Manco Go Cart 2 seater build up
Updated 6/13/2017
Picked up a used Manco Magnum 2 seater go cart to upgrade into a great buggy for the kids.  It came with a Robin 10hp 265 cc ex27 engine with comet 40 series clutch. No reverse and 1" travel suspension. Added a Polaris trans for lower gears and reverse. The stock clutch was broken.

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Specs:
  • Manco 2 seater model 720L -08
  • Robin EX27 10 HP 265cc OHC 4 stroke engine electric start
  • Vegas cart 1" clutch adapter
  • Polaris 1992 trailboss primary and driven Clutch, belt, trans, chain and rear sprocket.
  • Polaris 1998 sportsman rear coilovers.
  • Polaris sport 300 carb, thumbthrottle
  • Manco 1" hex axle and bearings and tires.
  • Manco rear disc
  • Honda trx250 front rims, spindles, rotors, calipers.
  • Nissan Pathfinder clutch master as a brake master cylinder. 
  • Yerfdog rack and pinion, steering column.
  • Manco steering wheel
  • Custom double wishbone front suspension, artic cat  coilover shocks
  • 3/8 heim steering through out.
  • stock swing arm in rear with Polaris trail boss rear coilover shock
  • Summit buckets
  • 4 point harness
  • Automotive style pedals for safety.
  • Nissan Pathfinder (wd21 )rear view mirror




First step was to install some new seats and seat belts. Stock wood bench seat was rotten. Had to widen frame to fit these.


I added a bar behind seats for seat belts to attach. And another 1 1/4" tube overhead.


Here is the polaris trail boss transmission which should gear it down add reverse and fix some other weak links.






 






 

I made new mounts for 2 new seats, added a bar for 4 point new seat belts.



Also added a tray for the engine to mount instead of on the swingarm.


I used another wheel hub to connect Polaris sprocket to Manco axle.

Trying to get the clutch to fit polaris belt. decided on using polaris clutchs instead.
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Here is the stock Polaris Shifter shortened. I added a few heims to jog around the seats.



First generation was 1 rear coilover Shock. Later added 2.


The swing arm before I moved the pivot point and made it adjustable. The pivot point must match the chain output to avoid a chain tensioner.


The swing Arm twisted due to the adjustable ends. So I made a better cleaner design.



I used 11gauge 3" tube. I welded the inner bearing retainer so they dont bend.

I then added dual coil overs.
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Then raised the engine 1" to allow easier clutch removal and more chain clearance.



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Converted the steering to true rack and pinion with a yerf dog column. Added front Honda hydralic brakes.

Then added a Nissan Pathfinder 1992 Clutch master as a brake master, since there is now 3 disc brakes.