My first build

souperman000 · Feb 8, 2012

Alright, I know that it has been a while, but I got my engine back from the guy that helped me with the clutch. We tried it tonight and we couldnt get it to idle.

If we lowered the throttle to just above the cutoff, it would start to jump and backfire. no clear clean idle was produced.

Besides that, I should be getting my kart frame back from my neighbor (he is head maintence guy at my HS, pretty sweet

). he used a supposedly pretty high tech power washer that the school had to take the paint off.

When I get my kart back, I will ask a bunch of questions, post a bunch of pics, and start ordering parts. Probably wont be until next week though because I am going out of town this weekend.

Thanks guys and I look forward to posting those pics for you guys to see! :auto:

souperman000 · Feb 26, 2012

Alright here we go...get ready for a long post and lost of Pictures!

Anyway, Yesterday I got my frame back from the High School (My neighbor sometimes forgets to bring stuff home cause hes so busy but hes a cool guy so its alright). The paint removal didnt turn out as well as I had hoped but I think it will work well enough. Pics:

Now, I got the engine back from a friend's friend That was making the adapter for the clutch. tell me what you think. I ran the engine for a long time and it stayed put...so I guess thats a good thing :roflol:

He even cleaned up the clutch parts and spray painted the outside which just went above and beyond in my opinion, I am really pleased with it.

Also, after looking at some charts for chain sizes and what Rchez said in one of his posts, this clutch is for a #35 chain right?

Here is a mock-up of what the rear of the kart will look like with the gas tank on the frame. I will be finding somewhere else to put the gas line as it is obviously in the way now. The rake handle is just reference for where the axle will be.

The clutch and the sprocket might be really close together but that shouldn't affect anything much right?

I have these rods that came on the kart, they are broken and I think I am going to take them off for a cable only control system.

Also in terms of hooking up the kill switch, I found this cut cable on the frame, is my assumption correct that it was used for a kill switch?

Do these wires near the throttle have something to do with the kill switch hook up too or not?

souperman000 · Feb 26, 2012

A big concern for me is how to hook up the throttle cable. It seems like it would be difficult to hook up as the throttle controls are on the back of the engine basically diagonal form the pedals. Sorry if the pic doesn't show it well.

I am just hooking up the remote throttle cable to where my finger is pointing, correct?

Since I am kinda bad at judging gear ratios, would this combo of sprocket and wheel be a good choice?The sprocket will be 72 teeth. My clutch is either an 11 or 12 tooth, I cant remember off the top of my head.

http://www.bmikarts.com/item/20-Rear-Superturf-Tire-Rim-&-Wheel-Hub-Assembly-05643-7324

http://www.bmikarts.com/item/35-Split-Sprocket-6335-6565

Alright guys, I know that my post was really long but I think that I am on my way to making some major progress. :wai:

here are some more pics of the kart.

Thank you. :cheers2:

EDIT - I fixed the idle too, the screw was too tight, just had too look at the manual...

souperman000 · Feb 26, 2012

I really like those tires from BMI but after looking at the pictures again, they might not fit. That really sucks cause I really liked those wheels

Bluethunder3320 · Feb 26, 2012

just an opinion, flip the clutch backwards so that the sprocket side faces the engine.

this is because it seems like your adapter sticks out pretty far, and its best to keep the torque load as close to the support bearing as possible.

and it should help keep the chain from derailing and flying off, and less flex from the engines torque

Bluethunder3320 · Feb 26, 2012

souperman000 said:
Do these wires near the throttle have something to do with the kill switch hook up too or not?

yeah, when you lower the throttle it should kill the ignition, so i would disconnect those

souperman000 · Feb 26, 2012

ok, Ill look into the clutch this week, i might not be able to do it though because I dont have a gear puller but maybe I wont need one. Thanks Blue

landuse · Feb 27, 2012

Yup, that wire is for your kill switch. It needs to be grounded to the frame. Your gear ratio looks like it will be 6.5:1 if you have a 72T sprocket. I counted your clutch, and it is 11T. You are going to see if this works out for you, but you should be OK I think. As long as you dont go higher than 6.5:1 (ie, something like 5:1)

I agree with blue about running your clutch inboard.

souperman000 · Feb 27, 2012

How do you think I should hhok up the throttle cable? I dont want to use rods but now that I have thought about it, because of the angle maybe ill need a rod to mitigate the turns of the cable? I don't know and i cant really think about a probable solution.

Ill try my best to work on the clutch, but as I said, I don't have a gear puller so it might be a little difficult for me.

qtband · Feb 27, 2012

Use a rod to go from the pedal to under your seat. Then use a cable. The turns should be OK if they aren't to drastic. Get a pack of bicycle brake cables from Walmart and use them. They are cheap!

souperman000 · Feb 27, 2012

ok well the clutch inversion is going to have to wait a little while, but I am hopefully going to start ordering parts this week. Just to make sure my clutch is #35 right?

Use a rod to go from the pedal to under your seat. Then use a cable. The turns should be OK if they aren't to drastic. Get a pack of bicycle brake cables from Walmart and use them. They are cheap!

Is it possible to recycle the rod that is already on the kart or is the end too chewed up? I was thinking of getting this package: http://www.bmikarts.com/item/Throttle-Kit-400725-790 because it has all of the fittings I need. Would that setup be compatable with the engine hookup and the rod or will I need some extra fittings? I will look into the bicycle brake cable also.

Thanks

landuse · Feb 28, 2012

souperman000 said:
Just to make sure my clutch is #35 right?

Thanks

Yes, you have a #35 sprocket, so make sure you get everything else the same. A #35 sprocket has a 3/8 inch pitch, which is what you measured in one of your pics

souperman000 · Feb 29, 2012

so, I dont have a chance to get to HF this weekend but next weekend is a parking lot sale anyways so I guess it works out. I am trying to order parts sometimw this week or next, I will keep my thread updated.

Thanks for all your help.

souperman000 · Mar 2, 2012

well I was messing around with the clutch tonight and I was able to pull it off with my hands :rolleyes3: Try and get some pics this weekend. gonna start taking apart the unneeded stuff on the frame in preparation for the new parts.

souperman000 · Mar 2, 2012

I am a bit confused. I have seen bearing kits with 2 flangettes and some with four.

Do I really need 2 on each side or will one suffice?

souperman000 · Mar 3, 2012

will this kill switch (or type at least) work for my engine? I am confused on how to wire a kill switch.

http://www.bmikarts.com/item/Toggle-Kill-Switch-400501-5917

souperman000 · Mar 6, 2012

I want to start ordering parts but I am extremely confused on the pedal to throttle and the pedal to brake caliper hook up. How do all these things work together? I have seen many kits around the internet and I am just really confused. :mad2:

fowler · Mar 6, 2012

Q1 u need 2 flages on each bearing

Q2 any 2 way swith will do for a kill switch
that one is good

the kill swith is like adding a short in the system by takeing the power the coil is produceing and grounding it to the engine

basically it means no power gets to the spark plug and since there is no spark there is no combustion

Q3
if u have medium fabrication skills u can make your own pedals

but all u need is pedals that allow u to attach a cable
and when u press the pedal it will pull the cable

souperman000 · Mar 6, 2012

Q3
if u have medium fabrication skills u can make your own pedals

but all u need is pedals that allow u to attach a cable
and when u press the pedal it will pull the cable

I have pedals and everything already. Maybe I phrased my question wrong. I mean how does the throttle cable connect to the engine throttle and how does the brake cable connct to the caliper? Which kind of wire stops/bolts/springs etc...will I need to make it work?

souperman000 · Mar 6, 2012

Does this kit have all the parts I need to hook it up to the pedals and engine? http://www.bmikarts.com/item/Throttle-Kit-400725-790

There are pics of my throttle linkage in the above post with all the pictures.

My first build

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