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Baja Reaction 150 Motor Swap with GY6150

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Baja Reaction 150 Motor Swap with GY6150

by Upnorthduck » Sat Jan 09, 2021 10:01 pm

My sons were given this project buggy from someone who decided they didn't want it any more. The motor was shot as it had thrown a rod and cracked up the housing. The buggy had an automatic reverse and a dual chain sprocket drive. The boys bought a GY6150 motor to replace it, with a manual reverse: https://www.ebay.com/itm/150cc-GY6-ATV-Go-Kart-Engine-Motor-AutoTransmission-Build-in-Reverse-Short-Case-/274621621422?nma=true&si=P29iAdyKT14RdCxVU1LwabCPWmk%253D&orig_cvip=true&nordt=true&rt=nc&_trksid=p2047675.l2557

The question is how to go from the shaft on this to the dual sprocket on the axle. The new motor shaft is shorter because there isn't the planetary gear set for the automatic reverse. I was hoping to do this as easily as possible, but would rather not replace the shaft.

Has anyone done this kind of a replacement before?
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Re: Baja Reaction 150 Motor Swap with GY6150

by Saleen27 » Sun Jan 10, 2021 3:34 am

Pics
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Re: Baja Reaction 150 Motor Swap with GY6150

by Upnorthduck » Sun Jan 10, 2021 1:29 pm

I attached some photos to help explain the situation.
Attachments
Motor (down position) and Sprocket.jpg
Motor is rotated down in this picture to show alignment with sprocket
Old Sprocket with Reverse To Show Old Alignment.jpg
This shows how the shaft from the old motor would have aligned
Old Sprocket Closeup Showing Reverse.jpg
This shows the old shaft and reverse gear set closer up
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Re: Baja Reaction 150 Motor Swap with GY6150

by Upnorthduck » Sun Jan 10, 2021 1:37 pm

The old shaft\sprocket\components are incompatible with the new shaft. I need an easy way to attach sprockets to the new shaft in proper alignment. I'd like to think it could be done without the use of canabilizing\modifying the old parts and\or using a welder.
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Re: Baja Reaction 150 Motor Swap with GY6150

by Funnyman » Sun Jan 10, 2021 4:42 pm

First thing, you dont have to run a double row chain. You can space out the sprocket from the hub.
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Re: Baja Reaction 150 Motor Swap with GY6150

by PGH » Sun Jan 10, 2021 6:23 pm

That engine is set up for a quad. Try finding a sprocket on that dealer's site. You may still need to shim the axle sprocket to get it to line up.
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Re: Baja Reaction 150 Motor Swap with GY6150

by Saleen27 » Sun Jan 10, 2021 11:17 pm

Or machine a splined coupler to slip over the output shaft with a center locking nut and will hold the sprockets on the outside of the coupler
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