmetically, the buggy looks fine. It's not a rust bucket by any stretch of the imagination (unless you're hiding something?) but I wouldn't look down on polishing then waxing the dull paint.

Just fluff and buff and drive on.
 

ShapeShifter

Tinker Ninja
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Just say "NO" to slop.
Nice job on that kart, I love the way you pick a area, Tackle it, Win and move on.

Bubba
My current project
https://www.youtube.com/channel/UCLhMC6nTpD19FN_2jeW45YA

Thanks. I'm almost tired of winning. :thumbsup:

Cosmetically, the buggy looks fine. It's not a rust bucket by any stretch of the imagination (unless you're hiding something?) but I wouldn't look down on polishing then waxing the dull paint.

Just fluff and buff and drive on.

Yes. I need a fluffer.
 

ShapeShifter

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I finally got a change to take it out and thrash it about on some rough trails in the East Lake Berryessa hills last weekend. This thing is awesome! It can easily keep up with an ATV on the trails even with two, fat, drunken adults strapped in it. I am definitely going to start doing more upgrades. :thumbsup:

Suspension and reverse gear are a must.
 

ShapeShifter

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The build has been distracted by kids graduating and the 109 degree heat in my garage.

I have started to piece together the front suspension parts from a LT250 ATV. Not as easy to find all the bushing and bolt parts that I need but I have it all now. I also opted to get some pre-made weld tabs to hang the a arms on. At $1.25 a piece, it made more sense than cutting and drilling them myself.

I put the kart on the trusty old harbor freight 4x8 trailer. The thing barely fits! It will remain on the trailer as I design, cut and tack weld the reverse gear setup and front end for two reasons - Its nice and easy to reach and work on up on the trailer, and I have to get it to my buddy Dave's 30 miles away for him to do the nice welds and I wont be able to get it in the back of the truck when its cut up.




 
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