4-cycle clone class

[John Kwong]

I was searching the web and came across some clubs that have started running Honda clone motors. SIKA (Southern Interior Karting Association) is the only one in Canada that I know of but they are getting fairly popular in the U.S. on dirt tracks. They have these motors at Princess Auto for $122 right now. Apparently, these ones (PowerFist) are actually built by Honda for Princess Auto. So with all the accessories to get it on a kart, they should come out to about $500. With the many used chassis that are around right now, an class like this couldn't be more affordable.

LInks:
SIKA club member site: http://www2.vip.net/~jgregg/
How to get a 6.5 hp clone engine race ready: http://video.google.com/videoplay?docid ... t=lf&hl=en

[RANDYKER]

John, these engines are not built by Honda, they are a different bird completly, Staying with the honda engines are a good thing, 1st it is recognized by asn, 2nd there is continuity between all clubs in Canada and finaly the Honda's are cheap 5.5 hp cost me 340$, 6.5hp cost me 435$.

[John Kwong]

I have found arguments on the web that the Honda's are not built by Honda anymore either . Anyway, I didn't mean to jump the gun on adding another class, which is the last thing we need. Staying with the Honda would be a good thing and exactly for the reasons you mentioned but the Senior class runs the Animal motor. I wonder, if the Animals ran on gas instead of Methanol would they be competitive with the Honda GX200? According to the MyLaps data that I saw on our track, the Animals are about a second faster on methanol.

[John Kwong]

Before anyone gets their neck out of joint. This kart will be used for training, coaching, enticing new people and is just for fun. I was intrigued when I read about the clone motors on Bob's 4-cycle forums and the SIKA page made by the Gregg's in BC. The success and tribulations of people using these motors has been interesting. I wanted a winter project and slowly assembled the parts that I needed to make this kart a reality. I bought the motor at Princess Auto about a year and half ago and the chassis has been in my garage for almost a year completely bare. Recently, I got off my proverbial butt and gathered most of the components needed. See pics of progress so far.

Side

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Front

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Close up of top plate

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Clutch side with view of throttle linkage

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Top view

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DC-One kart future clone chariot

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So far cost has been very affordable relative to what karting equipment costs are these days.

PowerFist engine $125
MaxTorque clutch $50
Pulse fitting $1.95
Fuel Pump $25
Top Plate & throttle linkage (both homemade) $10
Header, carburator cup and filter (package deal on Ebay) $40
BMI 15 degree motormount ($38 US+ shipping+UPS brokerage charge) $70
Muffler from Princess Auto $10
Throttle cable and sheath $10
Fuel line $5

Total $346.95

The only motor work so far has been to remove the governor which I learned how to do from a YouTube video (seriously) and drilling the hole for the pulse fitting. The motor plate was made using CAD (Cardboard Aided Design ) and the throttle linkage assembly was done by copying several others that I had found pictures of on the net through Bob's 4-cycle forum. I even made a choke lever holder (see pics). It has been nice to work on something that wasn't just bolt on or spec and required some creativity to put it together. The experience so far has been part puzzle and part treasure hunt.

John K

[John Kwong]

Here are pics of the BMI mount I got. http://www.bmikarts.com/shop/?shop=1&cat=166

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[John Kwong]

Here are some more pics. The kart is coming along and I only need a few more parts to complete it. If anyone has a used 50mmX90mm axle bearing that they have laying around, I would appreciate it. Joey gave me one already and a steering shaft bushing. Brent has also helped with some cheap parts too.

PowerFist clone mounted

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Side view of the DC-One PowerFist Special

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[John Kwong]

Response to the clone project has been quite positive with many interested parties and a few taking on their own projects. Here are a few more detailed pics of my throttle assembly and top plate.

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Here is a pic of where I drilled the hole for the pulse tube outlet for the fuel pump.

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Also, the low oil sensor plug on the front of the motor needs to be plugged. I just used the original plug and filled it with JB Weld.

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[John Kwong]

The Formula C-200 saw its first track time last night. It's been a couple years since I last drove a 4 stroke kart. A couple things were figured out. First of all the stock valve springs are pretty weak and the valves float at about 5500rpm. Best laptimes so far going CW south chicane was a 1.02.52. Not exactly quick but there is more potential there and that is the baseline to improve upon. With another donation of G200 valve springs (Thanks Gabor) and installation as darkness fell by Dan Lazar the motor made a much better sound at the end of the straightaway. Apparently, the gearing is too short as well with 15/60. 16/60 should get it more into the range to get more straightaway speed. The other thing figured out was the fuel pump needs to be flipped upside over to have the pulse tube facing down so that it doesn't fill up with crankcase oil. All you Honda Vets probably already knew this but I am practically a 4 stroke newbie again. This will be a small adjustment to the build. The emulsion tube is the EPA one which is apparently too lean for racing application, so I will be looking at getting the right one. Anyone know the right one for the Honda GX200 (E140 emulsion tube?)? As well, I think I will be getting the offset key to advance the ignition, which should help with the power in the higher rpm range.

This might sound like it is getting away from what the clone box stock concept was about but all these things are cheap and accessible to anyone and the overall investment will still be under $500 for a complete bolt on engine package. I will post updates to keep those interested in the know so these upgrades don't seem unobtainable.

John K

[Dan Lazar]

Hey John:
I saw this and had to reply.
The gearing probably should be 15/57 or so. Tho' 16/60 may be pretty close. Sorry if you/I got me wrong but I was thinking of just one sprocket change (keeping costs down) This should put you into 6200 or so for a 56.5 lap (using my GX200 numbers etc).
The ign timing first has to be read with a degree wheel in place of the clutch and a timing light to read what you have currently. Then changed to good spec. You have to pull the flywheel (I have a puller) and reset with a modified key or no key at all.
The carb mods are best started by doing the ASN spec for the GX200. We've touched on the fuel pump/ inverted and shorter vacuum line; and I'd look to try another spark plug (resistor) to maybe fix the Alfano tacho glitch.
I will be out with mine soon (maybe this Thurs eve.)(still skiing that great spring snow, they boot us out on this 24th weekend) and have my tools on board to "Trim up the sails". Gotta shoot for the 55's. By the results of last weekend they don't have numbers for a class, and are'nt that far away in lap times...
DML..

[thughes]

Hi Dan. Check the club records for the last five years. the animal group has always been a club class. We have over 15 karts in our group.
You are welcome to bring your clone motor but you don,t have the power to touch the animals.If you every get a chance to see racing in the states , there is hundreds of animal motors with up to 35 HP ..there is a bigger world out there beyond this club.