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Version01/17/2019
HighSchoolevGrandPrixElectricGoKartCurriculumandClassroomMaterials
WinterDisassembly,Redesign,andRebuildManual
APartnershipBetween
GettingStartedThismanualwasdevelopedasaguidetoassistreturningHighSchoolKartingteamsastheydisassembletheirkartsduringthewintermonths.Aphotographofthedisassembledkart,anditscomponents,mustbesenttoStuartWhiteatwhite152@purdue.eduAllreturningteamswishingtocompeteintheevGrandPrixWorldsFinalsattheIndianapolisMotorSpeedway(IMS)mustobtainconfirmationoftheirkartbeingdisassembledpriortocompetition.Theinformationcontainedhereinismeanttobeareferencetoolandnotadetailedstepbystepmethodfordisassemblinganelectricgokart.
PleasebeawarethatthefinalauthorityforkartsetupistheVehicleandTeamEquipmentSpecificationsdocumentfoundonthewebsiteevgrandprix.organdallkartswillbeinspectedforcompliancetotheserulespriortoracingintheWorldFinalseventattheIndianapolisMotorSpeedway.
Table of Contents Tools.............................................................................................................................................................3
RearAxleDisassembly.................................................................................................................................4
BrakesandMotor........................................................................................................................................5
SteeringAssembly.......................................................................................................................................8
BumpersandGuardsAssembly.................................................................................................................10
ElectronicsandWiring...............................................................................................................................11
Tools 1. BoxWrenchSet–Usedtoloosenaboltornut.Varioussizes
required
2. SocketWrenchSet–Usedtoloosenaboltornutbasedontheswitchsetting.Varioussocketsizesrequired.Canbeusedintightspaceswherearegularwrenchmaynotworkeasily.
3. AllenWrenchSet–Usedtoloosenspecificcrewsandblots.Varioussizesrequired.Hexagonalshapedtoolbenttoforman“L”.
4. WireCutters–Usedtocutziptiesandotherfasteningmaterial.Caution:cutsmallendshaveatendencytoflythroughairuponcutting.
5. Needle-NosePliers–Usedtoremovesafetywire,clips,etc.
6. Screwdrivers–usedtoloosenscrews.Flattippedandphillipsheadrequired.Notmeantasapryingtool.
7. DeadBlowHammer–Usedtoremovestubbornpartorcomponents.
RearAxleDisassemblySummaryRearaxledisassemblydoesnotrequirebearingstoberemovedfromcassettes.Disassemblydoesrequiremanyfastenerstobeloosenedduringthedisassemblyprocess.Thisallowsforeaseofreassemblyandproperalignmentofpartswhichwillenhancetheeaseofmaintenanceandrepairshouldpartfailureoccur.Allbolts,nuts,screwsandothersafetyfeatureswillrequirechecksforproperfunctioningandwarepriortothekartbeingreassembled.Oncetheaxleisremovedallmovingpartsshouldbelubricatedandcleaned.
Knowledgeofhowtodisassembletheaxleisimportantbecauseitisneededformaintenancepurposes.Agokartcanbreakdownforavarietyofreasonsanditmightbenecessarytotakethekartapartinordertoreplaceormodifydamagedkartcomponents.Mostkartshavethesametypeofrearaxleassembly.Commonvariationscomefromhowtheaxleismountedtotheframeandkartspecificsub-assemblies.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.
Tools
• Boxendwrenchset• Socketsetwithlongextension• Allenwrench
Step1–Removewheellugsandseparatereartiresfromwheelhubs
Step2–RemoveChainandchainguard.Placechaininasmallcontainerandsubmergeitinalightgrademotoroil
Step3–RemoveWheelHubsfromaxle
Step4–Loosensetscrewsfrombearings,sprocketbracket,androtorbracket.
Step5–Slideaxlefreeofbearings,sprocketbracket,androtorbracket.Youdonotneedtoremovetherotorfromtherotorbracketortheaxlesprocketfromthesprocketbracket.
Step6–Removerearaxlebearingcassetteboltsfrommountingbracketsweldedontoframe.SpraytheaxlebearingswithaproductlikeTru-Flow.Continuesprayinguntilthefluidcomingoutofthebearingsisascleanasthefluidgoingin.Bearingsshouldberotatedduringthisprocess.Ifyourkarthastherearbrakecaliperattachedtothecassettemountingbracket,goaheadandremovethecaliperbutleavebrakelinesattached.
Brakes and Motor Disassemblingbrakeswillnotincluderemovingbrakelinesfromthemastercylinderorthebrakecaliper.Youwillwanttoremovethedrivesprocketfromthemotoruntiladecisionhasbeenmadeonagearingratio.Althoughitisimportanttoknowhowtoassemblethebrakesystemthisisonlyneededformaintenancepurposes.Ifyourkartbrakesystemshouldbreakdownforavarietyofreasonsanditmightbenecessarytotakethebrakesystemapartinordertoreplacedamagedbrakelines,mastercylinder,orcaliper.
Mostkartshavethesametypeofbrakeassembly.Commonvariationscomefromhowthebrakeismountedtotheframeandkartspecificsub-assemblies.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.
Themotormountwillberemovedfromthekartwiththemotorstillattached.Thereisnoreasontoremovethemotorfromthemotormountunlessthemotorneedsreplacing.
Tools
• Boxendwrenchset• Socketset• Allenwrench
Step1–Removehebrakefootpedalconnectiontothemastercylinder.Thebrakepedalcanremainattachedtothekartchassis.
Step2–Removethemastercylinderfromchassismountbyremovingboltsfromthebracketweldedtotheframe.
Step3–Removethebrakecaliperbyremovingboltsfrombracketweldedtothekartframe.Ifyourcaliperisattachedtothebearingcassettebracket,thisstepwascompletedduringtheaxleremoval.
Step4–Loosenchaintensionboltfrommotormount.
Step5–Removemotorandmotormountbyremovingboldssecuringthemotormounttothechassis.Kartwillneedtoberaisedinordertoaccessthesebolts.
Steering Assembly Thesteeringwheelandsteeringcolumn,whichisattachedtothechassis,canberemovedasoneunit.Oneendofthetierodsconnecttoanattachmentpointonthesteeringcolumnwhiletheotherendsofthetierodsconnecttothespindleaxlearms.Thesewillneedtoberemovedfromeitherside.However,jamnutadjustmentisnotnecessaryatthispoint.Thespindleaxlesareboltedtothechassisandwillneedtoberemovedfromthechassisandfromthefrontwheels.Knowledgeofhowtodisassemblethesteeringisimportantbecauseitisneededformaintenancepurposesoritthegokartchouldbreakdownforanyreason.Itmightbenecessarytotakethekartapartinordertoreplaceormodifydamagedkartcomponents.
Mostkartshavethesametypeofsteeringlinkage.Commonvariationsinsteeringcomefromhowthesteeringrodismountedtotheframeandtierodsareattachedtotherod.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.
Tools
• Boxendwrenchset• Socketset• Allenwrench
Step1–Removefrontwheelsfromspindles.
Step2–Removesteeringwheelfairing.
Step3–Removethetierodsfromthespindleaxleandsteeringshaftbyremovingtheboltsecuringthetierodtothespindleandtheboltsecuringthetierodtothesteeringshaft.
Step4–Removethesteeringcolumnshaftfromthekartchassisbyremovingthenutonthebottomofthechassismountingbracket.
Step5–Ifyourkeyswitchismountedonthesteeringwheel,disconnectkeyswitchandsteeringwheelE-Stopifinstalled.Removethesteeringcolumnsupportbox
fromtheframesupportbracketbyremovingtheboltholdingthesupportboxinplace.Liftthesteeringshaftoutofthechassismountingbracket.
Step6–RemovethespindlefromthespindlemountweldedtothekartchassisbyremovingtheKingPinholdingthespindleinplace.
Bumpers and Guards Assembly Thefront,back,andsidebumpersareattachedtotheframeviaclamps.Thebumpersprovideprotectionforthedriverduringaraceandprotectvitalcomponentsofthekart.
Tools
• Boxendwrenchset• Socketset• Allenwrenchset
Step1–Removethefrontcrushablebumperfromfrontofchassisbyremovingthecrushablebumperclampsandbumpermountingbracketfromthechassis
Step2–Removerearmetalbumperbylooseningbumperboltsandremovingtherearbumperassemblyfromthechassis.Youdonotneedtodisassemblerearbumperassembly.
Step3–RemovetheE-StopfromthebatteryboxandthenremoveBatteryboxesfromnerfbars.
Step4–Removesidepods,ifattached,andnerfbarsbyremovingboltsattachingnerfbartochassis.Slidenerfbarfreeofchassis.Yournerfbarsmaybeattachedwithanaccompanyingspringwhichwillneedtoberemovedpriortodetachingnerfbarfromchassis.
Electronics and Wiring Componentsincludingtheconnector,contactor,fuse,shuntresistor,emergencystop,andcontrollermustberemovedafterbatterypackharnessisremoved.Thethrottlemustbeunboltedfromthefloorpanhowever,thepedalmayremainattachedtotheframe.Removalofthebatteriesshouldhavetakenplacepriortorearaxledisassembly.
Knowledgeofhowtheelectricalassemblyisputtogethercanhelponegraspabasicunderstandingofhowthesystemworks.Thisnotonlyempowersthatpersontobeabletotroubleshootmalfunctionsgiventhepossibilitythatproblemsmayoccuronthetrack.Therearemanypossiblewaystoassembleyourcomponents.Thissectiondescribeshowtodisassembletheindividualcomponents.Theorderisrandomascomponentscanberemovedinanyorder.
Tools
• Boxendwrenchset• Socketset• Screwdrivers• Wirecutters
Step1–Removemotorcontrollerbydisconnectingelectricalconnectionsandunboltingfromkartchassis.
Step2–RemoveE-Z-Gothrottlepotentiometerbyunboltingfromchassisandcuttingzipties(orelectricaltype)securingelectricalconnectionstochassis.
Step3–Removecontactorbydisconnectingelectricalconnectionsandunboltingfromchassis.Donotremovepre-chargeresistorfromcontactor.
PreChargeResistor
Step4–Remove300ampfuseassemblybyunboltingfromchassis.Removeonlytheelectricalconnectoronthebatterysideofthefuse.Ensurekeyswitchsideoffuseassemblyisleftintact.
Step5–Cutallziptiesandorelectricaltapeconnectingelectricalwirestothechassis.Collectallwiresandcablestostorewithelectricalcomponents.
Step6–Removefloorpanfromkartbyunboltingfromchassis.
Step7–Removeseatfromkartbyunboltingfromchassis
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