Tao Tao ATK-150 engine change/mods
 

I got this kart just over a year ago new for $875 delivered to my door in the crate. Did some of the basic mods but never got the power or speed out of it that I wanted. So starts the replacment of the chinese 150gy6 to a sweet honda 200es atc motor with a 5 speed trans w/high & low range.(no clutch; no rev but rev is for girls & old poeple lol) Hopefully it will give me the low end and top end I want. The 200 could pull 1000lbs and not skip a beat in high range for long periods of time, at least my old beat up one did and this is my good extra motor.(don't need it after the wheeler got stoolen:cussing:)
First thing was to get the wiring harness figured out so I can save as much as possable 3hours later that was done.
Second out with the old motor & the middle swing arm cross bar\battery box.Attachment 4347

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Now I was able to test fit the motor in the frame, and of corse it does not fit right so now the rear swing arm needs to be extended about 9''.

more work
 

now i found some cold rolled steal that would all most fit inside the swing arm.
so i cut the swing arm & ground down the steal stock to fit in the swing arm.
I decided to make the extension 10"
welded them in and put the axle in back in back in fliped around so the sprocket is on the left side.
checked the area out with the motor sitting there
now if i have some time this weekend I can get the motor/cross mounts cut and welded inAttachment 4352

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First, I hope you know the turning radius is going to suffer with that frame extension. I'm not up on how the Tao Tao buggies handle in stock form, but most of them with the swingarm/live axle set up don't have the beat turning radius. Also, be sure to brace up the extension and weld them really well.

Second, I like seeing other people using smaller quad engines for transplants. I am using an atc 200s engine for mine, and mulling over the final gear ratios to avoid clutch issues. I am not extending the swingarm, however, seeing as the spiderbox's already had abysmal handling from the factory. Mine won't have reverse either, but the buggy didn't have originally, so its not like I'm taking anything away, except the electric start of course, but if Honda's name holds true, pull starting it won't be an issue.

I do have one question. Will the hi/lo option allow for a low enough ratio to keep the cent clutch from slipping with the added weight of the buggy and rider(s)? Myself and others are opting for jackshafts to keep the chain aligned without hitting the shifter shaft, and allow for low final drive ratios without using a big axle sprocket and losing ground clearance.

Anyway, welcome to the forum, and would like to see this thing in action soon, and of course all the progress in the mean time.

I'm not too concerned about the clutch this is the big red motor. The big red wheeler I had (till it got ripped off) I used it like it was a truck 4x4 in the woods I beat it bad haling and pulling a lot more than what the cart weighs. The 200e was a work horse of the atc's and the cart only weighs 270lbs more than the atc did. But you never know till you try!! I'm not too worried about the turning radius all the trails around me are wide and the other trails are way to narrow to get a kart down. The extensions are welded very well all the way around and they extend 6.5" into each side of the swing arm tubing and when every thing is the way I like it I will spot weld through the swingarm tube to the extension inside. I love my welder best $100 I ever spent on some thing on c-list Thanks for the input never know when you forget about something. cant weight to get up north tomorrow night and start tinkering a gen.

The plus side of the longer frame will be more stable at high speed. I like the atc clutch less five speed trans. The problem with the gy6 cvt is the faster the motor goes the higher the shift. Having a five speed will be nice, building shifter linkage shouldn't be too hard. I love our Baja dune 150s but power is a problem at altitude. In the low desert at sea level power is okay when it is below 90 degrees. We went to a park called Gorman and it is at 3500 to 4000ft base level altitude and power on the buggys was bad even at 82 degrees but when the sun went down it got to 58 and power was back but not like at sea level.

Keep post on your progress, and what year atc motor is that?

It's a late 83 motor all most like new not much use on it

Soooo, its not an ES model then, the ES has reverse, what you have is an E model then. I was concerned at first with the ES, as they were shaft driven. Maybe concerned is too strong, curious... maybe, lol.

Either way, stout engines I hear, and from what you say, they run forever, even after a beating. I put a 200x piston(flat top, 9.6:1 CR) in my S model over the 7.8 stock dish piston for more pep in its step. I hope to have my engine back together this weekend, except for the side cover(need to drill for oil cooler ports).

Updates?

Yes now I have some updates. Work and the volunteer work for the historical society slowed me down the last couple of weeks. But with the long weekend I got a lot done yesterday. I got the motor cradle cut and installed, modified the rear hubs to fit the good rims, fit the new sprocket on the axel. Installed and welded in the motor, and shifter assembly. Did a temp wiring of the motor and I'm going to take it for a test run shortly to see what it does before I get more done. I need more wire for my welder too I ran out last night. Can't post any pics till Monday night maybe tonight if I can get the computer to work on the cell phone internet. Up here at the cabin. Now its time to try it out!!!!!

Nice. I too have a long weekend, and am tackling the mounts, I have them mocked up, but have a prior engagement to attend, and need longer bolts than I thought :crying: I can't wait to see the video :yumyum:

pics of what I have got done as of now

Now I got to take it for a test ride two weekend's ago, and of Corse it did Not go as good as I wanted it to go. The Motor Ran Like Sh*t.It was spitting & sputtering after about 1/2 Way on the gas.Spent two weekends & the first Couple of days of my Vacation this week getting the timing Right & Replacing The Stater Coil. Now it Runs ok took it out for a Ride, it has good power& the top Speed I got was 42*mph at the top of 4th gear. I think 5th gear is to high for the Big Kart. But that May Be also fixed By Rewiring, Due to the fact that there is a Bad Connection in the original wire harness of the Motor & when I get in to the High Rpm Range or hit Bumps it Cuts out. So now I got to get some more reinforcement in for the engine Cradle , a chain tensor, & Rewire / wire into The existing wiring.

How is the shifter working out, I was planning to do mine the exact way you did, but I am concerned with the required push/pull with the auto clutch.

It works pretty good you just got to remember that it is not going to return by its self. I have had no problems as of yet, I got about 15 miles on it now. corners like a dream came off the main dirt road onto the smaller dirt road to my place at 35mph and it drifted right in.
I like it very stable and the rear is smooth over the washboard atv trail now. But i might need to get better rear shocks, if Im going to have 2 people in it. but a set of jeep shocks will fit perfect and they sell air adjustable ones on ebay for about $55 and I think those would be slick

I got the Kart on 6-4-12, Built it that Night & Was all ready thinking about Mod's. 6-7-13 1 year 3 days later it was time.

Wow ur buggy weighs less then ur 200atc incredable. A friend of mine had a200atc long time ago i believe it ran 55mph stock. Im suprised ur buggy dont hit that especially being lighter in weight, unless ur not using the same size sprockets that comes with it... i also see you dropped ur motor about 6" below ur swing arm. I would of left it parralel to the swing arms hiegth. Youll have more ground clearance on ur motor. Then again im probably not seeing what ur seeing.

No the buggy weighs more than the atc did (270lbs more) I am using a smaller rear sprocket and the tires are smaller. It has 20" tires on it now when I have the money I want to put 22'' on. I also have not been able to wind out 5th gear it may be to high for the weight of the thing. I wanted to have the motor up higher but the High/low Tran's would Not allow the chain angle needed. the good thing is the ground clearance is the same as it allway's has been.

I think it looks pretty slick. Can't wait to see a video on it.

I was just thinking, I bet that thing rides pretty plush in the back with the axle that far back, I too am concerned about the lower portion of the engine being that exposed, but I'm sure you plan to put something in there for protection.

What are you plans for the gear ratio?

I was going to run into the same chain angle issue, that kinda forced the jackshaft option, and also to get the gear ratio where I want it to keep from destroying the cent clutch inside.

Overall, that thing looks like fun, and I hope you can get it running good and shoot us a couple of vids, cause I got the itch to get mine done now.

I haven't been able to do much work on my kart the last few week's. I had to sell some of my junk to get money to fund it. And then I twisted my ankle at work real bad and have been gimping around. I got a little done. Painted the new steal to stop it from rusting too much and got the top part of the rear end/what the old motor was mounted too extended and put on.
Now that I sold some of my junk I ordered the parts I wanted and should be able to resume work this weakend.

I have the new parts to put in and wiring to do.
New parts include
air shocks for the rear
speedo,tack,digital dash
18w led head lights
led running lights
volt gauge
clinometer
chain tensioner
and im sure some other stuff.

some of the new parts

looking good there furball