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Below are the general guidelines that are applicable to most go-kart assemblies. With any particular model, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. Always consult your owner's manual when undertaking a project of this type.
In addition to standard auto-mechanic's tools, specialty tools that will be helpful for this project include an air compressor and a set of air ratchets and sockets. If you don't own air tools, you can rent them from most equipment-rental centers.
Installing the Engine and Clutch
- There were several available engine models that you can opt for. The clutch is purchased and installed separately. Installing the clutch yourself will save you money in the go-kart project.
- The engine rests on the engine mounting plate (figure A), and is bolted in position through four slotted mounting holes in the plate. The holes are slotted so that the engine position can be shifted forward or backward to adjust the tension on the chain, which will be installed in a later step.
- Secure the engine to the mount using the provided mounting bolts and nylon lock-nuts. The bolts extend up through the bottom of the plate and engine. When installing the nuts, make certain that the nylon side of the nut is facing away from the threads of the bolt (figure B). Install all four bolts and nuts, but don't tighten the nuts down yet. The engine will need to slide forward and backward for chain adjustment.
- The next step is to install the clutch. Note that the clutch assembly has a front and back that are not interchangeable. The front side (figure C) has clutch-sprockets while the back (figure D) has key that installs in slot and holds the clutch in position on the engine Two set-screws help secure the clutch to the crankshaft.
- Align the key on the clutch with the key-way on the crankshaft, and make sure that the clutch is seated firmly against the crankshaft plate (figure E).
- Fasten the clutch using the provided bolt and flat-washer (figure F).
- Tighten the bolt securely using the appropriate socket.
Note:
- It's a good idea to oil the clutch after each use.
Installing the Chain
- The chain installs on the sprocket and comes already cut to length. It is formed into a complete loop using a master link.
- Place the chain on the lower sprocket, and bring the end up over the clutch sprocket.
- Where the two ends of the chain, the ends are fastened using a master link which is secured using a tiny link-washer and link-clip.
- Fasten the two ends together at the master link, install the washer, and the clip. Use needle-nose pliers to make sure that the clips snaps completely into place to secure the master link.
- This competes the installation of the chain. If the chain ever needs to be removed from the kart, the clip can be removed so that the two ends can be disconnected.
- With the chain installed, check to make certain that the top and bottom sprockets are aligned with each other.
- Once the sprockets line up, and the chain is straight up-and-down, mark the location of the lower sprocket on the axle, then install the key provided to secure the lower sprocket to the axle shaft. Use a hammer and pin to tap the key in as far as it will go.
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