My first Kart Project

[MikL99]

Hi guys. I am new to the site and very new to go karts. My son has always asked me for one and when my neighbor found a old Manco American Express i bought it off him for 100 bucks.

This thing needs work and i got it as a project for my son and me to work on. So really i bought a frame as everything is beat up.

The brake works but the cable doesn't return on its own. The throttle cable is snapped and rusted. The engine was well not good. The clutch was no good.

So the first thing i did was run out and buy a Predator 212cc motor at harbor freight. I was about the buy the one it thought everyone was using when someone recommended model number 60363. They were both the same price so i got it.

This thing seems to be setup a bit different than the model #69730. As far as i can see the throttle seems to be backwards compared to the 69730. Do you think i will have any issues with that?

As far as the clutch i ordered a 3/4 centrifugal clutch with 12t and #35. I checked the chain that was on it and it appears to be #35 looking at the measurements. I went with the 12t as this was what was on the kart to start.

I'll post pics soon. I have a couple on my phone just need to upload to photobucket.

I should also say i have 0 experience with cars and karts. I'm a computer guy.

 

[firemanjim]

This is what your kart should look like.....
LoL let me put up the pic first.....i hit submit too soon....
You will find all the info you need, here.....
The 60363 is the hemi head predator, the best one, so you did good..... They all have the same throttle hook up, so no problems there.....
To post a pic, hit "post reply" , NOT quick reply. In the middle of the pages, you will see "manage attachments ". Hit that, and load straight from your phone/tablet/computer.....

 

[JMINDY]

Welcome MikL99, I'm fairly new here also... lurking for the past few months. I am rebuilding 2 Manco Karts with my boys, current one is a AmExp. Mine has the roll cage included.

Post some pics, start a build log... people here are very helpful!

Build Thread Here...
http://www.diygokarts.com/vb/showthread.php?t=26449

 

[MikL99]

I have 2 pics from last night. They might not be too good but its a start.






Firemanjim, did yo move your motor bracket back? That is what i'm concerned about right now. i'm not share how well my motor fits with the bracket in the spot it is now. I slid the bolts all the way as back as i could so it would hit the seat bar.

Do you guy need to make "washers" to line the clutch with the sproket?

 

[davidbooth1991]

Hi guys. I am new to the site and very new to go karts. My son has always asked me for one and when my neighbor found a old Manco American Express i bought it off him for 100 bucks.

This thing needs work and i got it as a project for my son and me to work on. So really i bought a frame as everything is beat up.

The brake works but the cable doesn't return on its own. The throttle cable is snapped and rusted. The engine was well not good. The clutch was no good.

So the first thing i did was run out and buy a Predator 212cc motor at harbor freight. I was about the buy the one it thought everyone was using when someone recommended model number 60363. They were both the same price so i got it.

This thing seems to be setup a bit different than the model #69730. As far as i can see the throttle seems to be backwards compared to the 69730. Do you think i will have any issues with that?

As far as the clutch i ordered a 3/4 centrifugal clutch with 12t and #35. I checked the chain that was on it and it appears to be #35 looking at the measurements. I went with the 12t as this was what was on the kart to start.

I'll post pics soon. I have a couple on my phone just need to upload to photobucket.

I should also say i have 0 experience with cars and karts. I'm a computer guy.

Hi mate. Does your brake caliper open and close..if so your cable not returning to open position should just be a spring on the caliper end...

 

[MikL99]

i will look over the brake line tonight. I believe it is missing a spring. The brake band does open and close.

As far as ordering a throttle cable for this kart. Do you know if i can order GO CART THROTTLE CABLE, MANCO #8252 from amazon? Will this be long enough? Not sure what you guys all use. I don't really want to return it.

 

[Poboy kartman]

Welcome "Ohio Mike"........ (I only give nicknames to people I like. . )

Yep....You came to the right place! !!!!!

 

[jandj]

When I put a clone on the Grandkid's Manco, I had to use an adapter plate as the gas tank hit the back of the seat limiting my ability to slide the motor in the bracket.
www.hotrodminibike.com
Click on "engine install kits" and scroll down to the motor mount.
As for the gas cable, 8252 is casing length 55", cable length 61".

 

[davidbooth1991]

When I put a clone on the Grandkid's Manco, I had to use an adapter plate as the gas tank hit the back of the seat limiting my ability to slide the motor in the bracket.
I don't remember the name of the company (I'm sure it's in one of my old posts but I will search for it again), but they built the "doodlebug" minibike if I remember right.

Was that Baja???

 

[jandj]

I believe hotrodminibike makes stuff for the Baja, but I'm not a minibike guy and can't say for sure.
Their website shows some Baja's.
Not sure why I was thinking Doodlebug.

 

[MikL99]

This should be my last post of the day .

I'm going to break in the motor tonight as my kid is to excited about the project. The only thing i have done so far is bolt down the motor to the cart. I know i will have to line up stuff later but i did this for the break in of the engine.

There isn't a lot of information in the guide about breaking in the Predator 212cc engine. I was thinking about adding fuel and oil and then start it up and let it run for 3 hours at idle. after 3 hours let it cool down and then drain the oil. Add new oil and more gas. Is that all i need to do to break it in? Or after the initial 3 hours do i need to do another 1 hour of increasing the idle?

Not sure and any help you can give me with this will help. As i said i'm not a car guy so i'm learning along with my son.

Thanks.

 

[firemanjim]

The break in info is in the manual, but it's something like what you said. I think you rev it to half throttle on occasion to help everything seat properly..... As far as throttle cables go, I just buy a bicycle cable repair kit from walmart. It has a bunch of different lengths, and it's like $6..... You should be able to loosen the axle sprocket hub, and slide it over to line up with the clutch. If you have to, I buy 3/4" ID washers from homedepot.....

 

[OzFab]

Firemanjim, did yo move your motor bracket back? That is what i'm concerned about right now. i'm not share how well my motor fits with the bracket in the spot it is now. I slid the bolts all the way as back as i could so it would hit the seat bar.

Do you guy need to make "washers" to line the clutch with the sproket?

Due to the Predator being longer than the original engine, many have had the same problem; most simply move the engine mount but, I'm guessing that won't be as easy for you...

I only have 2 suggestions for you:
1. Find a friend who can weld to move it for you or
2. Elongate the existing slots (but, I'm not sure how well that will work)...

 

[MikL99]

I don't think i'm going to need to move the engine bracket as i think it just fits. if i did have to move it i do have a friend that can weld it.

I was able to take apart the throttle and flip the washer on it so now the throttle is not "tight" anymore. I was also able to add a return spring for the throttle. All that is left with that is waiting for my throttle cable to come in the mail this week.

I'm also waiting on the clutch to come in as well. Should be here tomorrow.

2 other things on the list is to wire a kill switch and figure out where to put a return spring on the breaks. Right now i just have a break line rod connected from the petal to the band break. it looks like they welded a small nut close the the band break however i think i would need a really small and strong spring to get it to return. I think i might have my friend weld another nut in a different location.

Oh and i also scored some quick and cheap front tires from Harbor Freight this weekend. $4.00 each. They were the same size that were on there.

 

[jandj]

Go get your $8 back and get some good wheels and tires.
You'll be glad you did, as you will need them shortly.

 

[Young One With A Manco]

WHAT HE SAID!!!!
I put HF Tires on my mini bike and they lasted 2 days with about 2 hour run time each day. Then there was almost no tread left.

 

[Poboy kartman]

Go get your $8 back and get some good wheels and tires.
You'll be glad you did, as you will need them shortly.

Naw....they will be fine. ...until he gets the engine hooked up.....

He can push the kart with them though........and they might last as long as a da day.....with a motor..... (records are made to be broken!!!!!)

 

[OzFab]

I think i might have my friend weld another nut in a different location.

I'm not sure that's a good idea; the rod can be threaded through a single nut quite easily but, adding a second nut will make it a tad more difficult... & by that I mean a LOT...

 

[davidbooth1991]

I agree with fabro man. If you want to do that you need to line them up spot on. As if the thread continuse through.

 

[MikL99]

I'm sorry, i meant add another nut so that i can hook up a spring to it. Not to change where the rod screws into. There are two holes on the rod. One has the screw threw it the other would be a spot for a spring. I was thinking of adding a nut to the frame so i could add the return spring.

As for the tires. i agree they might suck and get tore up fast. For now they are better than what was on there till i find tires. He is going to ask for tires for xmas. So if you guys know where a good place for 10 inch tires with 4 inch rims and 15 inch tires with 6 inch rims that would be helpful.

Also should I or do I have to stay with 4inch tires on the front? Or can i go all 4 tires with with 15x6?

Thanks.