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Old 11-12-2013, 01:23 PM   #1 (permalink)
captainslug's Avatar
Join Date: Sep 2008
Location: Sterling, VA
Posts: 383

BORK! - '89 Volvo 240 DL Wagon
90 day: 21.27 mpg (US)
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The "Impaler" - Go-Kart Dual Sport

So I learned a hell of a lot working on my electric motorcycle project, but it eventually hit a dead end in terms of budget and time available.
In March of last year I revisited the goals of that project and ended up deciding that what I basically wanted was a Go-Kart, but one that only had 2 wheels.

After 2 months of planning, machining, and welding this is what I had.

With some refinements over the summer I got to this point.

A year and a bunch of small changes later it now looks like this.

  • Top Speed: 45mph
  • Wet Weight: 180lb
  • The fender\headlight is made out of 22ga stainless steel that I cut and welded together.
  • The frame is from an X-Motos XB-31 (Chinestraulian Honda knockoff)
  • The motor is a 196cc LiFan clone of the Honda GX200 with electric start. I haven't removed the governor on it yet.
  • Primary reduction is a TAV2 Torq-a-verter CVT
  • The electrical system was added from scratch.
  • The air cleaner had to be moved and reoriented so I made a hose adapter for the carb.
  • The aluminum motor mount was made from scratch and doubles as an enclosure for the electrical system which is all DIN-rail mount components.
  • The forward motor mount is from scratch
  • The rear sprocket was milled out to match the rear hub bolt pattern and to reduce weight. It's the only custom part on the bike that I didn't make myself
  • The fan cover which replaced the old recoil start cover was 3D printed.
  • The push-button switch shown on the bracket above the fan housing that holds the air cleaner is the hidden push-button start.
  • Aluminum clip-on handlebars are from scratch. The core of them is a 5-inch long 1/2-13 bolt.
  • Speedometer is a bike computer
  • Headlight is a Vision-X Solstice 800 lumen LED spotlight

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Old 11-12-2013, 03:20 PM   #2 (permalink)
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You wouldn't want to convert it to electric, would you ?
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Old 11-12-2013, 03:27 PM   #3 (permalink)
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Looks a bit mean, but I like it
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Old 11-13-2013, 10:20 AM   #4 (permalink)
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Nice work!
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Old 11-13-2013, 04:03 PM   #5 (permalink)
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Old 11-26-2013, 04:45 PM   #6 (permalink)
captainslug's Avatar
Join Date: Sep 2008
Location: Sterling, VA
Posts: 383

BORK! - '89 Volvo 240 DL Wagon
90 day: 21.27 mpg (US)
Thanks: 2
Thanked 24 Times in 13 Posts
New exhaust is finished. I bought an 11-inch clearance mini bike header from OMB Warehouse, cut it short, welded a 3/4 NPT half coupler onto it, then made and welded on a tab so I can secure it to the frame.
The muffler is a cheap stock Briggs & Stratton.


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