Need setup advice

[BrownStainRacing]

You got plenty of knowledge now, and know what to look for.

Sounds like dad, likes to tinker and keep the kids happy, and maybe a ride now and then.

The fox sounds like a good deal also.

Be safe and have fun!!!!!!

 

[Denny]

Maybe you need to get mom’s but on one for a few hours?

 

[joshw0000]

Maybe you need to get mom’s but on one for a few hours?

Actually, I did get her on the Yerf and she enjoyed it. She just gets stuck on the whole money not growing on trees blah, blah. Ya can't take it with ya, right!

 

[Denny]

Tell her that it’s cheaper than being hooked on drugs!

 

[jschil3]

I know this is an old thread but I wanted to thank you guys. I have the same Kart and stumbled across it because I put on a 212 with a 30 series and I keep burning belts and not getting the power I thought it would have. Sprocket ratio plays a way bigger part on this kart then I assumed. Luckily I'm a welder by trade but not looking forward to cutting and extending the frame especially since just like you I already welded the new motor mount in, and I welded it so it would never move again lol. Was curious does any one know if they make a split universal adaptor along with the split sprocket? Be real nice just to cut the old sprocket off and bolt a new one instead of pulling the axle. I guess I could always buy the solid one and split it myself then bolt it and weld it back together.

 

[joshw0000]

I know this is an old thread but I wanted to thank you guys. I have the same Kart and stumbled across it because I put on a 212 with a 30 series and I keep burning belts and not getting the power I thought it would have. Sprocket ratio plays a way bigger part on this kart then I assumed. Luckily I'm a welder by trade but not looking forward to cutting and extending the frame especially since just like you I already welded the new motor mount in, and I welded it so it would never move again lol. Was curious does any one know if they make a split universal adaptor along with the split sprocket? Be real nice just to cut the old sprocket off and bolt a new one instead of pulling the axle. I guess I could always buy the solid one and split it myself then bolt it and weld it back together.

Welcome to the forum. Like me, you've found the right place to get help. You'll find that everyone here is super helpful.

Ok, some prerequisites... What gearing do you have currently? Front tooth count and rear tooth count? The goal here is to be 6:1, so 10T/60T or 12T/72T.

You're going to have clearance issues if you go any larger than I did with the rear sprocket. Since you're a welder, plan to cut the frame and either extend it completely or notch it out for the sprocket. I didn't do that but wish I did.

Do you have enough adjustment in the motor to move it over a little bit (the width of a sprocket)? If so, buy any split sprocket and weld it to the one currently there. You'll likely have to drill for the bolt holes, then go to town welding it.

I own a better MIG welder now and have gotten better at welding. But I no longer own the cart. If I did, and had it all to do over, that's what I'd do.

 

[jschil3]

Thanks for the reply. Yea I read this thread extensively and you guys had so much good information. Currently I have the original tao tao set up 13t 428 on the tav and 43t 428 on the axle. I played hell with making that 428 chain fit in the torque converter lots of modifications ( that now seem like a waste lol) . I'm gonna try to find a 60 tooth split and like you suggested possibly bolt or weld to the old sprocket. I would really like to not have to remove the axle but if I have to I will. Def gonna have to extend the frame to make it fit. I pretty much can move the motor to the right as far as I need but if I gotta go left I'm gonna have to raise the motor to avoid the brake. Any suggestions on a sprocket? I've found a couple on Amazon but haven't pulled the trigger yet.

 

[joshw0000]

Thanks for the reply. Yea I read this thread extensively and you guys had so much good information. Currently I have the original tao tao set up 13t 428 on the tav and 43t 428 on the axle. I played hell with making that 428 chain fit in the torque converter lots of modifications ( that now seem like a waste lol) . I'm gonna try to find a 60 tooth split and like you suggested possibly bolt or weld to the old sprocket. I would really like to not have to remove the axle but if I have to I will. Def gonna have to extend the frame to make it fit. I pretty much can move the motor to the right as far as I need but if I gotta go left I'm gonna have to raise the motor to avoid the brake. Any suggestions on a sprocket? I've found a couple on Amazon but haven't pulled the trigger yet.

Honestly, your best bet is going to be to convert to a 30 or 40 series sprockets.

I don't see any splits for 428 that are more than 30T. Here's a 56T (not a split). You'd still have to remove the axle and do a good bit of cutting/welding to make it work.

WPHMOTO Rear Sprocket 428 Chain 56 Teeth 52mm for 110cc 125cc 150cc ATVs Quad 4 Wheeler https://a.co/d/4JgPwGC

And I have this 10T that I ordered from over seas but never used if you go that route. Not 6:1, but pretty close if you can make a 56T fit.

If you decide to convert to 30 or 40 series, you can use the front sprockets that came with the T/C, chains are pretty cheap, and just cut the 428 rear sprocket off and find a split sprocket that fits the old bore. I'll have to dig through my old posts to find the bore size, but the one I ultimately ended up using did fit. I only had to drill out for the bolts.

 

[joshw0000]

Here's a split 60T 40 series.

Split Sprocket #41/420 (41SS)

The Split Sprocket #41/420 is a high-quality sprocket designed to fit perfectly in your heavy-duty machinery. This sprocket is made from premium-grade materials, making it highly durable and able to withstand even the most demanding working conditions. Its split design allows for easy...

www.gopowersports.com

Notch out the frame, clamp this to the 428 sprocket, drill out holes and bolt it (can't weld since it's aluminum), buy a 40 series chain, and use the 10T 40 front sprocket that came with the T/C.

Perfect 6:1 ratio and that Tao Tao will be a lot of fun.

 

[Denny]

Don’t forget to use a Genuine Comet Belt! On a properly geared kart they will outlast the cheap ones 10:1!

 

[jschil3]

Honestly, your best bet is going to be to convert to a 30 or 40 series sprockets.

I don't see any splits for 428 that are more than 30T. Here's a 56T (not a split). You'd still have to remove the axle and do a good bit of cutting/welding to make it work.

WPHMOTO Rear Sprocket 428 Chain 56 Teeth 52mm for 110cc 125cc 150cc ATVs Quad 4 Wheeler https://a.co/d/4JgPwGC

And I have this 10T that I ordered from over seas but never used if you go that route. Not 6:1, but pretty close if you can make a 56T fit.

If you decide to convert to 30 or 40 series, you can use the front sprockets that came with the T/C, chains are pretty cheap, and just cut the 428 rear sprocket off and find a split sprocket that fits the old bore. I'll have to dig through my old posts to find the bore size, but the one I ultimately ended up using did fit. I only had to drill out for the

I think I'm gonna abandon the 428 and go with a 420 because it's not as wide and everything will fit better in the 30 series. I found a 60t split on Amazon. I think I'm gonna go with that and extend the frame to fit.

 

[joshw0000]

I think I'm gonna abandon the 428 and go with a 420 because it's not as wide and everything will fit better in the 30 series. I found a 60t split on Amazon. I think I'm gonna go with that and extend the frame to fit.

Good luck. Let us know how it goes. Pics and videos are appreciated.

 

[jschil3]

Good luck. Let us know how it goes. Pics and videos are appreciated.

Had some time to work on the kart today. Ended up getting a regular sprocket off Amazon and drilling and cutting it myself. Only reason was I could get next day shipping and the split one was gonna be about a week wait. I knew I was gonna have some time today so I wanted the parts here. I lined it up and cut it so the old and new sprocket split are about 180 degrees from each other. It will give me more surface area to weld to when I weld them together. Also thought it would add a little stability since the old sprocket is threaded, I'm gonna sandwich the new one between the old one and the hub. I used a cutting wheel to split it as opposed to a band saw so I could have a bigger gap in between the split to try and weld all 3 pieces together (a backer kinda). Cut a quick notch out of the frame just so I could mock up the sprockets. I'll end up using pieces of the old motor mount bracket to tie them back together and create almost a triangle around the chain and sprocket. Added some pictures of the original set up and what I did today. Need to get some longer bolts so they can stick out of the back side of the original sprocket and I can double nut and put some thread locker on them. They are free at work so I'm done for the day I'll grab them when I go in tomorrow and continue.

 

[joshw0000]

Looks good. While you're playing with the grinder and welder, you might want to make a shield for that rear sprocket since it now sits lower than before. There's nothing worse than putting hours of work into it and your kid tears it up on the 2nd lap.

 

[jschil3]

Looks good. While you're playing with the grinder and welder, you might want to make a shield for that rear sprocket since it now sits lower than before. There's nothing worse than putting hours of work into it and your kid tears it up on the 2nd lap.

Good idea. They have a dirt bike and little four wheeler too and they break them faster then I can fix them most of the time. I was thinking about putting a complete skid plate on the bottom and semi enclosing the motor. I like to pull them around on a sled when it snows and water was never a problem. I worry now that the torque converter is driven by a rubber belt that its gonna create a problem. Guess I could always get some belt dressing and spray it between laps.

 

[Denny]

No Belt Dressing!!! Ever!!!

 

[joshw0000]

I don't use mine, but the T/C came with a plastic cover. You can buy them separately for about $20.

 

[jschil3]

Good luck. Let us know how it goes. Pics and videos are appreciated.

Got time to finish it up this weekend. It rips now even with me on it coming from a dead stop up a hill. Clearance on the sprocket is a little low but it's working for them. Got it up to 30 mph on the road with me on it. Plenty of power and speed for the little ones now I appreciate everyone's help.