Technical Manual-Go Kart

8/9/2019 Technical Manual-Go Kart

1/13

Beginners

Age 12+

With Parental Guidance

Build

A Go-kartTechnical Manual

Andre Morgan

Eng 352-Technical Writing

Prof. Mark Arnotwitz

April 27, 2009

Gas

Powered


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Beginners

Age 12+


Table of Contents

Introduction------------------------------------------------------------------------------------------- 1

Disclaimer ---------------------------------------------------------------------------------------------2

Procedure

Materials --------------------------------------------------------------------------------------- 3

Frame ------------------------------------------------------------------------------------------- 4

Steering Assembly ---------------------------------------------------------------------------- 5

Drive train ---------------------------------------------------------------------------------- 6, 7

Pedals, Brake, & Throttle -------------------------------------------------------------------- 8

Cable Stop -------------------------------------------------------------------------------------- 9

Roll Bars ---------------------------------------------------------------------------------------- 9

Seat --------------------------------------------------------------------------------------------- 10

Final Steps ------------------------------------------------------------------------------------- 10

Citations ------------------------------------------------------------------------------------------------11

Appendix A


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Introduction

Welcome to the Build A Go-kartTechnical Manual.

What is a go-kart?

A go-kart is a 4-wheeled vehicle resembling a car, powered by pedals,

gas engine, or an electric motor. Go-karts can be found at amusement

parks and other establishments where family fun and entertainment is

provided.

In this manual you will find the necessary information to build a

beginner gas powered go-kart. This build will contain some mechanical

aptitude and accessibility and knowledge about power tools. It is built with

catalog parts as well as some household items. Please see the Parts Listfor

more information on part numbers and catalogs.

This Manual consists of detailed instructions, with some pictures to

help along the way. This is a step by step process, following every direction

is key to the safe and fun completion of this project as well as years of

family enjoyment.

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***Warning***Disclaimer:

This manual is designed to reproduce a safe go-kart for family enjoyment. This project isfor Beginners Age 12+; only with the Supervision of a Parent or Guardian at all times.

This is a Gas Powered go-kart, hazardous materials and chemicals may be used in theprocess of this build. Some of these materials & chemicals are known to cause Cancer and/orbirth defects in the State of California. Power tools are needed to complete this project. Propersafety equipment and knowledge on the use of both safety equipment and power tools are

required.When the go-kart is complete please recheck all work. Verify every connection made by

repeating all steps in this manual. In some states go-karts are considered road vehicles andmay need titling, registration, and insurance to be used. Also the driver of the go-kart may needspecial licensing to operate legally. Please check local laws before attempting to operate thisvehicle on private, public, or government property.

By purchasing this manual, receiving this manual, reading this manual, using this book asa guide or supplemental reference material for any other project or go-kart manual, or bymanipulation of the instructions, you, the reader, accept all responsibility for the out come ofthis project.

The writer and publisher, seller, and any other company involved with the production anddelivery to market of this manual is released of all responsibility to injury, death, mental,physical, and emotional harm, pain and suffering, misuse, misguidance, misprint, false

impression, or confusion leading to the dangerous conditions or surrounding environment ofthis go-kart. Including but not limited to, other products used and suggested by this manual tocomplete the go-kart; gas, oil, and battery used to run the go-kart. Together with or without, fineand fees, accidents, lawyer fees, health care and/or hospital bills and restitution stemming fromthe use of this manual. Use at your own risk.

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ProcedureGather all Materials

Tools & Power Tools: Drill

Saw-Zaw - metal cutting blade

Circular Saw wood cutting blade

Drill bits

Welding Machine

Materials:

1 - inch 4ft x8ft Plywood sheet

2 - x x 6ft Square Dowels

2 - 1x 4 at 2 ft. long

1 - Old house chair

Multiple lengths of Galvanized pipe to create a roll cage and fittings and base Box of - 1 inch / 2 inch / 3 inch wood screws

Box of x 1inch Bolts, nuts, and washers

Box of x 2 Bolts, nuts, and washers

Box of x 2 Wood Bolts ( Coarse Thread Bolts)

1 - x 96 x .050 inch Angle Aluminum

2 - x 2x 3 inch Stainless U-Bolt

2 3inch door hinges

1 in cotter pins and assorted washers

Rubber Washers

Catalog Items: www. northerntool.com

Item # 1388 - Steel Go-Kart Axle - 44in. Length Item # 13793 - Extreme Duty Centrifugal Clutch

Item # 136510 - # 41 Drive Chain

Item # 13631- 60 tooth Drive Sprocket # 41 chain

Item # 1382 x 2 - Throttle & Brake Cable

Item # 13824 - Kill Button Switch

Item # 13891 - Right Spindle & Bracket

Item # 1389 - Left Spindle & Bracket

Item # 13825 - Go-Kart Steering Wheel

Item # 1366 - 4in Brake Band & Drum

Item # 13814 - Steering shaft & Hub

Item # 13811 x 2 - Tie Rod Kit

Item # 13760 x 2 Solid rubber tire Item # 60300 3.5 hp Briggs & Stratton Horizontal Engine

Catalog Items: www. mfgsupply.com Item # 8-374 4 Rear hub & Wheel

Item # 8-371 4 Hub & Wheel

Item # 8-879 x 2 280 x 250 x 4 Tires

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ProcedureFrame

1. Measure and Cut Plywood to the following Dimensions: 3 wide x 4 long.

2. Lay the plywood on a flat surface and place 2 - x wood dowels 2 feet apart and attachthem to the plywood using 1 wood screws at each end.( this will be the bottom of frame)

3. Drill 4 - Pilot holes at equal distance; starting from the top of the frame or the plywood side,through to the dowels and install x 2 bolts, nuts, and washers.

4. With Angle Aluminum cut 2-6in lengths and drill 2 - holes (1 at each end).5. Position them on the bottom of the wood dowels 10 from rear of cart.6. Drill Pilot holes and bolt Angle to the frame

using x 2 Wood Bolts.

7. In the front there are exposed dowels becausewe did not cut them to length yet.

8. Leaving a 1ft overhang cut the dowels to size(see picture).

9. With Angle Aluminum, cut 2- 2ft lengths10. Drill 2 - holes in each piece. The 1st hole

starts 2 from the end of the aluminum. The 2nd

hole is 8 from the first hole.

11. Fasten Angle Aluminum to the front end of thedowels, overlapping each other by 1ft, with x

1inch Bolts, nuts, and washers .

12. The front now needs to be connected together; box in the front section by cutting a length ofAluminum to size to close the front section.

13. Weld the front section of the cart at the seams to fully box in and strengthen front core support.Con

Congratulations Your Frame is Complete.

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ProcedureSteering

This is the beginning of the front steering assembly. This will require more welding and

measurements to be taken when the driver is sitting on the cart for safe positioning.Item # 13891 & 1389 - Left and right Knuckle and Spindle

Item # 13825 - Go-Kart Steering Wheel

Item # 13814 - Steering shaft & Hub

Item # 13760 x 2 Solid rubber tire

Item # 13811 x 2 - Tie Rod Kit

1. Assemble the steering wheel, hub, and shaft per the directions included with these parts.2. Have driver sit down and test driving position. Once found, mark locations and record

measurements.

3. Attach Tie rods to the steering shaft and lay them out to the approximate location of the frontknuckles.

4. When they are lined up take measurements and to be sure of equal distance from driver. Thiswill allow straight line travel with out left or right pulling.

5. Now the knuckles are aligned. Weld them to the frame.(Green in Picture Below)6. Using Angle aluminum and a pipe fitting

cap, bigger that the steering shaft to create

a rotating cup for the shaft to rest in and

rotate smoothly.

7. Install spindles onto the knuckles.8. Install solid rubber tire onto the spindle

with washers on both sides, Install the

lock nut on to the spindle.9. With the wheels pointing straight ahead

and the steering wheel centered, Cut thetie rods to length and bolt them to the

knuckles with hardware included.

10. Test by locking the wheel left to right fixany problems including binding.

Steering Shaft Support

1. To create a shaft support use left over pieces of wood to form a H2. The distance between the 2 long pieces should be 13. Adjust the H forward or aft to adjust the steering height.4. When position is found attach it to the Plywood and lay the Shaft in the middle.

Congratulations Your Steering Assembly is Complete.

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ProcedureRear Drive Axle

This Go-kart is has a Dead Axle. This means the rear axle does not rotate instead 1 wheel is the

drive wheel and the other is free rolling. They both rotate on or about the stationary axle. Some

welding is required. The items needed are:

Item # 8-374 4 Rear hub & Wheel

Item # 8-371 4 Hub & Wheel

Item # 8-879 x 2 280 x 250 x 4 Tires

Item # 1366 - 4in Brake Band & Drum

Item # 1388 - Steel Go-Kart Axle - 44in. Length

2 - x 2x 3 inch Stainless U-Bolt


1. Start By assembling the drive wheel in this order. Insert in bolts into the hub on Item # 8-3742. Then connect the sprocket and drum and followed by lock washers and lock nuts.

Next1. Center the steel axle on the go-kart2. The axle should be place on the angle aluminum from Step 4: Frame Build3. When centered mark location and drill and install U-bolts through angle aluminum wood

dowels and plywood. These U-bolts will hold the axle to the frame.

4. Place the axle through the U-bolts and center it again then tighten the U-bolts and weld the axleto the angle aluminum. But not the u-bolts.

5. Temporally place wheels on to the axle sit the car up right. This will allow for adjustmentbefore final fitment.

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Procedure

Items needed: Item # 13793 - Extreme Duty Centrifugal Clutch

Item # 60300 3.5 hp Briggs & Stratton Horizontal Engine

Item # 13824 - Kill Button Switch


Engine1. To prepare the engine follow the manufactures manual.2. To install the kill switch also follow the factory owners manual.3. Next install the Centrifugal Clutch on the engine shaft and tighten safety Allen screw. This

will keep the clutch form flying off the engine shaft.

4. Install the Shaft Key. This will connect the shaft to the interior clutch.

Drive Line Fitment and Final Positioning

1. Place the engine on the go kart.2. Attach the drive chain around the clutch and sprocket shift either wheel or engine to create a

straight path of travel for the chain. If not done correctly the chain will slip off.

3. After drive line is straight adjust the chain length with the parts supplied to allow a smallamount of play in the chain when it is connected. Again, too much play will allow the chain

to jump the sprocket (fly off).

4. The brake drum should fit as close to the frame as possible.5. Mark the location of the axle and wheel as the final fitment location.6. We will drill a hole at these locations through the axel; add a washer and cotter pin on both

sides of the wheel to eliminate wheel play. (The wheel will fly off if this step is ignored)

7. Repeat Step 6 & 7 for the other side. Make sure the exterior face of the tire of bothwheels, is of equal distance from the frame, for straight travel.

8. Now mark the location of the engine for proper operation (straight drive line with the rearsprocket); drill in holes through the plywood and bolt the engine to the frame. Place rubber

washer between the engine and Plywood to isolate vibrations.

Test1. With the wheels raised of the ground, Start the engine and test driveline and kill switch.2. Look for smooth spinning drive wheel with out chain binding or interference with frame.

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Procedure

Pedal Assembly

The pedals are made from 3in door hinges and screwed to 4in x 2in plywood.Drill a small hole in to the door hinge. The size of the hole should allow the cable to slide through,but not the cable head.

Items needed: Brake Band & Coarse thread wood bolt

Brake System

1. To install the Brake Band, slip it around the drum.2. Bolt the bottom side to the frame. (See Drawing below)3. Run the brake cable through the right pedal straight back to the brake band and connect them

with a cable stop.

Throttle System

1. Run the throttle cable through the right pedal to the engine.2. Following the Engine Owners manual connect the throttle cable to the engine.

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ProcedureCable Case - Hold / Stop

Cut a short piece of angle aluminum and form a slot similar to the drawing below.

Place the cable case on one side of the angle and allow the cable alone to be visible on the other

side.This will allow the cable to work correctly by sliding with in the case and transferring

movement along the cable to both throttle and braking systems. Complete this process 4x creating

1bracket for both ends of the cable, for the two systems. Adjust the placement of the angle relative

to the pedals and end connections

Roll Bars

Too create roll bars, use galvanized pipe to construct shape along with galvanized fittings

to make bends and anchor the pipe to the plywood. These bars can be any length and are left up to

your imagination. However, the roll bar system must consist of a minimum 4 corner

connection.

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Procedure

Seat installation

1. Find an old chair. Cut the legs off and bolt the seat to the plywood of the go-kart in acomfortable safe driving position.NOW wasnt that easy?

Good Job! Youre almost done.

Final Steps

1. Review entire manual to make sure no steps where missed or misunderstood.

2. Check all screws, bolts, and nuts for proper installation.3. Check all welds for strength and structural rigidity.

4. Review engine owners / operators manual.

5. Put on a helmet, Start the engine and have fun.

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Picture Bibliography

Cover Page & Page 10

These pictures are products of the Microsoft Corporation and do not reflect the productbeing built by this manual. These are not relation to this manual and should not be used for

design purposes. They are cartoons and are used for visual stimulation and to reduce white

space on the pages they are placed.

Page 6

Wheel, Hub, Sprocket, Drum

Karts & Parts. ".com.my: Go-Kart Cart Mini-Bike Drive Wheel Pkg 4.10 x 3.50 x 5" (item

390017611651 end time Mar 11, 2009 05:32:02 MYT)." EBay. 03 May 2009

.

U-Bolt Picture

"Product Information." The Home Depot. 03 May 2009

.

CAD PicturesThe CAD Pictures in this manual were produced by Andre Morgan the writer of this

manual using Pro Engineer and Auto CAD

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Technical Manual-Go Kart