Here to say hi

[big_tiger]

I was searching for info on my chinese gy6 motor and stumbled across this site. This site actually seems pretty popular (compared to other go kart sites).

I found a cheap little fox go kart with a independent front suspension and solid rear. It had a Sundiro 50cc two stroke motor, that I could not get running smoothly and find any parts for it. I came up with the great idea of buying another motor and installing it in the kart. I purchased a SUNL 150cc gy6 that came off of a scooter, and after that been ignoring the project.

I am getting back after it and want to ask a few questions and hopefully get some answers. Here are a few pics of my project, before I started the heart transplant.

http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0153.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0152.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0151.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0150.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0149.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0148.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0147.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/101_0146.jpg

I have already extended the frame to allow more leg room, and fit the gy6. I will have pics of that when I get back home. :biggthumpup:

[big_tiger]

Well the first set of pics is old so here are some newer pics that are up to date on the kart.

As you can see I think I picked the best spot to cut and extend the cart because of the support piece that is already there and its the widest part of the middle section. I know the gy6 will stick out past the cross bar area but I think it will be just fine. I extended the frame enough to allow room for the seat to move back more. I have not moved the seat tabs because I don't know the final resting place of the engine.

http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/223858667653.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/223858688005.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/223858706949.jpg

[big_tiger]

I purchased the reverse gear kit from motosportparts.com I kind of lucked out with there warehouse facility in DFW and across the street from my GFs job. :biglaugh:

I found out I need a bracket on the outside, and connect to front of the engine. So I went back to motosportparts.com, and the warehouse guy knew what I needed. I probably overpaid for the bracket but it beats making one. I found out now I must have the longer CVT gy6 clone because of how the brackets hang. I am sure it will be ok. SEE PIC

http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/IMAG0108.jpg

Ok the next issue is with the output shaft on the gy6, and using a reverse setup. SEE PICS

http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/IMAG0109.jpg
http://i26.photobucket.com/albums/c138/big_tiger19/Go-Kart/IMAG0110.jpg

The gear hits the case, and doesn't thread, on the shaft, as much as I think it should can think. SO question One: What output shaft do I need to use this reverse gear? Question Two: What goes between the case and reverse gearbox?

[metalstudman1]

Here's what the reverse looks like on a Howhit just for reference (sorry about all the mud).Your missing the shaft bushing between the gear and gear box.I might be premature asking but it appears that where the engine sets the chain is going to hit the frame, also how are you mounting the engine? if it doesn't hang from the carriers bolt at the top then you won't have a way to adjust the chain.I believe you have to remove the pin at the bottom of the gearbox as I think that was pat of the wheel rotation stop assembly for the scooter.The output shaft on mine is about 4-1/4" long.

[big_tiger]

I haven't got to mounting yet because I don't know exactly where the final gear on the motor will be. I know and understand what you are asking.

I FOUND IT!!!
16. Place the step-down spacers (one spacer in Silver kit, two spacers in black kit) and the yellow plated spacer (from stock assembly) onto the output shaft with both spacer step downs pointing outwards.

I think I do need a different output shaft, since only about 1 inch of thread is being used... Is that enough?

[metalstudman1]

As long as the nylon portion of the nut has threads in it I'd think you'd be good,mine has about a 1/4" of shaft beyond the nut.Great job on getting us pics of your build,I'm looking forward to your progress.

[GX150]

1. The reverse assembly bracket needs an additional extension to the lower engine mount to create a traingle

2. You need to purchase the matching output shaft to the reverse assembly you now have. The DFW dealer should have it.

3. There will be a spacer between the output shaft bearing and drive sprocket to keep proper alignment.

4. The stud in the bottom of the case mus be remove to prevent clearance issues.

5. Your chain tensioner needs to be on the section of chain that moves from the axle back to the drive sprocket. If you have it on the other section, it will be subject to forces that can cause it to flex or fail.

[big_tiger]

1. The reverse assembly bracket needs an additional extension to the lower engine mount to create a traingle

2. You need to purchase the matching output shaft to the reverse assembly you now have. The DFW dealer should have it.

3. There will be a spacer between the output shaft bearing and drive sprocket to keep proper alignment.

4. The stud in the bottom of the case mus be remove to prevent clearance issues.

5. Your chain tensioner needs to be on the section of chain that moves from the axle back to the drive sprocket. If you have it on the other section, it will be subject to forces that can cause it to flex or fail.

1. I can do that

2. What is the matching output shaft I need? They kinda suck when it isn't listed on there website.

3. I have the correct spacer

4. I see what you are talking about, but how do you remove it?

5. I was going to make the rear mount adjustable to pull the rear of the engine up. That is how they are designed on other carts correct?

Thanks yall are helping me out a lot :biggthumpup:

[GX150]

2. The output shafts vary in length 133-215mm based on the reverse assembly thickness and the spacer used. Most likely you need the 202mm (7.95") shaft that Buggy Depot sells. This site does not allow me to post the link, so search their site for output to find the different shafts. On the end you need a lock nut - This can be purchased at the same site.

3. If you get the Buggy Depot output shaft, you may want to check your spacer width compared to theirs.

4. The pin is pressed in and has lateral splines. Ideally a clamp or press from the left side should push that pin back out.

5. Yes, on buggies the rear of the engine is raised or lowered to adjust chain tension. Since your axle is sitting so much more forward of the output shaft, this may not be as effective to control tension. Look at most buggies and you will see that the axles sit farther back on the swing arm. You will find this is an advantage if you choose put a larger axle sprocket on later, but it will extend your wheelbase making turns wider.

[big_tiger]

I called up buggy depot and talked to them. There are currently out of the 7.95 output shaft but say the dual chain will work, I will just need a spacer on the end.

Also by looking at the way the exhaust will end up running will have to be more like scooters. Something like this.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=170307019663&viewitem=#vi-content