Roteka Rebuild

[TXST8tj]

Roketa Rebuild

As some have seen, I just bought a Roteka 110cc kart from a coworker for $150. Rather than clog a Q&A thread with updates on the purchase, I am starting this thread since this is the Photo Gallery & Project Log section.

For those that have not seen, this is how it was delivered to me yesterday...

It was in basically good condition. It was dirty and the paint was faded, but overall...pretty decent.
The kart does need a complete rewire and a couple little odds and ends replaced.

Considering a rewire was in order, and the paint was not so fresh, I decided to disassemble it and have it blasted and painted. The work on it is being done in the shop at work during lunch breaks and after close. A couple guys are giving me a hand with it.

The plans are very simple....paint it black, reassemble, install new headlights, rewire lights and ignition, add keyed ignition switch, present to my son for Christmas.

 

[TXST8tj]

We set it up on some sawhorses to get a better look, and to make it easier to disassemble.

 

[TXST8tj]

This is also the time (with the guidance of the forum) I was able to determine which engine it has......E22.

 

[TXST8tj]

That gets me to today. I came in this morning and the guys had it completely stripped down.
It should be headed to get blasted and painted today.


I picked up some new headlights for it last night. The original lights still worked from what the PO said, but the brackets had cracked at some point, so they cannot be adjusted.

We decided to leave the swingarm half of the chassis with the engine intact. We will just hand sand the tube, tape off the parts, and spray paint a fresh coat. Just didn't seem worth the hassle.

We are just going with a black paint color. I do not anticiapte swapping the seats, so with them being blue, it will still look good.

 

[jamyers]

Nice!!

Regarding wiring, I did some digging online, and it seems that the E22 came from the 80's Honda 3-wheelers, and that most online sources like http://www.roketapartsonline.com/electrical-parts-chinese-atv-wiring-c-398_325.html show the "ATC110" diagram, but there are differences based on how many wires go into the CDI ignition box.

Also, most of these machines have the headlights powered off of the engine and not the battery, so they only come on when the engine is running. That's probably a great idea, since most of these use the really wimpy motorcycle-type batteries.

If you want lights without the engine running, I'd strongly suggest a bigger battery of some sort - I've been using old "tired" automotive batteries that don't have the CCA to crank a car engine, but will spin a small engine no problem. Check with autoparts and battery shops for deals on their core/scrap batteries, all you need is 12V and at least 60-100 CCA (most new auto batteries are rated 500-850 CCA.)

 

[TXST8tj]

I was interested in wiring the lights off of a relay and switch...powered by the battery because I did not realize the lights ran off of the engine.

I have a sealed, rechargeable 12v, 18amp hour battery that I was planning to use. This (below) is the one I have:



I figured running the lights off of the battery via a switch, would keep them from running the battery down if they are not needed. There is enough juice in that battery to run the lights as long as he would be riding it at night.

If the lights can be run off of the engine with no drain on the battery, that would be an even better route.

I am basically starting with a rats nest of wires that is incomplete, and what is there has gone through numerous splices. If I can locate the correct diagram, I would be a happy dude.

 

[TXST8tj]

Do these seem like they could be the proper diagrams?

 

[jamyers]

Best bet is to compare then with what's on your kart, keeping in mind that the chinese seem to be color-blind when it comes to wires.

In your other thread with the link to the Roketa page with your kart, I think there was a wiring diagram - but in chinese, lol. Might try and ignore the words and compare wire paths...or maybe they've got one in Engrish hidden somewhere?

 

[TXST8tj]

Here is an update on the kart and paint.

It has been blasted and epoxy coated. It will get the gloss black tomorrow. Should be ready for assembly on Friday.

 

[TXST8tj]

Another small update. Back from paint.

Should be reassembling next week. I am anxious to get it back together so I can find out what parts I need to order to make sure they are in and finished by Christmas.

 

[TXST8tj]

They started reassembly on Friday.

As soon as the new battery tray is welded in place, the back half will go back on. My battery is a little longer than the original, so a new tray had to be made.

 

[TXST8tj]

It is almost done.
The little fuel regulator thing broke, so I need to find a new one...hopefully locally.
The wiring is just about done. Only thing lacking is installing the new headlights.

I also need to go back and paint the rear swing-arm portion.

 

[jamyers]

Looking GOOD!

(fuel regulator?)

 

[TXST8tj]

It looks something like this....
"Gas Fuel Valve"..."Petcock"..."Fuel Switch"...take your pick.
Just need to find the right one...or similar that will work.

 

[jamyers]

Ahh, the old fuel cut-off valve...which also allows you to run the fuel tank low, then switch over to the "reserve"...

If it screws into the bottom of the fuel tank, you might check local atv shops...

Or, if there's a way to hook a fuel hose directly to the fuel tank, you could put one of these (available at just about any carparts store or Lowe's) in the middle of the fuel line (but you'll lose the "reserve" capability: