Newbie here. Rebuilding carter gx150IIr

[Sandmanbjj]

I have had this frame in my shed for 2 years. Got it for $100 and im finally putting the time in to restore it.
Thanks to this forum i have gotten a jump start on what i need to start the restore.
I initially bought a new motor with no knowledge of what i was doing, but i think i got lucky.
I currently have a 30 series TC coming, along with new axel bearings, new electrical parts, chain and some other odds and ends.
Im in the break down phase. Getting rust off. Stripping old paint.
Any suggestions or comments will be awesome. I will try to post pics.

 

[Sandmanbjj]

I will add that i have never owned a kart before. I am sure i will have a ton of questions as i go.

 

[Sandmanbjj]

I got my Tc today. But wont mess with it until i get closer to installing the motor. I have stripped a bunch of old paint and rust off. Primed the top half. My goal is not a prestine paint job but more to stop the rust and corrosion from getting worse. So i have been grinding and sanding a bunch. Took off the gas tank, stripped the paint, sanded any rust spots, primed it and painted it. I have a new petcock im installing on it then it will be ready to be out back on the kart when i get every thing cleaned up. I will post a few pics of my current progress shortly

 

[Sandmanbjj]

Some in progress pics and some of the new parts i got in. This is fun and exciting.

 

[mckutzy]

I kinda missed this.. I'm not sure how... I would have asked earlier, but are you going to use that motor you have pictured here.... Cause that TC won't fit it at all, and further more it already has one...
Interesting build.. It'll look good..

 

[Sandmanbjj]

Really? I am completely new to this. So what goes on that shaft coming off the motor?
Im so glad i started posting this. Snd didnt open any of this stuff yet. I appreciate you speaking up.

---------- Post added at 05:33 AM ---------- Previous post was at 05:27 AM ----------

I am feeling pretty stupid right now to be honest.

 

[itsid]

first take a look at the manual for your kart:
https://www.carterbrothersparts.com...rother_Talon_150_GX_FX_DLX_Service_Manual.pdf

unfortunately it doesn't come with an engine/transmission parts list ..
so we refer to the GSX GSR manual for that instead:
https://www.carterbrothersparts.com/media/manuals/Carter_Brother_GSX_150_Owner_Parts_Manual.pdf
https://www.carterbrothersparts.com/media/manuals/Carter_Brother_GSR_150_Owner_Parts_Manual.pdf

since engine and forward/reverse gearox are identical on all three models AFAIK.
(I linked both just in case you can spot a difference)

Now, you need the gearbox that carries the sprocket.. carterbothersparts has it for 230:
https://www.carterbrothersparts.com...-iir-parts/carter-talon-150-reverse-assy.html

but you can find the same style gearbox for less on ebay (new)
https://www.ebay.com/itm/530-Chain-...329977?hash=item2c9e6a55f9:g:3hsAAOSwo4pYbU44
or
https://www.ebay.com/itm/New-CHINES...108949?hash=item2354f3a4d5:g:QBwAAOSwR8ZaxZDL

I cannot guarantee that this will fit your engine shaft, unfortunately those gy6 enignes are notorious for being slightly different each time depending on who actually made them.

but chances are good that output shaft dimension is one of the few fairly consistent values

And after that, a chain to the rear axle is what you need.
Oh that is if you still have the shifting lever of course (which I think I spotted on the pics with a light blue knob), else you will need one of course.
https://www.carterbrothersparts.com/carter-talon-150-reverse-lever-assy.html

'sid

 

[Sandmanbjj]

Ha. I really appreciate this. You have saved the world about 10,000 Fbombs so far. Thanks. I will update as i move forward. And im sure i will have more questions.

 

[itsid]

Since your series 30 appears to be new..
you can just resell it on ebay (maybe even return it to the seller and get a full refund)
not much lost but time

you're very welcome..
and yes please let us know about any updates.
even if everything's working out nicely and you don't have any questions
we are still interested

'sid

 

[Sandmanbjj]

I am returning it to go power sports. I am going to snag the reverse assembly on e bay from the link you posted. I do have the lever.
I am always about giving back. So i will post as i go, it may help the next guy. These forums dont work without that.

 

[mckutzy]

Well I'm glad I pointed that out.. Kinda wish I had gotten in earlier.. But glad they'll take back the TC..

 

[Sandmanbjj]

And after that, a chain to the rear axle is what you need.
Oh that is if you still have the shifting lever of course (which I think I spotted on the pics with a light blue knob), else you will need one of course.
https://www.carterbrothersparts.com/carter-talon-150-reverse-lever-assy.html

'sid

It says 530 chain on the gear box on e bay. I assume the 420 i have wont be what i need then?
I can order a 530. Would a 56 link chain work or do i need longer and just cut it down?

 

[itsid]

uhm.. yeah, you got the wrong chain as it seems..

IIRC the original chain is a 52L (??) but measure the tooth distance on your axle sprocket, if it's half an inch it'd be a 5x chain for sure..
chances are 530 is a good match (since that's fairly standard size for gy6 engines on karts)

and yes, that means you'll need to buy new chain of course.
unfortunately carter doesn't state the link-count in their manuals..
so IDK.
pitch is half an inch, so 56 links are 28" of chain... back and forth 14" with a 19T up north and a 32T down south... that's uhmmmm 25 links for the sprockets and 31 left to span the distance, right? 15 links more or less per side.. 7.5 inches of sprocket center/center distance for the 56link chain??
as an estimation.. too lazy to do this correctly,
but that doesn't sound too short, does it?

ideally: get everything mounted, then align the sprockets and wrap a tape measure around..
the length in inches divided by two (rounded up to the next whole number) gives you the amount of links to buy

'sid

 

[Sandmanbjj]

Ahhh. Makes sense. I appreciate the input. I have the gear box ordered. I will get it all mocked up and measure. I really do appreciate the help

 

[itsid]

hm, thinking about it...
530 is that common that the 52L in the manual might NOT be the agricultural chain I thought it was
but a hint that chain length is 52 links... *shrugs*

'sid

 

[Sandmanbjj]

I ended up pulling the back half off to clean and paint it. 2 bolts off the shocks not an issue. One of the bolts on the frame was fused to the bushing. I ended up cutting it off with my grinder. So i will be replacing the bushings on the frame. Haha. This is becoming more of a project than i thought.... but i would have it any other way

Here is the back

 

[mckutzy]

With these type of motors.... Did you get all the motor components ie... The wireing harness(I think there is a cdi or voltage regulator box) carb intake, carb exhaust... Ect..

Does the motor fit the rear end properly??

 

[Sandmanbjj]

The wiring is there. Not all in that pic. The components are there, but i bought a new cdi, regulator, solenoid. I may change out the wiring but i wanted to wait until i made sure i could replace what i took off so i didnt get lost.
I have not put the motor on yet. Maybe a rookie mistake but i bought what i assumed is the stock motor and assumed it would fit. Now i am nervous and will be checking that today when i get home haha.

I did see wiring connected to the carb also. I have not gone through all the electrical yet. I am sure i will end up changing some switches and connectors.

 

[Sandmanbjj]

Got the back half disassembled, cleaned up most of the rust. Primed and painted with a black engine enamel. Im not looking for a high end paint job. So be gentle with the critique hahah

 

[Sandmanbjj]

Tc returned and the proper parts bought. Again, i appreciate this forum and the help fellas