Stock. With a leaky carb, seized throttle cable, rotted seat, bald frt tires, worn drive belt and some bent swing arms.

Before the upgrade begins.



First step was to install some new seats and seat belts.



Then upgrade and fix the bent suspension



New lower a arms.


Now to install 2 21" buckets seats. The stock wooden 24" bench was wrotten. I had to swap the side rails to make room. Also moved seats 2" from center.



The steering wheel had to be moved 2" outward.


Here is the TRX90 rims I tried on the front.


I made some knuckles to widen that stance. They also allow for the honda brakes.

I added a 2x4 tube to mount the UCA and steering brace.

New rear shocks from a artic cat 4x4 quad. There are so nice compare to stock ones. I moved the mounts for more travel.



I moved the brake pedal. I dont like the idea of driving with 2 feet. And I may add a clutch to this with a different engine trans combo one day.


First test drive. Found out the shocks are not working, clutch is sticky (rusty) and steering is too heavy and unresponsive.

Adjusted the length of the tie rods to match the LCAs to fix bump steer. Made the spindles longer to reduce camber changes.



Here is the new frt suspension version 2.0. The limiting factor for wheel travel is the heims. Need to find better ones. Turns out go carts have no oil in the shocks. There only 1-2" travle sprnigs. So I picked up some more ATV shocks.

Here is some Artic cat coil overs. Front suspension works awesome. Finally was able to jump it a few times.


Sold the 6.5 engine now to fit the 8hp flatty. Stock Robin 6.5 compred to 8hp B&S.



To get the new motor mounted. I had to remove the engine mount and lengthen the hole pattern. Drill 2 new holes in engine block.


Then flip the sprocket to the right side.


The rotor will stay, but the gear will slide to right side.

Added an extra jack shaft to solve the clearance issues and lower the gear ratio.


Moved the gas tank up high.


Added a battery to other side.
no picture yet

Now to reinstall the chain guards again. Also needed a 1" comet clutch.


Need to order some rear manco to 4 lug adapters. And modify to fit the honda pattern. I found some hex to 4lug adapters but they do not fit the 7/8 hex axle.



I moved the shocks outward for more clearance for the new disc brake and a softer ride.


I found a honda cbr600 rear brake system for $20 on ebay. I installed the master with some tabs. Good job I relocated the brake pedal. Fits perfect.

 

I have to add another jack shaft to reach the chain. Also I wanted to gear it down. This worked great but chain got real hot.

   
Here is the new frt suspension with Honda trx brakes and tires.


Here is the 30 and 40 series I tried before. The polaris belts are bigger and thicker.


Sled vs ATV polaris clutch


I had to fix some mising o rings. I made a jig to dissassemble.




So I added a Polaris Trail Boss 250 transmission. This solved my chain and gearing issues. Also added reverse. I decided to use all Polaris drivetrain. Starting with an adapter to convert 1" output to polaris taper.


This mount is in the way. I also chopped off the excess axle shaft


I love being able to flip upside to weld the bottom.

 
Sprockets and axle hubs. I had to add some 16g shims to space the 7/8 axle for the 1" wheel hubs that I used for sprocket hub.



I added a new 25mm Mikuni on the stock manifold. The carb was too lean and we threw a rod after a few hours. Oops.


 
So time for a 420cc Honda clone 16hp upgrade. But it dont fit in the frame.  First modify crank for adapter.

Added a 1" to taper adapter from vegas carts. This allowed the use of the polaris clutch on the Honda engine.