Build Your Own Go Kart: Assembly Instructions

1. Weld frame together as shown on the "One-Person Go-Kart Frame Drawing". Be careful when welding the 16 Ga.
         tubing, it 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 it 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 "Single Go-Kart Seat" drawing.
2. Drill the 12" X 18" and 8" X 18" 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 18" and 8" X 18" 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: Figure 3 and Table 3
Brake: Figure 5 and Table 5
Throttle: Figures 6 & 7 and Tables 6 & 7