- Weld frame together as shown on the "Two-Person Go-Kart Frame Drawing". Be
careful when welding the 16 Ga. tubing, if is easy to burn through the thinner
walls.
Weld brackets (part # 1389 and 13891) to the front of the frame
as shown. To position correctly, place the spindles inside the brackets and line
up the center line of the spindle with the center line of the front "axle"
(horizontal tubing) both horizontally and vertically.
Position steering
shaft and weld hollow round tubing in place:
a) Cut square tubing steering
support at angles shown.
b) Weld 2" long round tubing to the top of the
steering support. Center it both horizontally and vertically.
c) Weld the
steering support to the frame. If needed, you may want to weld on a gusset on
each side of the steering support to give if added strength.
d) Slide the
steering shaft through the round tubing and use the shaft to line up the second
piece of round tubing with the piece on the steering support.
e) Weld the
second piece of round tubing between the two parallel segments of square tubing
at the front of the frame. |
| 2. Insert the rear axle through the square tubing at the rear of the frame
so that equal lengths (5") stick out of both sides. Weld in place. (NOTE: The
axle is fixed and is not meant to spin inside of the tubing; the tubing is for
added support to the axle and frame.). |
| 3. Assemble the drive wheel, sprocket, and brake as shown in Figure 2.
(NOTE: The bolts provided with the rear wheel and hub need to be replaced with
the longer bolts specified in the material list.). |
| 4. Slide the 3/4" flat washers on the axle and then slide on the rear
wheels. |
| 5. Weld the engine mount as shown on the "Go-Kart Engine Mount" drawing. The
hole-to-hole dimensions are very important. If these dimensions cannot be held,
you may want to drill slightly larger holes. |
6. Attach the clutch to the engine shaft:
a) Apply an anti-seize compound
to the engine crankshaft prior to mounting the clutch to the engine shaft.
This prevents the two shafts from rusting together.
b) Be sure to use the key
provided.
c) Secure the clutch to the engine using a 5/16" flat washer, 5/16"
lock washer, and a 5/16-24 X 3/4" fine thread bolt. Torque bolt to 14-19
ft.-lbs.
d) Prior to starting the engine, be sure the clutch drum rotates
freely on the crankshaft. If it does not, replace immediately with a new
drum assembly. |
| 7. Attach the engine to the engine mount (after allowing the engine mount to
cool). |
| 8. Position the engine/engine mount so the sprocket on the clutch and the
drive sprocket are lined up on the same vertical plane. |
| 9. Cut the chain to length, place it around both sprockets, and attach the
two ends using the master connecting link (#136511). |
| 10. Slide the engine/engine mount forward or backward (while keeping the
sprockets lined up on the same vertical plane) until the chain is
tight. |
| 11. Clamp the engine base in place (or mark it's location) and remove the
engine from the engine mount. Weld the engine mount at the marked position and
then reattach the engine (with the chain around both sprockets) to the engine
mount. |
| |
|
SEAT
1.
Weld and drill the seat frame as shown on the "Double Go-Kart Seat"
drawing.
2. Drill the 12" X 30" and 8" X 30" pieces of plywood to match the
holes in the seat frame (the 8" X 18" piece is the back rest).
3. Get the 12"
X 30" and 8" X 30" pieces of 1" foam padding, and the 3/4 running yard of vinyl
fabric.
4. Place the carriage bolts through the holes in the plywood so
they are sticking out the side that will be touching the frame.
5. Place the
foam padding on the plywood (on the same side as the bolt heads).
6. Cut the
vinyl as if it were wrapping paper. Then wrap the foam and plywood like a gift,
allowing holes for the bolts to go through.
7. Secure the vinyl fabric in
place using a staple gun (or thumb tacks, etc.).
8. Slide bolts through holes
in the seat frame and seat brackets at the desired position and secure with
washers and nuts listed. |
| |
|
STEERING, BRAKE and THROTTLE
Assemble as
shown.
Steering: See Figure 3 & Table 3 (except replace the right 11" tie rod
kit with the 24" tie rod kit)
Brake: See Figure 5 and Table 5
Throttle:
See Figures 6 & 7 and Tables 6 &
7
|
