Hey guys. Tkart here from Southern California. Im a small engine/go kart mechanic at a local concession kart track. Just chiming in to say hello. I mainly work on Honda 5.5hp and Honda 9.0hp engines, 2:1 gear reduction clutches, axles, brakes, tire basically everything to keep the fleet of 35-40 karts performing safely. Im by no means a high performance karting guys just a dude with automotive knowledge and mild fabrication skill transferred over to small engines and chassis.
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Here's a couple of pics out what I work on. Sorry images are super huge.
http://i1161.photobucket.com/albums/q506/terikandmiriam/IMG00143-20130121-1433.jpg
http://i1161.photobucket.com/albums/q506/terikandmiriam/IMG00147-20130124-1001.jpg
http://i1161.photobucket.com/albums/q506/terikandmiriam/IMG00143-20130121-1433.jpg
http://i1161.photobucket.com/albums/q506/terikandmiriam/IMG00147-20130124-1001.jpg
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Doc Sprocket
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Welcome to the forum. Say- in the second pic, what's that black box with the yellow label that is ziptied near the axle?
Welcome to the forum. I am sure you will be able to hold your own on the forum and give noobs some much needed help
That box is a component of the Kart Control system. Its basically a remote cutoff switch. If there's a wreck, wreckless driving, or the ride ends the attendant can kill the ignition or interrupt the coil and reduce power.
jamyers
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Soo... You ever bypass the reduction gear and see what those babies will do??? 
jamyers
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I've always wondered - why do they use 5 and 9 horse engines, then gear them down 2:1? - seems like a waste of power / money to me...a 5hp geared down to those speeds oughta pull 2 or 3 riders around no problem, a 3hp oughta do a single rider... must be a bulk-purchase deal for the manufacturer, and not all buyers gear down?
Just wondering...
Just wondering...
Doc Sprocket
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That's very interesting. I did something very similar for my kids. While I was building their kart, I gave them a lawn tractor to have fun on. I bought an automotive remote module (designed to actuate accessories with a key fob) and wired it to the ignition thru a relay. If they were doing something foolish or out of control, I could shut 'em down from hundreds of feet away. I did this because trying to yellover the engine from a distance was a total exercise in futility. I wired in a big red light on the dashboard so that if I cut the ignition, they knew it- not just a stall or out of gas.
All of the karts from the concession suppliers, at least the ones we deal with, are geared down. The cool-tek clutches are 80.00 each and they last quite awhile. Basically you can run the kart full throttle against a wall for 5 minutes until the oil temp is super hot. Back the kart out without cooling and its still good to go. I change clutches about once every 1500 hours. Youre right though it is a waste of power. The other issue is safety. People act crazy out there and are regularly removed from the track. I have a honda gx 9 hp I ported the head , cam, roller rocker, flat top piston, no governor, open pipe exhaust, and open air cleaner stock flywheel :0...with those mods alone with the gear reduction on a fully dressed kart is about 7-8 mph faster. I've taken it on the track with other riders and its way too fast for customers to use. As far as using the Honda GX 5s and 9s they are tough little engines as long as we stay up oil changes.
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