New guy trying to tweak a cheap Kart with my sons

[itsid]

The Kawasaki KLX110 has used a variant of that engine (I think) for a very long time. It predates the Honda and even most of the clone usage AFAIK.

Certainly NOT

the KLX series was introduced in 2003 to replace the KLR series bikes
I think you slipped up on the model..
Anyways..
Honda Dax started production in 1969 using the CT engine series
the engine came to be in 1964 on the Honda CT200 Trail 90 changing to 110cc in the eighties
and was based on a 1960 50cc version ..

A year before Kawasaki's FIRST EVER motorcycle left the manufacturing plant (in 1961) and three before the first kawasaki four stroke was introduced (a 250cc in 1963)
Soooo more than just slightly unlikely that any kawasaki motorcycle engine predates the origines of this one.

chances are that indeed the KLX 110 uses a variant of that engine..
but they also sold Suzuki DR-Z125s as Kawasaki KLX 125s in the past... maybe they just borrow what they can


'sid

 

[SUBMAWEINER]

Your engine number will be located here:

View attachment 113906

Inspected both engines:
Engine not installed is 1P52FMH (think was the original that failed and was replaced) and the current non-operational installed engine is 152FMH.

I got the battery installed and keyed it on, the starter clicks when ignition button is pushed, one light is broken but neither lights work, horn works, when placed in reverse the Shifter R illuminated, N indicates, 3 indicates but no other gears. Kart has gas but nothing coming in the fuel line via inline fuel filter dry. Recommendations?

 

[Budget GoKart]

Try the starter from the other motor

 

[JTSpeedDemon]

I don't think he has it anymore........

 

[SUBMAWEINER]

I do still have it, is there a way to bench test the other one before bolting it up? If it clicks when ignition switch is pushed doesn’t that mean it is working?

 

[snowjob]

Wow, was not aware of the CT200 series. Apparently that engine has been making the rounds for a long time. I knew Honda had the CRF70, but that was a 3 speed. The first 4 speed I recalled was the KLX110. Does this version even have a reverse?


Sent from my iPhone using Tapatalk

 

[SUBMAWEINER]

So I bench tested the other starter and it turned over. The one installed was definitely bad. I installed the other one on the engine and it worked but still no engine start.

 

[itsid]

Inspected both engines:
Engine not installed is 1P52FMH (think was the original that failed and was replaced) and the current non-operational installed engine is 152FMH.

I got the battery installed and keyed it on, the starter clicks when ignition button is pushed, one light is broken but neither lights work, horn works, when placed in reverse the Shifter R illuminated, N indicates, 3 indicates but no other gears. Kart has gas but nothing coming in the fuel line via inline fuel filter dry. Recommendations?

Awesome a 1P52FMH means it's indeed a Lifan.
they are of rather good quality..

152FMH unfortunately means it's one of the cheaper ones (mostly generic stuff.. that's easily available on alibaba and such)
Quality wise it can be everything from a nice working reliable engine
to a paperweight
[a telltale sign if they 'copy' the designation from a well known engine.. just like a Bolex or Qmega watch ]

First check the engine stop button on the dash board
(at best disconnect it completely for now)

use some starter fluid, or just feed some fuel with a syringe
directly into the carb's fuel line.
so the bowl is filled and we can be sure you have fuel.
if it's still not even trying to start at all

check for spark, I'd almost bet there is none.
Next I'd check the regulator (rectifier)
it's that ribbed aluminium box with the four pin wire.
get a multimeter out and put it in continuity test
probe all pins against all the remaining ones..
back and forth you should find that two pins have continuity with two other pins but only in one direction.

And if that's okay it means you need to swap the CDI.
very seldomly the ignition coil is causing the problem with these.

And once you got a sparking plug and a fuel delivering carb..
I really hope the engine will fire back up
the only variant then would be compression.. if that's busted you
will need to crack the engine open
(head at least to check the gaskets.. maybe piston/cylinder etc)

gear indicator leds might be busted or the pindial needs to be cleaned.
nothing to worry for now, it's not something that can make a running engine fail

Wow, was not aware of the CT200 series. Apparently that engine has been making the rounds for a long time. I knew Honda had the CRF70, but that was a 3 speed. The first 4 speed I recalled was the KLX110. Does this version even have a reverse?
...

Again the KLX110 is from 2005 or later..
way past any chinese clone really..
(around since 1989 IIRC when the Honda patents ran out)
And I don't recall any of them having reverse (other than the chinese clones) but a changed gearbox doesn't make it a new engine really, right?
I think the Ct90 had a four speed but I don't know for sure tbh.
IF the KLX has reverse (I doubt it) you can place your bets on it being a chinese engine!
A reason I never was quite fond of Kawasaki motorbikes was their lack of ingenuity.. they mostly bought what they needed unlike Honda, Suzuki or Yamaha who actually made some contributions
and did most of the heavy lifting themselves.
All Kawasaki efforts in engineering and inventing went into trains and heavy industry as far as I know...
also green.. me no like green... Ima go with blue


'sid

 

[SUBMAWEINER]

I’m thinking about just ordering a new engine and attempting to rebuild this one when it starts to snow here in WA to have a backup/spare and to learn a little bit about these engines.

Which replacements would you recommend ? Open to either same size or slightly bigger/mire powerful that would be compatible knowing what I have in it Now (110cc 1P52FMH)? Links would be appreciated if possible.

I bought new LEDS, batteries good to go...getting excited to get it on the dirt and road.

 

[itsid]

If I'm seeing this correctly you already have two buying a third now... IDK
but sure if that kart has to be done for christmas.. maybe a new one is quicker.

IMHO that engine should run within a few hours of dirty hands
and maybe waiting for the 30-100 dollars in spare parts once the problem is located.
So I wouldn't exactly get a third enigne .. but that's just me

I cannot provide you with reliable links for one I'm afraid..
cheapest would be alibaba but shipping would likely take several weeks..
same goes for some ebay/amazon offers some take weeks some just a few days..
I cannot tell which seller is actually reliable on the shipping dates...
"Local" retailers are usually a bit more expensive but quicker in delivering;
but still; some are just idiots
(ordering from china when you placed your order and you still wait forever)

The exact model of yours might be a
1P52FMH-F
(107cc e start dual auto clutch 4 speed )
and I think I'd replace it with it's longer stroke brother..
the
1P52FMI-F
(125 cc same bore more stroke otherwise identical specs)

But there are so many different variants...
in transmission: (2 speed, 3speed, 3 speed plus reverse, 4 speed, 4 plus reverse (?))
in clutches: (hand clutched, auto clutch, dual auto)
starters: (kickstarter, kickstart plus electic, just electric, estart on top of engine, estart below the engnie)
or in primary reduction, compression, stroke...
and I bet I only got half of it listed by now

IDK what gearbox you need if the hanging starter or kickstarter would fit your frame
etc.
much less if it's more important to be shipped quickly or bought cheaply.
so here's an ended auction of one with more stroke..(125cc)
auto clutched three speed reverse and top mounted e start, no kickstarter
https://www.ebay.com/itm/125cc-Semi...-3-forward-1-Reverse-Gear-Speed-/143094614795
located in Texas just to give you an idea what I think you'll be looking for.

looks to be a generic manufacturer so it's good that auction ended (imho it's been a bit too expensive)

Some sellers (ebay or amazon) do not care to list the exact model,
but just the specs as you can see...
which makes them harder to compare IMHO.
(hence I don't want to grab the wrong link off the internet leading you to buy a mismatching engine by mistake)

I think you should contact bv powersports (bvpowersports.com) who imported your kart
and ask them for a replacement either in 110cc or 125cc (maybe 140 or 150 if they can provide such)
it'll be the more expensive but likely most reliable
and quickest way of getting a matching replacement engine.
And you have someone to talk to if the engine doesn't fit for one reason or another.

IF you want to buy a new engine that is.

'sid

 

[SUBMAWEINER]

Thanks for the response SID, I’m still troubleshooting as you mentioned. I Wanted to parallel with purchase options to speed up the process if needed to order an engine. I purchased starter fluid to troubleshoot the carb and fuel systems and will be doing the ignition/spark testing tonight. I’m military and travel a lot, so I’m limited on my time I can spend on this at the moment vice spending quality time with my boys. Goal u I s to get it operational as quickly as possible with balancing my available time at the moment.

 

[JTSpeedDemon]

Thank you for your service sir!