Version01/17/2019

HighSchoolevGrandPrixElectricGoKartCurriculumandClassroomMaterials

WinterDisassembly,Redesign,andRebuildManual

APartnershipBetween

GettingStartedThismanualwasdevelopedasaguidetoassistreturningHighSchoolKartingteamsastheydisassembletheirkartsduringthewintermonths.Aphotographofthedisassembledkart,anditscomponents,mustbesenttoStuartWhiteatwhite152@purdue.eduAllreturningteamswishingtocompeteintheevGrandPrixWorldsFinalsattheIndianapolisMotorSpeedway(IMS)mustobtainconfirmationoftheirkartbeingdisassembledpriortocompetition.Theinformationcontainedhereinismeanttobeareferencetoolandnotadetailedstepbystepmethodfordisassemblinganelectricgokart.

PleasebeawarethatthefinalauthorityforkartsetupistheVehicleandTeamEquipmentSpecificationsdocumentfoundonthewebsiteevgrandprix.organdallkartswillbeinspectedforcompliancetotheserulespriortoracingintheWorldFinalseventattheIndianapolisMotorSpeedway.

Table of Contents Tools.............................................................................................................................................................3

RearAxleDisassembly.................................................................................................................................4

BrakesandMotor........................................................................................................................................5

SteeringAssembly.......................................................................................................................................8

BumpersandGuardsAssembly.................................................................................................................10

ElectronicsandWiring...............................................................................................................................11

Tools 1. BoxWrenchSet–Usedtoloosenaboltornut.Varioussizes

required

2. SocketWrenchSet–Usedtoloosenaboltornutbasedontheswitchsetting.Varioussocketsizesrequired.Canbeusedintightspaceswherearegularwrenchmaynotworkeasily.

3. AllenWrenchSet–Usedtoloosenspecificcrewsandblots.Varioussizesrequired.Hexagonalshapedtoolbenttoforman“L”.

4. WireCutters–Usedtocutziptiesandotherfasteningmaterial.Caution:cutsmallendshaveatendencytoflythroughairuponcutting.

5. Needle-NosePliers–Usedtoremovesafetywire,clips,etc.

6. Screwdrivers–usedtoloosenscrews.Flattippedandphillipsheadrequired.Notmeantasapryingtool.

7. DeadBlowHammer–Usedtoremovestubbornpartorcomponents.

RearAxleDisassemblySummaryRearaxledisassemblydoesnotrequirebearingstoberemovedfromcassettes.Disassemblydoesrequiremanyfastenerstobeloosenedduringthedisassemblyprocess.Thisallowsforeaseofreassemblyandproperalignmentofpartswhichwillenhancetheeaseofmaintenanceandrepairshouldpartfailureoccur.Allbolts,nuts,screwsandothersafetyfeatureswillrequirechecksforproperfunctioningandwarepriortothekartbeingreassembled.Oncetheaxleisremovedallmovingpartsshouldbelubricatedandcleaned.

Knowledgeofhowtodisassembletheaxleisimportantbecauseitisneededformaintenancepurposes.Agokartcanbreakdownforavarietyofreasonsanditmightbenecessarytotakethekartapartinordertoreplaceormodifydamagedkartcomponents.Mostkartshavethesametypeofrearaxleassembly.Commonvariationscomefromhowtheaxleismountedtotheframeandkartspecificsub-assemblies.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.

Tools

• Boxendwrenchset• Socketsetwithlongextension• Allenwrench

Step1–Removewheellugsandseparatereartiresfromwheelhubs

Step2–RemoveChainandchainguard.Placechaininasmallcontainerandsubmergeitinalightgrademotoroil

Step3–RemoveWheelHubsfromaxle

Step4–Loosensetscrewsfrombearings,sprocketbracket,androtorbracket.

Step5–Slideaxlefreeofbearings,sprocketbracket,androtorbracket.Youdonotneedtoremovetherotorfromtherotorbracketortheaxlesprocketfromthesprocketbracket.

Step6–Removerearaxlebearingcassetteboltsfrommountingbracketsweldedontoframe.SpraytheaxlebearingswithaproductlikeTru-Flow.Continuesprayinguntilthefluidcomingoutofthebearingsisascleanasthefluidgoingin.Bearingsshouldberotatedduringthisprocess.Ifyourkarthastherearbrakecaliperattachedtothecassettemountingbracket,goaheadandremovethecaliperbutleavebrakelinesattached.

Brakes and Motor Disassemblingbrakeswillnotincluderemovingbrakelinesfromthemastercylinderorthebrakecaliper.Youwillwanttoremovethedrivesprocketfromthemotoruntiladecisionhasbeenmadeonagearingratio.Althoughitisimportanttoknowhowtoassemblethebrakesystemthisisonlyneededformaintenancepurposes.Ifyourkartbrakesystemshouldbreakdownforavarietyofreasonsanditmightbenecessarytotakethebrakesystemapartinordertoreplacedamagedbrakelines,mastercylinder,orcaliper.

Mostkartshavethesametypeofbrakeassembly.Commonvariationscomefromhowthebrakeismountedtotheframeandkartspecificsub-assemblies.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.

Themotormountwillberemovedfromthekartwiththemotorstillattached.Thereisnoreasontoremovethemotorfromthemotormountunlessthemotorneedsreplacing.

Tools

• Boxendwrenchset• Socketset• Allenwrench

Step1–Removehebrakefootpedalconnectiontothemastercylinder.Thebrakepedalcanremainattachedtothekartchassis.

Step2–Removethemastercylinderfromchassismountbyremovingboltsfromthebracketweldedtotheframe.

Step3–Removethebrakecaliperbyremovingboltsfrombracketweldedtothekartframe.Ifyourcaliperisattachedtothebearingcassettebracket,thisstepwascompletedduringtheaxleremoval.

Step4–Loosenchaintensionboltfrommotormount.

Step5–Removemotorandmotormountbyremovingboldssecuringthemotormounttothechassis.Kartwillneedtoberaisedinordertoaccessthesebolts.

Steering Assembly Thesteeringwheelandsteeringcolumn,whichisattachedtothechassis,canberemovedasoneunit.Oneendofthetierodsconnecttoanattachmentpointonthesteeringcolumnwhiletheotherendsofthetierodsconnecttothespindleaxlearms.Thesewillneedtoberemovedfromeitherside.However,jamnutadjustmentisnotnecessaryatthispoint.Thespindleaxlesareboltedtothechassisandwillneedtoberemovedfromthechassisandfromthefrontwheels.Knowledgeofhowtodisassemblethesteeringisimportantbecauseitisneededformaintenancepurposesoritthegokartchouldbreakdownforanyreason.Itmightbenecessarytotakethekartapartinordertoreplaceormodifydamagedkartcomponents.

Mostkartshavethesametypeofsteeringlinkage.Commonvariationsinsteeringcomefromhowthesteeringrodismountedtotheframeandtierodsareattachedtotherod.Thekartsmayhavedifferenttypesofboltsandmountingsbutwillhavethesamerelativelocationsofwherepartsareattached.

Tools

• Boxendwrenchset• Socketset• Allenwrench

Step1–Removefrontwheelsfromspindles.

Step2–Removesteeringwheelfairing.

Step3–Removethetierodsfromthespindleaxleandsteeringshaftbyremovingtheboltsecuringthetierodtothespindleandtheboltsecuringthetierodtothesteeringshaft.

Step4–Removethesteeringcolumnshaftfromthekartchassisbyremovingthenutonthebottomofthechassismountingbracket.

Step5–Ifyourkeyswitchismountedonthesteeringwheel,disconnectkeyswitchandsteeringwheelE-Stopifinstalled.Removethesteeringcolumnsupportbox

fromtheframesupportbracketbyremovingtheboltholdingthesupportboxinplace.Liftthesteeringshaftoutofthechassismountingbracket.

Step6–RemovethespindlefromthespindlemountweldedtothekartchassisbyremovingtheKingPinholdingthespindleinplace.

Bumpers and Guards Assembly Thefront,back,andsidebumpersareattachedtotheframeviaclamps.Thebumpersprovideprotectionforthedriverduringaraceandprotectvitalcomponentsofthekart.

Tools

• Boxendwrenchset• Socketset• Allenwrenchset

Step1–Removethefrontcrushablebumperfromfrontofchassisbyremovingthecrushablebumperclampsandbumpermountingbracketfromthechassis

Step2–Removerearmetalbumperbylooseningbumperboltsandremovingtherearbumperassemblyfromthechassis.Youdonotneedtodisassemblerearbumperassembly.

Step3–RemovetheE-StopfromthebatteryboxandthenremoveBatteryboxesfromnerfbars.

Step4–Removesidepods,ifattached,andnerfbarsbyremovingboltsattachingnerfbartochassis.Slidenerfbarfreeofchassis.Yournerfbarsmaybeattachedwithanaccompanyingspringwhichwillneedtoberemovedpriortodetachingnerfbarfromchassis.

Electronics and Wiring Componentsincludingtheconnector,contactor,fuse,shuntresistor,emergencystop,andcontrollermustberemovedafterbatterypackharnessisremoved.Thethrottlemustbeunboltedfromthefloorpanhowever,thepedalmayremainattachedtotheframe.Removalofthebatteriesshouldhavetakenplacepriortorearaxledisassembly.

Knowledgeofhowtheelectricalassemblyisputtogethercanhelponegraspabasicunderstandingofhowthesystemworks.Thisnotonlyempowersthatpersontobeabletotroubleshootmalfunctionsgiventhepossibilitythatproblemsmayoccuronthetrack.Therearemanypossiblewaystoassembleyourcomponents.Thissectiondescribeshowtodisassembletheindividualcomponents.Theorderisrandomascomponentscanberemovedinanyorder.

Tools

• Boxendwrenchset• Socketset• Screwdrivers• Wirecutters

Step1–Removemotorcontrollerbydisconnectingelectricalconnectionsandunboltingfromkartchassis.

Step2–RemoveE-Z-Gothrottlepotentiometerbyunboltingfromchassisandcuttingzipties(orelectricaltype)securingelectricalconnectionstochassis.

Step3–Removecontactorbydisconnectingelectricalconnectionsandunboltingfromchassis.Donotremovepre-chargeresistorfromcontactor.

PreChargeResistor

Step4–Remove300ampfuseassemblybyunboltingfromchassis.Removeonlytheelectricalconnectoronthebatterysideofthefuse.Ensurekeyswitchsideoffuseassemblyisleftintact.

Step5–Cutallziptiesandorelectricaltapeconnectingelectricalwirestothechassis.Collectallwiresandcablestostorewithelectricalcomponents.

Step6–Removefloorpanfromkartbyunboltingfromchassis.

Step7–Removeseatfromkartbyunboltingfromchassis