Beginners

Age 12+
With Parental Guidance

Gas
Powered

Build
A Go-kart
Technical Manual

Andre Morgan
Eng 352-Technical Writing
Prof. Mark Arnotwitz
April 27, 2009
Beginners
Age 12+
With Parental Guidance

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
Beginners
Age 12+
With Parental Guidance

Introduction

Welcome to the Build A Go-kart Technical 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 List for

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.

1
Beginners
Age 12+
With Parental Guidance

***Warning***
Disclaimer:
This manual is designed to reproduce a safe go-kart for family enjoyment. This project is
for 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 the
process of this build. Some of these materials & chemicals are known to cause Cancer and/or
birth defects in the State of California. Power tools are needed to complete this project. Proper
safety 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 and
may need titling, registration, and insurance to be used. Also the driver of the go-kart may need
special licensing to operate legally. Please check local laws before attempting to operate this
vehicle on private, public, or government property.
By purchasing this manual, receiving this manual, reading this manual, using this book as
a guide or supplemental reference material for any other project or go-kart manual, or by
manipulation of the instructions, you, the reader, accept all responsibility for the out come of
this project.
The writer and publisher, seller, and any other company involved with the production and
delivery 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 of
this go-kart. Including but not limited to, other products used and suggested by this manual to
complete the go-kart; gas, oil, and battery used to run the go-kart. Together with or without, fine
and fees, accidents, lawyer fees, health care and/or hospital bills and restitution stemming from
the use of this manual. Use at your own risk.

2
Beginners
Age 12+
With Parental Guidance

Procedure
Gather all Materials

Tools & Power Tools:

Drill

Saw-Zaw - metal cutting blade

Circular Saw – wood cutting blade

Drill bits

Welding Machine

Materials:

1 - ½ inch 4ft x8ft Plywood sheet

2 - ¾ x ¾ x 6ft Square Dowels

2 - 1x 4 at 2½ ft. long

1 - Old house chair

Multiple lengths of Galvanized pipe to create a roll cage and fittings and base

Box of - 1 ⅝ inch / 2 ½ inch / 3 inch wood screws

Box of ¼ x 1½inch Bolts, nuts, and washers

Box of ¼ x 2½ Bolts, nuts, and washers

Box of ¼ x 2½ Wood Bolts ( Coarse Thread Bolts)

1 - ¾ x 96 x .050 inch Angle Aluminum

2 - ¼ x 2x 3½ inch Stainless U-Bolt

2 – 3inch door hinges

1 ½ 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

3
Beginners
Age 12+
With Parental Guidance

Procedure
Frame

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 - ¾ x ¾ wood dowels 2½ feet apart and attach
them to the plywood using 1⅝ wood screws at each end.( this will be the bottom of frame)
3. Drill 4 - ⅛” Pilot holes at equal distance; starting from the top of the frame or the plywood side,
through to the dowels and install ¼ x 2½ bolts, nuts, and washers.
4. With Angle Aluminum cut 2-6in lengths and drill 2 - ¼” 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 ¼ x 2½ Wood Bolts.
7. In the front there are exposed dowels because
we 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 lengths
10. Drill 2 - ¼” 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 the
dowels, overlapping each other by 1ft, with ¼ x
1½inch Bolts, nuts, and washers .
12. The front now needs to be connected together; box in the front section by cutting a length of
Aluminum 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.

4
Beginners
Age 12+
With Parental Guidance

Procedure
Steering

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 front
knuckles.
4. When they are lined up take measurements and to be sure of equal distance from driver. This
will 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 the
tie rods to length and bolt them to the
knuckles with hardware included.
10. Test by locking the wheel left to right fix
any problems including binding.

Steering Shaft Support

1. To create a shaft support use left over pieces of wood to form a “H”
2. The distance between the 2 long pieces should be 1”
3. 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.

5
Beginners
Age 12+
With Parental Guidance

Procedure
Rear 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 - ¼ x 2x 3½ inch Stainless U-Bolt
Item # 13631- 60 tooth Drive Sprocket # 41 chain

1. Start By assembling the drive wheel in this order. Insert ¼ in bolts into the hub on Item # 8-374
2. Then connect the sprocket and drum and followed by lock washers and lock nuts.

Next
1. Center the steel axle on the go-kart
2. The axle should be place on the angle aluminum from Step 4: Frame Build
3. 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 axle
to 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 adjustment
before final fitment.

6
Beginners
Age 12+
With Parental Guidance

Procedure
Items needed:
Item # 13793 - Extreme Duty Centrifugal Clutch
Item # 60300 – 3.5 hp Briggs & Stratton Horizontal Engine
Item # 13824 - Kill Button Switch
Item # 13631- 60 tooth Drive Sprocket # 41 chain

Engine
1. 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 small
amount 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 both
wheels, 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 rear
sprocket); drill ¼ in holes through the plywood and bolt the engine to the frame. Place rubber
washer between the engine and Plywood to isolate vibrations.
Test
1. 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.

7
Beginners
Age 12+
With Parental Guidance

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.

8
Beginners
Age 12+
With Parental Guidance

Procedure
Cable 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.

9
Beginners
Age 12+
With Parental Guidance

Procedure
Seat installation

1. Find an old chair. Cut the legs off and bolt the seat to the plywood of the go-kart in a
comfortable safe driving position.
NOW wasn’t that easy?

Good Job! You’re 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.

10
Beginners
Age 12+
With Parental Guidance

Picture Bibliography
Cover Page & Page 10
These pictures are products of the Microsoft Corporation and do not reflect the product
being 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
<http://cgi.ebay.com.my/ws/eBayISAPI.dll?ViewItem&item=390017611651&translate=no&ss
PageName=LanguageToggle>.

U-Bolt Picture
"Product Information." The Home Depot. 03 May 2009
<http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10051&langI
d=-1&catalogId=10053&productId=100203609>.

CAD Pictures
The 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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