Larger Sprocket, Extended Pedals & Steering For Grandson

Posts: 2

Modifications to 2005 Carter Talon GX150IIR to allow 6 year old Grandson to drive buggy.

PEDALS: I added a second set of pedals with linkages that set back 10" from originals. The pedal mount uses the holes that were already there for the rubber floor protectors that were removed. The pedal mount and linkage can be cut and redrilled a couple of time as little legs get longer. The only modification that can not be unbolted and removed are the four clips that I welded to the back of the existing pedals, but these do not have to be removed to reinstall the rubber petal covers once the extension is completely removed.

STEERING: I changed the steering wheel to one made by Grant with 5" set back. Drill new hole in Grant steering wheel using existing wheel as template. Diameter is only 10", which is 2" smaller than the 12" original.

BATTERY: I reposition the battery mount box from the inside of the frame to the outside of the frame. This allowed me to lower the box a little so that I can now install a taller size battery using a longer bungee. This will give more reserve power for a horn and more lighting that I am planning on installing. This taller battery is also available just about anywhere (Wal-Mart).

CHAIN DRIVE: I have slowed down the buggy. I consider installing a jack shaft and even purchased the shaft and sprockets, but decided that I did not want to have two chains to adjust. So my choice was to install a larger driven sprocket. Larger than what would fit without some modification. I moved the rear axle back 1-5/8" and down 1/4". These dimensions are approximate. I centered the rear axle mounts so there would be equal space between the motor, the rear frame, and the brakes support cross member. This will allow a sprocket at least 4" larger to be installed. The total clearance space measured diameter wise is a little more than 12". For this project I picked a 52 tooth sprocket, which has a diameter of 10-3/4" to replace the original 32 tooth sprocket which has a diameter of 6-3/4". This gave a clearance of approximately 5/8" at the motor, the rear frame, and the brakes support cross member once the chain was installed. This changed the chain drive reduction ratio from (2 to 1) to (3.25 to 1). I left the 16 tooth drive sprocket the same. Theoretically, this has slowed the buggy down to about 60% of the original speed. Now that the buggy has plenty of take out power with the lower reduction I plan to use an adjustment throttle stop to control speed even farther. The only negatives are that it decreased the ground clearance at the sprocket to 3-1/8", and the original plastic brake and sprocket guard that mounted on the brakes support cross member does not fit. Please note that moving the axle required cutting, grinding, and welding the axle’s mounts and brakes supports and machining the center hole and drilling the four mount bolt holes in the new sprocket. Worth it if you like modifying things, but primary purpose was to make the buggy safer for my Grandson to start driving. The original speed was just to fast for a 6 year old.

TURF TIRES: The original 19" mud grip type tires were tearing up the yard. As all our riding for now is in our yards and a 2 acre vacant lot I changed to lawn mower type turf tires. I installed Carlisle Turf Master tires sizes Front 18-6.5-8 and Rear 18-9.5-8. These do not tear up the yard so much. Grandmother likes that. The 18" tires also help reduce the speed a little because of the 1" smaller diameter.

BLEED BRAKES: I found while working on moving the axle that the rear brakes when pushing the pedal were not engaging. Bleed brakes and found air is system from factory. After bleeding brakes work correctly.

Sprockets purchased online from www.surpluscenter.com - Look under Power Transmmision - Item# 1-1980-52 - #50 Sprockets are the same as 530 Sprockets. Note: These sprockets require machining the center hole size and drilling the four mount bolt holes. I have a lathe so I did my own machining and drilling.

530H Chain purchase online from www.jcwhitney.com - Item ZX011288R - Universal Cycle Drive Chain, Heavy-duty, Size 530H, 126 Links. Note 126 link chain is a link or two more than twice as long as needed, so I will have a replacement chain when needed.

Tires purchase online from www.tiresunlimited.com - Carlisle Turf Master Front 18-6.5-8 item T511417 and Rear 18-9.5-8 Item T511413

See More Photos in Gallery.

Carter 2005 GX150IIR
Petal Extendings 10"
Deep Set Back Steering Wheel 5"
Relocated Battary Mount Box to Outside Of Frame
Moved Rear Axles and Brakes Back 1-5/8" and Down 1/4"
Install 52 Tooth Driven Sprocket Final Chain Reduction 3.250 to 1
Carlisle Turf Master 18" Lawn Mower Type Turf Tires

Thanks! fab_n_weld_man

Posts: 4459

very nice, looks professional Applause

Posts: 9

Looks great! I bet he will have a lot of smiles after driving his kart. My husband and I were just talking about doing something along the lines of what you have done with the modifications. Welcome to Buggy News!

Posts: 6290

Sweetness!!!!!! Where did you get the peddles?

Posts: 2

I found and purchased a used older twister buggy for parts. Thanks! fab_n_weld_man

Posts: 1163

It might be easier to slow the kart down by putting some slack in the throttle cable to prevent full throttle operation and/or putting heavier weights in the variator. I have heard of exhaust restrictors for kids atv's to limit speed. Choking down the exhaust might be another easily reversed fix.

Posts: 896

nice work, and a really good idea!!

Posts: 436

looks great and it almost looks like it came that way. NICE JOB!

Posts: 98

very very nice job!! Applause