I Love It When A Plan Comes Together

Free Go Kart Plans

These are completely free go kart plans we are not in the business of selling plans and information. We do not publish "by the numbers" !"# plans$ we hope that you%ll find your personal design from our road map. The only limiting factor to your designs is yourself if you can dream it& you can build it. 'aterials for karts are (aried. )ee the fabrication tips section for information on materials& bending& cutting& and more. Want to calculate your go kart speed*

Go Kart Parts
When you%re ready to buy& we%(e found that +orthern Tool generally has the lowest prices on most parts. !lick on go karts& then go kart accessories.

Hazards
"s you should know& welding can be ha,ardous& and we encourage you to re(iew our welding tips. -nsuring that your welds are good is (ery important. .f you%re not an accomplished weldor ha(e someone inspect them or ha(e an accomplished weldor help you with the pro/ect. Go karts are machines with lots of mo(ing parts& and are dangerous. Please read our safety information& use common sense& and be safe.

Basic Frame Design

0ow to 1uild a Go Kart Frame

Go kart frames (ary in shape in si,e as much as the weather. .f you can think it up& you can make it. People ha(e made all kinds of wacky frames. We%d lo(e to post pictures of your frame& contact us2

Basic Frame Design

3ou%ll want to take plenty of time to design the frame. " well designed frame will be customi,ed to your si,e. #on%t rush here if you get something wrong now& it will take twice as long later. Frames are often designed for two riders& and if so need to incorporate hand holds for the second rider. 'ost frames ha(e a width between 456 and 756 the wheelbase on the wider end for best stability.

To design your custom frame length and width& sit on some clean concrete and imagine yourself in your go cart. 8sing chalk& draw the frame%s dimensions to the si,e and shape you want so that your legs are comfortable and it is wide enough. #raw where your feet will rest. 9ecord your personali,ed dimensions.

Materials
Tubing :round or s;uare< may be used& or angle iron. For angle& use a thicker si,e than if you%re going to use tubing. Pipe isn%t recommended because it%s much too hea(y& and weight hurts performance. .f you don%t ha(e a tubing bender& angle has the benefit that making bends is easy. )imply notch one side& heat the material and bend as necessary. When it%s bent to shape /ust weld in some filler material. The most efficient solution is some mi=ture of types. We like round for the rear a=le support& and s;uare for the rest& with angle intermi=ed as needed for support. 8se thick wall tubing for the a=le. )ee our full discussion on materials for more information.

Can You Over Build?

Keep in mind the weight of the rider& and let your design choice reflect their needs. .f the kart is for a 4>> pound kid& then the frame can be less stout than if the frame is for a 7>> pound man. What we mean is that it%s easy to o(er build until you%(e got supports e(erywhere and no fle=& but unfortunately all that weight will kill the performance. The trusty ? 0P motor is a good engine& but it can%t push a tank.

Roll Bar
9oll bars are great additions to karts. .f you%re putting one in& a bar that starts in the front and terminates abo(e the rider%s head is the best design. This helps ensure that if the kart crashes into something like limbs& the bar will help push them up and out of the way. " roll bar that only e=tends abo(e the head but doesn%t ha(e this front guard isn%t as useful.

Ground Clearance
@ur one seat plans suggest lowering the frame to within 7 inches of the ground. That%s fine if you%(e got a lot of open and safe asphalt to dri(e on. 1ut you%ll lose so much ground clearance that it would ha(e to be an on road only kart. "lternati(ely& too much clearance raises the center of gra(ity. The higher that center& the easier to flip o(er& so make sure roll bars are used.

Basic Frame Design

0ow to 1uild a Go Kart Frame

These frame plans are for a one seat go kart& but they%re really /ust for your starting reference anyway. They use 4" angle for the frame. This has the ad(antage of being easy to bend. We like using s;uare for the frame& and angle where it%s needed& but to each is to own.

Two Seater Frame 0ow to 1uild a Go Kart Frame 1uilding a frame is not complicated& but you must ensure that you%re building it s;uare. )ince e(erything else builds from this& you don%t want to start the pro/ect with a frame that isn%t true. 0ere we lay out the frame on le(el concrete which& if you don%t ha(e a giant welding table& is ;uite handy. -nsure that you use a s;uare to make sure you%re getting the angles right. We elected to make a two seat go kart& and made it long enough that a si= foot tall person could fit in it. This design will incorporate the ad/ustable seat. To attach it to this frame we%ll probably use cotter pins. When building the frame& don%t weld up the engine mounting plate until you fit the engine. 3ou can tack it in. +otice the bo=ed in area at the rear left a=le. That is for support for the mounting plate. !areful though that your mounting bolts will still fit. The steering arm is (ery sturdy in this set up. 3ou could instead ha(e one support coming in from the side at an angle. The front bumper si,ed as shown will clear only for A" wheels. We ha(en%t hit anything yet& but we suspect that it will bend the angle into the tire and cause a lot of grief. The pedals are fabricated from 45B" flat stock.
Fig. 6 Fig. 7 Fig. 4

Fig. A

Fig. ?

Rear Wheel Drive - Fixed Axle

0ow to 1uild a Go Kart #ri(e "ssembly

The rear dri(e assembly shown uses a fi=ed a=le instead of a li(e a=le. This will ma=imi,e handling at the e=pense of traction on loose surfaces. CWhat%s the difference between li(e a=les and fi=ed a=les*D

Parts Needed
The rear a=le is easily fabricated from 65A" thick wall pipe or 4" thickwall round tubing and threaded bolts si,ed for your bearing. 1earings are generally ?5B" or 65A" .#. The bolts are a(ailable from any hardware store. !heck your hubs to find the right length to buy.

Pre
'ost bolts ha(e raised lettering on the end. Prep your bolt by grinding any raised lettering from the head. !ut the a=le to length and make a (ery straight cut& ideally using a chop saw. .f cutting by hand& you make use a carpenter%s s;uare to get it as close as possible. Getting the bolts s;uare is a difficult /ob& but you%ll need to get it right or face e=acerbated tire wear. )tart by putting the bolt of the a=le and eyeballing the straightness use the framing member as a known straightedge :Fig. 4<. Then get your s;uare and make sure it%s straight from multiple angles :Fig. 7<. -nsure that your s;uare can sit flush and the tack welds don%t get in the way. Tack your bolt from multiple sides before finish welding applying too much heat to one side without tacking will result in heat distortion.

! roc"et Drive !#stem

The dri(e system for a single wheel dri(e kart with fi=ed a=le is the simplest to deal with and the least e=pensi(e. The parts in(ol(ed in this set up areE

double flanged hub your wheel5tire sprocket brake drum brake band

"ll these parts are bolted together& and you get your dri(e assembly :Fig. 6 A<. 'any parts houses sell this as a complete set. There are other choices for brakes& as well. 8se a spacer to ensure the opposite rear wheel rides at the same distance from the frame as the dri(e wheel.

Fig. 4

Fig. 7

Fig. 6

Fig. A

Fig. ?

Fig. F

Don t Steer !o"rsel# Wrong

'ake )teering !omponents for a Fraction of !ost

)teering components can be purchased off the shelf& but you can sa(e a lot by making your own steering parts if you ha(e the tools. @therwise these parts are all readily a(ailable from any of the parts houses.

Fig. 4

!teering $ssem%l#
The steering assembly must be tight and secure. 8se Gocktite and5or retainer keys on the nuts and bolts to pre(ent failure.

!teering !&a't and Pitman $rm

3our steering shaft connects the steering wheel to the Pitman arm& and runs through a protecti(e tube. )ee Fig. 7 for the schematic. We used 65B" steel rod and sheathed it in iron water pipe that was 457" .#. To use a tube& you%ll need some sort of bearing surface that the rod will turn on. We used a simple but effecti(e brass bushing. Figures 6 and A show how these were fabricated from water faucet seats. They made a (ery tight press fit with the pipe. The bushings were then drilled out to 65B" to fit the steering rod. Fig. 7 shows where the steering rod terminates into the Pitman arm. @ur arm was made from 4.?"=45A" stock& but we found that 65A"=45A" would ha(e been more appropriate. Fig. 7

Fig. 6

(ie Rods
Tie rods are (ery simple to make& and e=pensi(e in comparison. 0owe(er you ha(e the opportunity for a lot of play if not made to e=acting specifications& so we recommend you buy them. The tie rods that connect in the diagram are also 65B" rod& with 65A"=45A" flat stock used to make the ends. " gal(ani,ed bolt holts the entire assembly together. To make your own tie rods& simply take 45A" = 65A" = 4.?" flat stock and make the "8" shape in the Fig. ?. 8se an inside diameter of about H54F" to allow mo(ement and the inclusion of an ad/ustment nut. "t least one end of your tie rod needs to be ad/ustable so you may align your steering properly. @nce you%(e completed the "8"& drill a 45A" hole in the short side and weld a 45A" bolt inside. :)ee Fig. ?<. 3ou may now cut your actual rod to length. 'easure (ery carefully how long the bar stock should be. When the wheels are aligned perfectly straight ahead& allow for at least 457" of threads for ad/ustment in or out. The non ad/ustable side of the tie rod is where you%ll connect to the Pitman arm. "gain use 45A" = 65A" stock at 7" length. Fig. ?

Fig. A

$d)ust (&e !teering

3ou can get better handling through the proper alignment of the steering. The Fig. H shows the correct alignment. 1y ad/usting the alignment to a slight toe in :as suggested by the diagram< you%ll get better turning. 0owe(er you%ll also eat up the tires faster since the wheels don%t run perfectly straight. This isn%t really needed for fun karts& but is used widely in the racing world.

Fig. F

Fig. H

$a%ing !o"r &o 'art S(indles

0ow to 1uild a Go Kart )teering )ystem

+ote that all these parts are readily a(ailable for purchase instead of fabrication. We%ll assume you understand the components. .f not& read up on go kart steering parts.

Overvie*
The spindle is the pi(oting front a=le for the go kart. They connect to the steering system at the tie rod. )ee Fig. 4.

Brac"ets
First you%ll fabricate the spindle brack. 8se 45A" = 4.?" flat stock to make the bracket 6"h = 7" w. The brackets must be perfectly s;uare. 3ou can see from Fig. 7 that heating and bending :the first two< doesn%t work (ery well. We suggest cutting and welding :third bracket<. These welds are critical. When they%re perfect& weld them to your frame. The Fig. 4 shows there should be H degrees tilt out at the bottom of the spindle& and H degrees rear facing of the spindles :camber and caster<. .t%s not critical& but it will allow you to turn faster. +ote that we didn%t use the H degree pitch when building our assembly.

! indle $+le
+ow measure your spindle bracket inner si,e. 8sing a pair of digital calipers is almost a necessity howe(er you can make a rough cut and then grind until it fits. 8sing your precise measurement& cut a length of 65A" @# thick wall :.47>< tubing. This tubing has an .# of .?4>"& so no bushings are needed for a tight fit. +ow prep the a=le bolts. Grind down a straight notch in each. This will help you align them better and to get a better weld. "t right is a notched bolt and the finished product.

Fig. 4

Fig. 7

$ssem%le t&e ! indle

8sing the calipers again& find the center of the brackets. 8se a metal scribe to mark the = and y a=is& then drill out where they intersect. #o this for the top and the bottom of the brackets& as your hand drill will not drill s;uare from top to bottom. )tart with a small bit and increase to a larger bit until you reach 457". "ssemble the tubing5a=le into the bracket with a 457" = A" bolt. 8se Gocktite or locking pins. 3ou could add a grease fitting& or /ust disassemble periodically and grease them. 0arbor Freight sells grease fitting packs cheap. "fter the spindle a=le is assembled to the bracket& weld on the spindle arm at 4>? degrees from the a=le& according to the Fig. 4. !ut the 65A" = 45A" material in the chop saw at 4? degrees for an easier alignment& but use an angle finder to be sure. Fig. A

Fig. 6

Fig. ?

Fig. F

Fig. H

&o 'art Bra%es

.nstalling a Go Kart 1rake

These figures will e=amine se(eral ways to install a brake on a go kart. There are (arious types of go kart brakes. )uffice to say& anything but a scrub brake is ade;uate.

!ingle Go Kart Bra"e

1y far the easiest way to accomplish adding a brake is using a band brake assembly as shown in fig. 4. 'any shops will sell this assembly as a complete kit for con(enience.

Bra"e Mounting and $ssem%l#

The front band attaches to the frame on a small post which is welded to the frame. .n fig. 7 you can see the post that is welded to the frame. )lide the band o(er this post& secure& and then slide the sprocket5brake drum assembly into place. We used a sheathed cable for our brake cable. 3ou may also use a brake rod similar to the throttle rod we used for the throttle& :below<. !ables will often rust o(er time& but are easier to route through the kart. " tab was welded to the frame& and a hole was drilled through :fig. 7< to help route the cable and keep it properly aligned. The free end of the cable is secured to the pedal with a wire nut& shown in fig. 6.

Bra"e and (&rottle Pedals

Pedals may be purchased from parts houses& or fabricated yourself. We elected to make our own :figs. 6 A<. This was accomplished by welding 65A" = 45B" flat stock to 4.?" = 45B" stock. The pedals are attached to the frame using bolts. -nsure you use locking nuts& Gocktite& or some other method to secure the hardware.

(&rottle $ssem%l#

3our specific throttle assembly may not work with these plans depending on your engine& and whether you%re running a go(ernor. 9efer to your manufacturer for specific information on attaching the throttle. )ince we%d used a cable for the brake& we decided to use a rod for the throttle to gi(e you an e=ample of rods. The rod was attached to the pedal as shown in fig. A. The rod then runs along the floor pan of the kart to behind the seat. Fig. ? shows where the thottle rod connects to the throttle cable. The cable will then attach to the engine%s throttle mechanism. 3ou can see the return spring in the photo. -nsure you use a ;uality spring and attach this system securely.

Dou%le Go Kart Bra"e

.f you%re looking for a two brake setup& figures F I show a way to install dual band brakes. .n our opinion you probably don%t need two unless you%ll be doing some (ery fast racing& hea(y off roading& etc. @ne brake is generally sufficient.

Fig. 4

Fig. 7

Fig. 6

Fig. A

Fig. ?

Fig. F

#etail """

#etail "1"

#etail "!"

$o"nt It

0ow to 1uild a 'ounting Plate

"n engine mounting plate that allows the engine to be mo(ed back and forth to remo(e the slack from the chain is needed. "ll engines use the same mounting hole pattern. .f you are going to make your own& follow the pattern shown in Fig. 4. 3ou%ll need a way to cut the holes in the plate. " /ig saw with a metal blade would work. )ome ha(e drilled lots of holes and then used files to cut away the rest of the material. " cutting torch would work as well. 1ut buying the plate is often cheaper and much less of a pain. We purchased an 4>" = F" = 45A" piece of metal in 7>>? for JI locally. " parts house was selling a mounting plate for JH with pre cut& pretty holes. #uring the frame mock up& don%t finish weld in the mounting plate. Though the dri(e wheel can be ad/usted slightly with bushings& you want to make sure the dri(e assembly will all line up. 1etter to lea(e it off until the rear is assembled. When you do ha(e the rear dri(e assembled& install the engine and clutch and inspect for mounting position :Fig. 7<. Then finish weld. )ome kits are sold that use rubber donut dampeners to limit the (ibration. We%(e used them in the past& but they%re not a necessity. Fig. 4

Fig. 7

Sit Down)

Go Kart )eat #esign

$d)usta%le !eat

This design is for a seat that will mo(e forward and back& allowing both young and old to ride the kart in comfort. The idea is that the seat will be framed separately from the kart& and then attached to the frame railings with either bolts or pins The basic idea is to build a bench seat that will slide along the frame rail in some way. This design uses angle that rests on top of the frame rail.

Frame
First you%ll design you seat framing. Fig. 4 shows the basic completed frame. .t%s up to you to decide at what angle you%ll want the backrest& and the width will ob(iously be dictated by the kart frame. Fig. 7 shows the underside of the frame. The angle iron was measured to pro(ide 45B spacing on either side of the frame. )o for a A>" wide kart& our seat frame would be A> 45A" from the inside to inside. The two pieces of angle are connected with 65A" = 45B" flat stock& which is then bolted to the bottom of the seat pan. The seat angles back at 4? degrees. The side rails were made from angle& which was filled in and ground at the corner shown :Fig. 6<. "fter you%re done making the basic frame& you can frame out the seat area. Plywood or boards make fine seat pans. !ut the wood to si,e& and round the edges with a sander for comfort.

$ttac& t&e Cus&ions

)pecial nuts make seat attaching easier. They are made to be pounded into wood& and then used with normal bolts. This allows you to attach the seat without cutting into the upholstery on the front side. )ee fig. ?.

, &olster#
Fabric stores sell foam and (inyl for the upholstery& but you should wait until you%re done welding on the frame before putting the finished seat in. 8ntil then& install the boards in their positions so that you can sit in the kart as you continue building.

Finis&ing ,
When completed& the seat is installed on to the kart frame.

+ow you%ll mark at least two positions you%d like the seat to be ad/ustable to. #rill through the seat frame and kart frame to make your securing holes. The seat will be secured to the frame with hea(y duty cotter pins or bolts. !onsider that this design is drilling through the frame& and that will weaken your frame. .f you%(e compromised your frame%s strength& you%ll need to strengthen it with additional support. 3ou%ll note that this design doesn%t use any rollers. When ad/usted carelessly this may tear the paint up& so we unbolt it& pick it up& and set it down at the other ad/ustment. We%(e used a really tough "grippy" paint on it& too& and that%s helped.

All Shin* and +ew

"dding !hrome and Painting 3our !hopper

"fter you%re done with the build& you%(e still got to add the paint. "nd if you%re thinking about chrome on your bike& you%ll need to consider it before the build.

-&at Finis& (o ,se?

"s far as looks go& paint is as important as design. " bad paint /ob will ruin the look of your machine. "nd a good one will help hide imperfections and work with the design to enhance the look. The rule of paint is thisE Gloss paint%s smooth& shiny surface makes imperfections easier to see. 'atte paint hides imperfections& but is dull. )atins are somewhere in the middle. 1ut there are other ways besides matte finish to hide imperfections. Get%s consider one& the primer coat.

$ Primer on Primers
3ou should definitely use a primer for your pro/ect. Though many paints will say they don%t need a primer& they will be enhanced by a primer. This first coat fills in the rough surface of the metal and creates better adhesion for the top coat. Primer is cheap. Finish paint is more e=pensi(e. 3ou don%t need the most e=pensi(e primer& since you%ll be co(ering it up. There are primers that 9ustoleum makes that are made to co(er rust. These are fairly e=pensi(e& and might be worth it. We used them for our pro/ects. .f you ha(e a re(iew about the long term use of the "9usty 'etal" primers& please let us know2

!anda%le Primer
To really impro(e the smoothness of your metal frame& a sandable primer is what you%ll need. These primers spray on& and then the high spots may be sanded down. 3ou can continue to add coats and sand until you%re happy2 This will smooth out many imperfections such as pitting marks and then rough nature of hot rolled material. That smooth surface will look better and you%ll use less of your final coat paint filling in a rough surface.

Paint C&oices For Mini C&o

ers and Go Karts

Paint comes in (arious gloss le(els. "t the two ends of the spectrum are gloss :shiny< and flat :matte& not shiny<. Gloss paint shows imperfections (ery readily. This is because the shine accentuates e(ery little nick. 'atte paint hides imperfections& but it%s flat and boring. .n the middle are satin and semi gloss. !heap gloss paint will work& especially in con/unction with a good primer& but it will show those nicks2

We elected to use a new paint offered by 9ustoleum. .t is called "0ammered Finish"& and comes in a (ariety of gloss colors. When laid on the frame& it somehow coagulates to where it has a hammered metal finish look which looks really cool. This te=ture makes it ideal for hiding the imperfections on a pro/ect. "nd the gloss of the paint makes it look great. 1ecause of the hammered finish& the paint has a deeper& richer look that is fabulous. )o& if you ha(e welding imperfections& grinding spots& and other rough areas of the frame& the te=ture of the hammered finish will help to mask those problems.

Chromed Parts

"dding !hrome 'akes 3our Pro/ect Professional Gooking

"fter you%re done with the build& and you%(e painted& you can still dress up your kart or chopper with some well placed chrome. Guckily there%s a lot of choices a(ailable.

-&at Kind o' Parts $re (&ere?

"ll kinds2 For go kart chrome& the absolute easiest and best way to dress up the go kart is with the products on the right. !hromed racing wheels :well& they%re aluminum& but they%re shiny2< look sharp on your pro/ect. "nd the mag style of the wheels ha(e a nice look as well. " chromed racing style steering wheel is another easy choice. The shiny metal is wrapped in a soft rubber grip. .n addition to this small sample& there are lots and lots of products offered from different retailers.

-&ere Do . Get (&e Parts?

#ifferent parts houses will offer different selections of material. !lick For Wheels We suggest you check our parts sources page and see what each business has to offer. 1'. has had a lot of good products in the past.

!lick For )teering Wheels

,ow to Paint !o"r Pro-ect

" Good Gooking Paint Kob is -asy

Painting a go kart can be a big problem. The frames are large and bulky. They%re /ust not easy to deal with. "nd e(en painting a mini chopper isn%t cake. These tips will help make paint no problem.

!elect #our 'inis&/

We like the "hammered finish" line of paint by 9ustoleum. They look great and ha(e a te=ture that looks like worked metal& which will hide minor imperfections in the metal. They come in a (ariety of colors.

Paint .n $n O en $rea
3our paint area needs some air flow& otherwise the fumes will build up and you%ll get sick. 0owe(er& you do not want to paint where it%s too windy& where there is dust and debris blowing& or in direct sunlight. "dditionally& spray paint is notorious for "o(er spray"& meaning if you paint your go kart ne=t to your car& your car will get spray paint on it. 1e aware of your surroundings.

Ho* (o Paint Bot& !ides

When you flip the frame& you%re going to risk damaging the paint. 3ou can do one of two things. @n solution is to paint the bottom first& so that if you damage the bottom when you flip it won%t be a huge problem. The other is to hang the frame from a rope. 3ou%ll be able to paint e(erywhere e=cept around the rope. #on%t try to paint anywhere near the rope when it%s hanging. That way you can feather in the paint after you let the frame dry and take it down from the rope. 0ang it by the back of the frame to gi(e yourself a little more leeway on getting the area perfect.

Follo* (&e .nstructions

'any spray paints dictate that you can make a repeat coat within a short amount of time& but if you wait too long then you%ll need to let the coat dry completely before adding another. For best results& read that label& e(en if you think you know what you%re doing.

,se a Primer Coat

Primer is cheaper than your finish coat. 1y building up a layer of primer& you%ll ensure more e(en co(erage later when you spray with your finish coat.

0et (&e Paint Dr#

3ou%ll want to keep working on the kart 5 mini chopper far before the paint is dry. 3ou want to let your paint cure before you get back into mucking around with the frame. .f you don%t& you%ll get a finger prints& dulled finish& or at the worst you%ll scratch off some of the paint. #o yourself a fa(or and let it dry. Gi(e it more time than it calls for.

P"tting $etal Together

Welding Tips for Kart 1uilders

3ou don%t need to be an e=pert weldor to weld a go kart. .n fact& it can be a good pro/ect to learn on. 3ou will need to make strong welds& but if you don%t mind spending some time with the grinder& you%ll be fine. .f you%re a neophyte weldor& we suggest you team up with a better weldor. They%ll gi(e you more hints on your style that you can%t get from reading about welding. This is in no way an e=hausti(e tip or safety list for what you%ll need to know to weld a kart& or any pro/ect.

" good welding resource are the Weld Talk forums at 0obart Welders.

-elding 1inc Plated and Galvanized Material

.f you didn%t already know that welding on ,inc is incredibly dangerous& you do now. 1reathing the (apors can make you (ery sick& or end your life. This doesn%t mean that you can%t weld the material& but it does mean that you need to be (ery careful.

-elding Helmets
.f you don%t yet own an auto darkening helmet& go get one2 0arbor Freight carries an affordable& though cheapie feeling one. Whiche(er one you get& you%ll lo(e it. .t makes welding so much easier.

-elding Round (u%ing

"s a matter of asthetics& making a go kart frame completely from round tubing would look better than a frame of round and s;uare tubing. 0owe(er& using both tubing types greatly reduces your need for prep work on the tubing. "dditionally& you%ll need fewer tools. 'ore on this sub/ect is in on the materials page.

Fig. 4

This Page is ."st A/o"t $aterials

What 'etal to 8se& 0ow to 8se it.

For your framing you%ll want a strong& but light frame. @ur kart pro/ect used thinwall s;aure tubing. 45B" = 4" angle would ha(e done as well. For round tubing& thinwall might be too thin. .f you ha(e made a kart from thinwall& let us know. 'ost of the store bought karts use thinner walls and weak materials. The life of the cart surely won%t be as long as a ;uality hand made product. We like using a mi=ture of s;uare and round material. .f you want pretty bends in the frame on the cheap& re(iew the differences between pipe and tube before deciding which to use. Fig. 7

-&# use a mi+ o' tu%ing?

1y using round tubing and s;uare tubing& you will need a chop saw& band saw& or hacksaw& a grinder& and your welder. .f you want to weld round to round& you%ll need a tubing notcher or time consuming prepping of the round tubing. This is because welding round to round re;uires you to "fishmouth" the end of one of the pieces so that it /oins solidly to the other :Fig. 4<. 0owe(er& welding round to s;uare is a cinch because you can /ust cut the round flat and weld to the flat surface of the s;uare :Fig. 7<. 3ou can also heat the end of round material and pound it flat. This will gi(e you a flat edge to weld to another piece of round :Fig. 6<. 3ou will sacrifice looks and strength& so be cautious. Fig. 6

Fig. A

Bending Material

8sing angle iron has the benefit that making bends and angled connections is (ery easy you can notch one side& heat& and bend. 1y adding filler material to the notched area you re strengthen the frame. -(en if you don%t make the whole frame with angle iron& you can still use it for pieces that need to be bent at angle. .f you want to /a,, up your frame with bends& we suggest using pipe and getting a 0arbor Freight pipe bender. +ote that it only bends pipe& not tube. CWhat%s the difference*D )ince it%s more difficult to bend s;uare tubing and fishmouthing round is difficult& many people use a mi=ture of s;uare and round. Cutting Your Materials 3ou%ll need a chop saw& grinder with cut off wheel& or a hacksaw to cut your materials. !ircle saws will often accept an abrasi(e blade as well. .f you%re using a hack saw& buy a new blade. 3our old one is surely dull. " chop saw is the best since you can get nice straight cuts. .f you don%t ha(e one& you don%t need an e=pensi(e one& so keep that in mind. " handy way to ensure you get two pieces of tubing e=actly the same length is to use (ise grips to keep two pieces together :Fig. A<. .t sa(es time& too2 1efore you start welding& make all your cuts first. Then lay out the frame completely to get an idea of what the finished product will look like. "t this point you%ll know if something isn%t working& and can fi= it before it eats up time later. "nd if you%re getting a someone else to do the welding for you then they will greatly appreciate that e(erything is ready to go.

Pi(e vs T"/e

"d(antages of Framing 'aterial For Karts and 1ikes

When building your own go kart or mini bike frame& you%ll probably like smooth bends rather than a s;uared off design. 0owe(er& bending materials re;uires special tools. We%ll look at the two best ways to do thisE using a pipe bender and using a tubing bender.

Pi e vs (u%e
9ound pipe is commonly a(ailable e(en at your local hardware store. Tubing is a(ailable at your metal supplier. Price the material beforehand& and steer clear of seamless tube :aka #@'& drawn o(er mandrel<. .t is (ery e=pensi(e. Tube is called out by the outside diameter :@#<. " 4" round tubing will be e=actly 4". Tube is a(ailable in thin wall :>.>F?"< and thick wall :>.47?"<. To find the inside diameter :.#<& double the wall thickness :ie .47?=7L.7?>"< and subtract from the @#. Pipe is called out by its inside diameter rather than its outside diameter. Therefore a 65A" pipe will actually measure 4.>?" @#. " 4" pipe will measure 4.64?" @#. Though the pipe is called by the inside diameter& the actual .# is slightly greater. " 65A" schedule A> pipe has a wall thickness of .446". The .# is therefore .446"=7L.77F". 4.>?" .77F"L >.B7A".

-&# Doesn2t Pi e2s Real .D and Called .D Matc&?

"d(ances in pipe making are to blame for the mismatch between the called out si,e and the actual si,e. @ld pipe was weaker than today%s pipe& and to perform at the rated pressure had to ha(e a thicker wall than is necessary for modern pipe. 1ut if the @# si,e of pipe was shrunk& new pipe would be too small to fit old pipe fittings. )o the wall thickness became thinner and the .# increased.

Cost o' Bending Material

" tubing bender is ;uite e=pensi(e& starting around J?>>& and likely includes only one si,ed bending die. 3ou%ll need to purchase more dies to bend other si,es of tube& and these can run at least J7>> each.

@n the other hand& a hydraulic pipe bender can be found often for around JH> that includes all the bending dies you%ll need.

(# e o' Bends Possi%le

Tubing benders are more more elegant than pipe benders. !heap pipe bender will only do around 4>> degrees ma=imum bend& whereas a tubing bender may do a full 4B> degrees. 0owe(er& 4B> degree bends can be accomplished with the pipe bender by welding two I> degree sections together.

,ow to Bend !o"r Framing $aterial

8sing a Pipe 1ender Gooks Great& is -asy

There are two main ways you can make your frame with or without a bender. 8sing a bender on your pro/ect will make the frame look much more professional. 1ut wait a tubing bender is e=pensi(e2 True& but hydraulic pipe benders are ;uite affordable. Therefore we suggest building your frame from schedule A> pipe and using a hydraulic pipe bender& which can be purchased for less than J4>> at 0arbor Freight& +orthern Tools& etc.

!o" ve &ot To $aintain000

0ow to Perform Go Kart 'aintenance

'aintenance. .t%s the thing that no one wants to do. )top and change the oil* "rgh... Pull the spark plug and clean it* 8gh2 @il that chain* "ir up the tires* Well& you ha(e to if you want your parts to keep working. "nd it%s really not that hard. These pages will list a step by step suggested guide on how to maintain your go kart and mini bike. Granted& we can%t possibly co(er e(ery make or model& so this is a starting suggestion. "lso follow your manuals and common sense.

The Chain

)i,e Go Kart !hain and !hain 'aintenance

3ou must learn to si,e your chain& but this isn%t hard. "fter that& you%(e got to keep it properly ad/usted and oiled.

Resizing Your C&ain

To resi,e your chain the pins must be dri(en out. .ne=pensi(e tools are sold that do /ust this or dri(e the pins out with a punch that%s slightly smaller than the pin. 'ake sure you don%t remo(e too many links. 'ost will tell you that you can%t use multiple chain clips to add chain. "ny it%s easier to remo(e links& anyway. "fter remo(ing the appropriate links& the chain is re connected. The special connecting links :at right< are sold that ha(e a clip snap that holds the pins. .nstall the clip so that the closed end faces in the direction of chain tra(el. !arry a few links of chain and spare clips as part of a small tool kit on your kart.

$d)usting t&e C&ain (ension

!hains will stretch o(er time& and if you don%t ad/ust it& sooner or later it will fall off. 3ou%ll need to loosen your engine mounting bolts and mo(e the engine forward or back to re tension the chain. The correct amount of tension is about 457" of mo(ement in the chain when tested between the clutch and sprocket. " good amount of play in the chain is essential. .f you o(er tighten& chain life and horsepower will suffer. )e(ere o(er tightening will cause clutch engagement at idle. When fitting a new chain& e=pect the chain to rela= ;uite a bit. 3ou may ha(e to ad/ust se(eral times the first few trips out on a new chain.

0u%ricate t&e C&ain

Go kart and mini bike chain is referred to as roller chain. The steel pins rub inside of the steel tubes. Proper maintenance of the chain gets lubricant under the tubes and on to the pins. The best way to lubricate is to remo(e the chain and soak o(ernight. 8se a penetrating chain lubricant ask your dealer for their recommendation. The lubricant will need time to ade;uately penetrate the rollers a ;uick spray /ust won%t do it for proper maintenance. .f you need immediate lubrication& you may get by for the day with a ;uick spray and waiting a few minutes& but you%ll end up with a lot of chain spray on your clothes and little lubrication where it matters.

$lign (&e C&ain

When maintaining the chain& ensure that the clutch and dri(e sprockets are in alignment. 'isalignment will cause faster wear. 9otate your dri(e wheel backward and check that the chain is feeding straight back on the rear sprocket. The chain should ride in the middle of the sprocket otherwise add or remo(e spacers on the dri(e wheel a=le until aligned.

-orn Out Parts

9eplace the chain when there is too much slack and doesn%t fit between the sprocket teeth properly. 9eplace sprockets if they ha(e "pointy" teeth from wear.

Change the 1arl

Go Kart @il 'aintenance

!hanging the oil is easy& cheap& and often neglected. #oing it on a schedule will add to the life of your kart%s engine.

Oil 0evel
First& check the oil le(el each time before riding. Generally it should be (isible at the bottom of the filler cap threads.

Ho* to C&ange t&e Oil

There%s a few ways to do this. The first is the easy and dirty way& and the second is the hard and clean way. @il will flow better and you%ll remo(e more sludge if the engine is brought to operating temperature before changing the oil. .f done this way& use caution because the oil will be (ery hot.

3as# -a# to C&ange Oil

" 1riggs engine will ha(e a s;uare headed bolt at the (ery bottom of the block. This is an oil plug. 1y unscrewing this& the oil will flow from the lowest point on the engine helping ensure you get the sludge out. 8nfortunately this means that the oil flows out all o(er the mounting plate and hopefully then into your oil catch pan. !lean up time2

Harder4 Cleaner -a#

3ou can remo(e the engine and dump the oil& but this isn%t really possible if you heat the engine first& so the flush won%t be as good. @r& you could remo(e an oil filler plug and tip the whole kart backward on the back bumper& dumping the oil into a carefully positioned pan.

Maintenance !c&edule
3ou should change the oil according the engine%s specifications. 1riggs recommends changing the oil after 7? hours or once per season. !onsidering that karts go more action than lawn mowers& try to adhere to the hours usage.

1nd o# the Season

'aintenance When the )eason -nds

When the season ends& you%ll need to do a few simple things to store your pro/ect.

3ngine
#rain the gas from the tank by letting the engine run until empty. .f the carb is e;uipped with a bowl& check the bottom for a drain plug at its base. 9emo(e the rest of the gas from the tank (ia e(aporation in a open& (entilated area away from any sparks or flame& or by using rags. 8se caution. )ome products like ")ta 1il" are made to store gas& but the best bet is to remo(e it. 1efore using in the spring& remo(e the spark plug and add a small amount of oil to the cylinder. 9eplace the plug and slowly pull the starter before reattaching the plug wire.

Ca%les
1e aware of your brake and throttle cables when storing. Gubricate the ends with W# A> or other lubricant so they don%t sei,e.

!torage
Keep the machine out of the rain. " cheap tarp will sa(e you rust headaches2

-&en ! ring $rrives

When you%re ready to ride again& perform standard maintenance.

use fresh gas& not last season%s check the air filter change the oil oil all parts oil engine ad/ust chain inspect tires for dry rot

Sto((ing on a Dime
Go Kart 1rake !hoices

)urprisingly to some& there are ;uite a few choices for brakes on go karts these days. 3ou can use anything from the traditional scrub brake to the high tech disc brake. !lick the photos for specific product information from +orthern Tool.

!cru% Bra"es
" scrub brake uses metal paddles to press against both rear tires when the brake is pressed. )ometimes these are hand acti(ated by pulling up on a braking bar instead of running an actual brake pedal. This pro(ides ade;uate braking in most scenarios& but is hard on your tires.

Band Bra"es
" band brake uses a metal band to constrict around the outside of a brake drum when the brake is pressed. These brakes are simple to install and ine=pensi(e. They won%t perform great when wet. 'ost people run one brake on the dri(e wheel& but two would pro(ide better braking.

Drum Bra"es
9ather than constricting around the outside of the drum& a drum brake e=pands inside a brake drum. They ha(e real brake shoes& and may last longer than the band brake. They pro(ide (ery good stopping ability& and are less likely to get wet since they are more enclosed inside the drum. 3ou usually only need one drum brake.

Disc Bra"es

The best of the braking solutions& a disc brake is a high tech ad(ancement in go karting. They pro(ide superior stopping power& e(en when wet. " little bit of o(erkill on some karts& but it you want the best& this is it. We recently heard that some people are using the dri(e sprocket as the brake disc instead of ha(ing a dedicated brake disc. We first tried this system on our mini chopper& and it does work. 3ou do need to be concerned about keeping the sprocket clean of oil& though& and therefore it%s not the most trouble free disc brake setup.

T"rn2 T"rn2 T"rn

Go Karts "=les and )teering )pindles

The front steering assembly for a go kart need not be a complicated connection. First you%ll need the steering shaft. .t begins with the steering wheel& and terminates at the bottom with the Pitman arm. This arm is attached to the tie rods& and pushes them. The tie rods connect to the wheel spindles& aka the front a=les.

Go Kart ! indles
.n the front of the kart& the a=les are known as spindles. The spindles are pretty hard to fabricate& so if you%re not an e=pert weldor& you can buy them. They are about J4? each. The spindle is basically the steering connection to the a=le. They are usually about A inches long& but can be longer or shorter if the wheels dictate.

Go Kart (ie Rods

The tie rod is the connection between the pitman arms and the spindles. They are the ad/ustable part of the linkage. 3ou ad/ust the amount of "toe in" so that the go kart corners well. .t%s said that you want a slight toe in because this helps lift the inside tire when turning. We ha(e great articles on steering by people in the racing world that we%ll link to soon that more elo;uently e=plain this. 3ou can make your own tie rods& or buy them off the shelf. The trick for the tie rod is the end& which is threaded for the ad/ustment.

Go Kart Pitman $rm

This piece is what%s at the end of your steering shaft. When you turn the steering wheel& the shaft turns. "t the bottom is the pitman arm. This attaches to the tie rods and pushes them in the appropriate direction.

Cl"tching The Power

!entrifugal !lutches and Tor;ue !on(erters

3ou%ll need a way to transmit the engine%s power to your dri(e wheel& and that way is usually the centrifugal clutch. 3our other option is a high performance& high price tor;ue con(erters. !lick the photos for specific product information.

Centri'ugal Clutc&
" centrifugal clutch is a (ery simple mechanism. There is the clutch housing& which is the outer part of the clutch that%s (isible. "ttached is a sprocket. These come in a (ariety of tooth patterns& commonly between 4> and 47. .nside the clutch housing there is the actual centrifugal clutch. When the engine shaft spins& the clutch e=pands based on the centrifugal forces. When it spins fast enough& the shoes "lock up" with the outer housing (ia friction. When locked up& the engine%s force is transferred to the sprocket and chain. The clutch allows the sprocket to be disengaged at idle& which allows you to idle without mo(ing2

+e(er& ne(er run the engine if the clutch housing is remo(ed& as the clutch will fly apart. "lso be careful not to remo(e lock pins that hold the clutch together& as they are nearly impossible to get back together.

(or5ue Converter
!omet%s tor;ue con(erters allow you to get a lot more power from your engine. They are basically an automatic transmission for your pro/ect. The design allows automatic infinite (ariation and smooth shifting action. The belt and two pulleys work together& changing in relation to the kart speed. The change in si,e changes the gear ratio. Therefore& at low speed& the con(erter automatically is in "low gear" which means more tor;ue and power. "t higher speed the pulleys change so that there is a lower gear ratio& meaning more speed. The weatherproof system is completely mechanical and can be mounted in any position. 3ou can use a tor;ue con(erter on a go kart or a mini bike. "t around J4B>& they aren%t cheap& but they will allow you to go faster& or climb hills offroad. )o& consider sa(ing your money on a 4> 0P engine and getting a tor;ue con(erter for a ?.?2

Welcome to S(roc%ets

Go Kart #ri(e )procket !hoices

" chain and sprocket is a good and popular choice for the dri(e assembly& as they will wear better than a pulley system& are simple to install& and ine=pensi(e.

! roc"et !izing
)prockets are si,ed by the chain pitch and the number of teeth. The more teeth& the larger the sprocket is. The larger the sprocket& the better your low end power will be. The smaller the sprocket& the better your top end speed will be. 0owe(er& small sprockets really punish the already weak low end tor;ue of the kart. For this reason some use tor;ue con(erters. .f you e=pect great performance from a smaller engine& they are a must.

Gear Ratios and ! eed

The gear ratio is the ratio between the engine sprocket :little one< and the dri(e sprocket :big one<. The ratio helps understand your top end and your bottom end. We%ll publish detailed charts as time allows. The most commonly used sprocket is likely the M6? pitch F> tooth& though we%ll ha(e to take a poll to find out for sure. .t is the only si,e we%(e e(er used.

!ingle -&eel Drive $ssem%l#

For a single wheel dri(e& the sprocket can mount directly to the wheel so that there are no mo(ing a=le parts. 'ost parts dealers sell complete dri(e wheel assemblies in A"& ?"& and F" that ha(e the rear wheel& sprocket& and brake. )ince you won%t need to match bolt hole patterns for independently purchased pieces these combinations sa(e you money and headaches.

Chained 3(

'easuring !hain )i,es and 9esi,ing

!hain comes in some (ariety of si,e :pitch< for go kart applications. 3ou can tell the pitch of your sprockets or chain by measuring the distance from the top of one tooth to the ne=t& or by measuring between the chain pins.

6 78 C&ain
This is the most common pitch used with #.3 pro/ects& and is good for standard duty. The M6? pitch has 65B" between pins.

6 9:4 9;4 9<: C&ain

This chain is hea(ier duty than 6?& and has a 457" between pins. The A4 pitch is narrower than the others. The A> and A7> will fit on A4 pitch sprockets& but the A4 is too narrow to fit on the others. The A7> is the hea(iest duty.

Fitting C&ain
To resi,e chain& the pins must be dri(en out. .ne=pensi(e tools are sold that do /ust this. 3ou can also dri(e the pins out with a punch that%s slightly smaller than the pin. "fter adding or remo(ing links& the chain is re connected. )pecial connecting links are sold that ha(e a snap that holds the pins. "lternati(ely you can dri(e one of the pins pushed out earlier back into the linkage on some chains& and only if the linkage is in good condition.

Sta* Single2 or &o Live4

Go Kart Gi(e "=les Great For Traction& 1ad for )teering

Go karts use a (ariety of rear a=le types. The most common for #.3 types is the single wheel dri(e& but two wheel dri(e karts are also popular. The simplest of these is the li(e a=le& and the more complicated use a differential. " li(e a=le means that the wheels are mounted directly to the a=le& and the a=le spins. " dead a=le would be where the wheels spin freely and the a=le does not turn.

0ive $+les 'or (raction

" li(e a=le on a go kart means that the engine will power both rear wheels at the same speed and power. This is accomplished with a single sprocket mounted to the li(e a=le. )ince both wheels are locked in to the power all the time& off road go karts often use a li(e a=le. When both wheels are turning at the same time& you%ll ha(e twice the traction. This is great for sand& loose dirt& etc& where a single wheel would often spin out. This is not to say that li(e a=les don%t ha(e their drawbacks. 8nfortunately for the on road set& a li(e a=le means that turning is difficult. This is because both rear wheels turn at the e=act same speed. When making a turn& the outside wheel must be able to spin faster than the inside wheel. .f they are forced to turn at the same rate by a li(e a=le& then the outside wheel must slip on the dri(ing surface in order to turn as fast as needed. That%s easily accomplished on dirt and sand$ the outside wheel can slip without problem. 1ut on hard dirt and roads& the wheels ha(e much more traction& and therefore it%s harder for that wheel to slip.

Di''erentials
" more complicated solution to this problem is to use a differential on the rear a=le& /ust like a car has. This allows both wheels to be powered& and allows for easy cornering. 0owe(er& it%s not the best solution for serious off roading. This is because when traction is lost on one wheel& it will spin and the other won%t turn at all& effecti(ely gi(ing you a single wheel dri(e. These systems are readily a(ailable for less than J4>>.

!ingle -&eel Drive =Fi+ed $+le>

.f you plan to use the kart for serious off roading& then a li(e a=le is the way to go. 1ut for hard pack and asphalt& you can%t beat a single wheel dri(e for the price. " single wheel dri(e runs a chain from the engine clutch straight to the dri(e wheel& which has a sprocket mounted directly to it. The other rear wheel is left to spin free wheel. " single wheel dri(e is by far the easier and cheaper than a differential& and gi(e you the needed slip for on road and hard pack dirt dri(ing. 'any parts houses sell complete assemblies that ha(e the rear wheel& sprocket& and brake as one. This will sa(e you some cash and simplify the need to match bolt hole patterns for independently purchased pieces.

B"rning R"//er

Go Kart Wheels and Tires

Traditional go karts used whate(er wheels and tires were a(ailable. This probably resulted in the premature end of many a wheel barrow tire2 Today& there are a (ariety of wheels and tires a(ailable. !ommercial karts use (ery large rear tires& "TN style. 9acing karts use a F4 type slick. 1ut the traditional tire has always been a A.4>=6.?>=?& as far as we%re concerned.

!tandard Go Kart -&eels

'a/or parts suppliers carry A"& ?"& and F" wheels that fit the A.4>=6.?> pattern. The traditional standby wheel has been the 7 piece split steel wheel. .t comes in a A bolt pattern generally at 7 4654F" bolt hole circle. The bolt hole measurement is the distance between two opposite holes :the two farthest apart<. When buying a split wheel& you%ll need a separate hub that bolts to the wheel and holds the bearings. For all non dri(e wheels& you%ll need a single flange hub as shown in the photo. For the dri(e wheel& you%ll need a double flange. @ne flange mounts to the wheel& the other to the sprocket. "nother choice in rims are the integral hub rim. The rims shown in the photo are cast aluminum and retail at around J6>& though some are far more pricey. The ",usa brand also makes a nylon plastic wheel that is pretty cool and less prone to cracking when wrecking.

(ires
)licks are definitely the coolest for karts& but wheels come in a ribbed pattern and the traditional knobby. 3ou know the drill by now$ consider your use. 9ibbed is the best compromise between traction and long wear. Knobby wear out ;uickly. )ome tires& such as those at +orthern& are sold as "tubeless". This is only is you also ha(e tubeless rims& which most are not. 'ake sure that you get the tubes.

Bearings

The standard bearing si,es are ?5B" or 65A". 1oth are common& and it%s a personal choice which to use. We use ?5B" /ust because we always ha(e& and the a=le bolts fit nicely on the 4" tubing. )ome bearings are high speed and high priced& but will last longer than standard bearings. " "low speed% bearing will generally handle up to 7? 'P0& which is often well within the range of a kart. There are other& (ery cheap bearings for hand trucks and such that are (ery cheap& these are near worthless for go karts.

C&ea !olutions
Gately& looking around for cheaper wheels& we found A.4>=6.?>=A" hand truck wheels at 0arbor Freight on sale for JA each2 They came with a steel A bolt 7 4654F" pattern& tires& tube& and bearings. The tire is acceptable& though isn%t a long wear. The bearings are unacceptable and must be replaced. 3ou%ll sa(e a little using these little wheels& but the clearance is (ery tight using a F> tooth M 6? sprocket. For M A> the wheels would be far too small.

5RR666$)

Go Kart -ngines -=plained

Today there are many choices for engines on the market. Kunked old engines can usually be rehabbed& and new engines that are guaranteed to start easily are widely a(ailable locally.

-&ic& Brand to ,se?

)ince 1riggs is the most common engine& most people use a 1riggs engine. 0owe(er& Tecumseh and 0onda engines are used ;uite often. 'any people are /umping on the 0onda band wagon& as their legendary reliability is a huge plus for generally finicky go karts. We%ll hold a poll this Fall 7>>? to find out /ust how popular each are. The commercial go kart industry has been hammered lately with law suits and recalls for their products :you can learn more in the links section<. #ue to liability concerns& 1O) no longer markets any of their engines as go kart engines. 1ut of course people were building go karts with 1riggs engines far before they marketed that way& and still are. )o when you%re told at the dealer shop that 1O) doesn%t make a go kart engine& that%s why.

Ho* Muc& Horse Po*er Do . Need?

.f you%re building a smaller kart& a smaller engine in the 6 0P class will suffice& but you%ll need to build light and ha(e a light dri(er. We%re going to switch out engines on one of our karts and see how they perform with someone full grown. 1ut in our opinion& the older ? 0P 1O) engine is the classic engine of go karting. With a a F> tooth sprocket these will go around 7> mph. Today engines are rated a half horse higher. " large engine F.? and abo(e is great for off road karts that need more tor;ue. With larger tires and a hea(ier frame the e=tra 0P help. 1ut it%s easy to get too much speed and not enough low end from a large engine. We%re building a B 0P road kart that will be completed soon& and we%ll let you know how it goes& and whether the F> tooth sprocket is a good match for it.

Horizontal Mount vs ?ertical Mount

" go kart engine needs a hori,ontal mount engine. " hori,ontal mount engine is what a tiller uses where the shaft of the motor comes out in the hori,ontal position. " lawn mower uses a (ertical mount motor& and will need hea(y customi,ation :readE lots of money< to be used in a go kart.

T*(es o# 1ngines

Go Kart -ngines Types With -=amples

This is a page about the different engines you may encounter. 1oth engines had air (ane style go(ernors& but we remo(ed them immediately after we got them& since they were old and messing with go(ernors is often a lot of trouble. The first is a small tank set up. .t uses a (ery simple carb. The gas is drawn directly from one tube. There is no bowl or float. There%s one needle (al(e for the mi=ture ad/ustment. The second engine displayed is also a 6 0P& but has a larger tank and slightly more ad(anced carb. There are two down tubes on the carb. @ne draws gas from the tank and deposits it in the smaller bowl that%s integrated into the tank. This allows the second tube to always ha(e a constant le(el of gas to pull from& whereas the first e=ample& when on a sharp incline with low fuel may suck air. This e=ample has a screw in the back& but it doesn%t do anything. The forward screw is the needle (al(e.

!&are Your P&otos

.f you ha(e photos and descriptions of more engines& please share2 We want to show all kinds of engines people use for their pro/ects.

Lawn $ower $an

0ow to 8se a Gawn 'ower -ngine for a Go Kart

Gawn mower engines are a dime a do,en& you think to yourself. )urely there%s a way to use one and sa(e some cash... 3ou already know that go karts traditionally use hori,ontal mount engines for good reasons we%ll discuss. 1ut if you%re committed to being a nonconformist let%s figure this thing out.

0a*n Mo*er 3ngines

" lawn mower uses a (ertical shaft motor. .t%s designed to be mounted and used in the (ertical position. This can not be changed without a lot of work& maybe not at all.

Re ositioning to Horizontal
The mounting face for the motor is generally on the same side as the shaft& so you%ll first need to design a mounting bracket to hold the engine in the hori,ontal position. +ow you%ll reali,e that carb is turned on its side. 3ou%ll need to drill and tap new mounting holes. .f you open the crankcase& you%ll see that the oil slinger won%t be in the oil supply. 3ou%ll ha(e to figure something out to ensure the engine stays oiled. Those are at least two giant problems that you%d face with this "easy" solution. +ow let%s e=amine using the engine in the stock configuration.

,sing a 0a*n Mo*er 3ngine -it&out Re ositioning

.f you decide that changing the mounting design is too in(ol(ed& then the other option is to use the motor as normal& and get the (ertical shaft%s power transferred to the hori,ontal shaft%s plane. For this& you%ll need to get under a riding mower and e=amine how they do it closely. Probably you%ll want some kind of gear bo= to do this. We might say "use the lawnmowers2" but then again& it will need to be (ery hea(y duty to withstand the off road dri(ing that you%re considering. )o you%ll spend some time beefing it up. We scored a free lawn mower recently& and are tearing it apart to try to find a good way.

!&are Your .deas

"dmittedly& this section is here /ust to float some ideas around. We ha(e little intention of trying (ery hard to do this oursel(es& because using a hori,ontal mount is simply much easier. 1ut if you%re willing to try it& document the process2 Get us know how it goes& and ha(e your own pro/ect published on the site. We%d lo(e to help you show off2

6ne Lo"d $achine

Go Kart !ustom -=haust .deas

The function of the e=haust system is to get the outgoing gases away from the motor as ;uickly as possible. The more efficiently the e=haust e=its& the better the motor will perform. " muffler ser(es to ;uiet the e=haust gases& yet doing this constricts the outgoing gases. "n open pipes e=haust would be (ery efficient for the engine& and impro(e the output the most. -(en so& most people prefer some amount of a muffler as open pipes are (ery loud.

Go Kart Custom 3+&aust

3ou can make your own pipes& or customi,e an off the shelf solution to make it more efficient. )mall engines are threaded at the e=haust port& and some also ha(e holes for a flange mounted e=haust. The thread pattern is the same as a standard pipe thread meaning you can weld up a custom header 5 muffler. 9emember that you want high flow& and bends and restrictions lessen the flow. )ince the screw in type e=haust must screw into the e=haust hole& it restricts the flow a little more than a flange type. .f you don%t ha(e mounting holes& it may be possible to drill and tap them. "sk a engine dealer for their recommendation for your model. Gawn mower supply shops sell (arious mufflers as well. "sk for their high flow muffler to replace a low flow.

!&are Your Creations

We%d lo(e to see what you come up with in this area. .f you%d like to share your pro/ect on the site& /ust contact us2

Fig"ring It 6"t What s Wrong

0ow to Troubleshoot 3our )mall -ngine

With the simple design of small engines& repairing them is often (ery easy. 0owe(er& figuring out what to repair usually takes the most time.

-&at2s -rong -it& M# 3ngine?

)mall engine mechanics generally rely on the ma=im& ".t%s gotta be spark& gas& or air". To be more e=act& there%s a few other reasons that your engine won%t run& but these are the first to check. Guckily& it%s not difficult.

Fuel and $ir C&ec"s

First& check if you ha(e gas. We%(e all made this mistake& and we%(e all kicked oursel(es later. +e=t& pull the air cleaner off. .nspect it to see if it%s clogged with dirt& and if so& try starting the engine with it off. .f you%re still hunting& grab a can of starting fluid and gi(e the carb a s;uirt. This is a highly combustible material that gi(es the engine a short shot of fuel& e(en if the carb is plugged up and not deli(ering gas. When the engine starts with the starting fluid& but dies ;uickly you%ll know that you%(e got a fuel deli(ery problem& or a fuel5air mi= problem.

Car% Pro%lems
For deli(ery problems& pull the carb off and disassemble& looking for problems and clearing all passages. 'ost often the problem is /ust "gunk"& but their could be a diaphragm problem& seal

problem& etc. !heck with a dealer or good book for your carb if you clean it and still ha(e problems. For the fuel5air mi=& pull the needle (al(e screw out and inspect. !areful not to wrench these down& be gentle. 1O) usually call for 4.? turns out from the seated position. 8se good gaskets on the carb to tank and carb to block connections& otherwise a (acuum leak could be getting you.

! ar" C&ec"
.f the engine doesn%t start after checking the fuel5air mi=& then head o(er to the ignition system. )tart by pulling the plug wire off the plug& and position the wire so that there is a small gap between the wire and the top of the plug. Gi(e the engine a few pulls. " (isible spark should /ump between the wire and plug. 3ou may ha(e trouble seeing it in a (ery bright area& so if you don%t see one& make sure that the gap is not too large and try in a shady area. .f you don%t get a spark& then there%s an ignition problem. )tart by changing your small engine points. .f you do get spark& then your ignition is probably working @K. 9emo(e the plug and inspect. .t will be helpful if you start to learn what a normal plug looks like& what a lean5rich plug looks like& etc. There%s pictures in repair manuals. .f the plug is (ery dirty and sooty& you%(e probably got your carb%s ad/ustments wrong. !lean the plug by spraying with carb cleaner and using a wire brush to remo(e the deposits. 9einstall the plug and try again using starting fluid. .f you%re still not getting the engine started& then replace the plug.

Coil and Magneto C&ec"

.f you%re getting a spark and replaced the points and still can%t get it running& check the compression& and the coil and magneto& if e;uipped. 8se a feeler gauge to check if the coil to flywheel gap. For most 1riggs it should be .>>F" :call your dealer5check the book for other models<. .f that%s @K& ensure that the flywheel magnet is still magneti,ed. " screwdri(er should be strongly attracted to it. Then mo(e to check the coil. They rarely die& but can be tested at a lawn mower shop :or /ust swap another on it to check<.

Com ression
There%s no listed compression check for 1riggs engines& but the dealers say that when the plug is installed& the engine should pop forward when spun backward. We understand that many engines ;uickly leak down due to the (al(es& so a normal automoti(e compression check won%t work. !all you local dealer to see what their ideas are. .f you%(e reached this point without getting it started& then you%re in bad shape& and probably cussing up a storm. Pull the head and check the (al(es& they could be stuck. That should get you going Good luck2

S(ar%s2 &et To The Point

0ow to Fi= 3our Go Kart )park 5 .gnition )ystem

.f you%re ha(ing an issue with weak spark& or no spark& the cheapest and easiest repair after changing the plug is to change the points. +ote that not all engines use points. .f you%re ha(ing performance problems with your small engine& this repair& along with gapping the coil might drastically impro(e the power.

Overvie* o' !#stem

The magnet on the flywheel and the coil are (isible when the recoil starter is remo(ed. To change the points you don%t need to remo(e the coil& but checking the gap at this time is recommended. For most 1riggs& the gap should be .>>F". The points and the condenser are located under the flywheel. Points are to be gapped at .>7>". 3ou can file the points and re use them& but the replacement parts are (ery ine=pensi(e& so replacing them outright isn%t prohibiti(e.

Remove t&e !tarter Clutc&

)tart by remo(ing the recoil starter housing& e=posing the flywheel and starter recoil clutch. 8sing a special tool& or a pair of channel lock pliers& grasp the clutch and turn counter clockwise to remo(e the clutch. 8se a stout screw dri(er between two of the thickest fins to keep the flywheel from mo(ing. The flywheel is cast iron& which is brittle. 1e careful with it. .f your starter sometimes doesn%t catch& or if its sticky and it is hard for the spring to recoil it& open up the clutch with a cold chisel. There should be no lubrication of the bearings inside. .f it%s sticky& clean with carb cleaner to get all dirt and grease out. #on%t grease the bearings$ lubrication will attract dirt& which will make the clutch stickier.

Remove t&e Fl#*&eel

)pecial pullers are made to remo(e the flywheel& but we found that a large 7 or 6 /aw puller worked /ust fine. The puller will need /ust a partial turn to break the flywheel loose.

(&e Points
The co(er for the points will now be (isible. 9emo(e the screws and inspect the o(erall system. There should be no moisture or oil behind the co(er. .f there is& new seals will need to be installed. !ontaminants behind the co(er speed fouling of the points. +ew points kits are a(ailable at most hardware stores& and at lawn mower dealers. 9emo(e and inspect the contact points for burning and strange wear& then discard the condenser and the rocking arm. .nstall the new ones& using caution not to strip the small bolts. Gap the points at the recommended distance using a feeling gauge. Finally& use 9TN gasket material to seal the hole where the wires e=it the co(er.

Reinstall t&e Fl#*&eel

Put the wheel back on& and tap with a wooden mallet& 7=A& etc. #o this e(enly across the entire surface so that the blow doesn%t strike /ust one fin& or push it une(enly. !heck the coil gap again& reinstall the clutch and housing& and you%re done2

.' (&is Doesn2t !olve Your ! ar" Pro%lem

.f this doesn%t work& then your coil is bad. Take it to a dealer and ha(e it tested to be sure.