Go-KartA go-kart is a small four-wheeled vehicle. Go-karts come in all shapes and forms, from motorless models to

high-powered racing machines, some, like Superkarts, being able to beat racing cars on long circuits.

National Go Kart Championship (NGKC)It is a competition to bring and enhance good engineering approach and practice for graduating and diploma students in

engineering. The competition is basically to design and fabricate a Go-Kart in extremely low budget followed by a competition of the selected teams.

Indian Society Of New Era Engineers (ISNEE)ISNEE is an organization for students focusing on the technical and managerial development of future engineers.

It gives the opportunity to the undergraduate and diploma engineers to research and develop innovative projects. We inspire them to imagine because imagination is more important than knowledge.

RULE BOOK LIMITATIONS

Engine:

Yes’s

•Engine Type - Single Cylinder, Four Stroke Gasoline Engine

•Cooling System - Air Cooled

•Maximum Capacity - 125cc

No's•Increase engine capacity•Temper the Rated RPM of engine

•Modify the internal of engine.

•Maximum speed of the vehicle should be restricted to 80kmph.

Chassis:

• Tube must be seamless.

• Minimum cross section must be 1 inch (25.4mm).

• Wheelbase of at least 1066.8 mm (42 inches).

• Smaller track width (front or rear) must be no less than 80% of the wheelbase of the vehicle.

• Minimum of 25.4 mm (1 in) of static ground clearance measured from the lowest point.

• Bumpers must cover front and rear tires.

• Maximum overall weight is 200kg.

Safety:

• 3 Kill switches.

• Locknuts must be used.

• All bolts must be at least of 8.8 metric grade or more.

• Fire extinguisher.

• Driver suit, helmet, underclothing, balaclava, hand gloves, shoes are mandatory.

• Fire wall must be installed.

• A 3 point or 5 point seat belt must be properly installed in the way it gets locked to protect driver.

For the designing of the kart there were some limitations regarding both from the go-Kart perspective and the organizers perspective. These limitations are important for making the kart safe.

Keeping all the constrains in mind we kept our approach to design a Go-Kart that can meet all the performance

requirements. We planned to make a design that is simple and dedicated to the main goals. We considered some of the

parameters to be set according to the characteristics of a Go-Kart .

Chassis

• Structure of the chassis must be able to bear the load that may be applied on collision.

• The material must have high strength as well as low weight.

• Availability and price.

Transmission

• Must be designed to reduce the friction of the system.

• Should give a performance that matches the class of the vehicle.

• It must be reliable.

• Flexible designing.

Steering

• Minimum turning radius to posses sharp turning

• Less cost

• Less effort to be applied by the driver

• Vehicle must be stable.

Wheel base was kept minimum to make the kart have smaller turning radius and also a compact layout

that is favorable for a Go-Kart.

Front track width was kept smaller then rear track width to

make the kart easily steerable and fallow smaller turning radius.

Rear track width is bigger which helps the kart to be stable while

cornering sharp turns at high speed or in the condition of skidding.

Four bar linkage steering system was used to enable sharp

turning at high speed without much of the work for driver.

The rear sprocket was designed to deliver a balance of acceleration and top speed which is

appropriate for go kart racing. No. of teethes were reduced from 45 to 36.

The rear mounting was made to fit a conical roller bearing which reduces

friction and can bear both radial and axial loads.

AXLE SHAFT HUB NUT WELDED PLATE

This kind of mounting for rear tire was better in the ways like it was easier in

disassembly and assembly. Also it had lesser bolts with extra support to the bearing.

Engine (Discover 125 ST)

Engine Type : 4 Stroke Petrol

Maximum Power: 12.4 hp

Compression Ratio : 9.5: 1

Swept Volume : 124.6 cc

Maximum Speed : 12000rpm

Torque : 11 Nm

Cooling System :Air cooled

Ignition System: Electrical

Brakes Brake type : Disc Brake

Disc Diameter: 190mm

Disc Thickness : 3 mm

Master Cylinder Piston Diameter: 16mm

Caliper Piston Diameter : 35 mm

SteeringLinkage Mechanism

Turning Radius C.G. : 2.0971 m

Maximum steer angle: 35 degree

Length of Tie Rod: 26 inch

TransmissionType : 5 Speed Constant Mesh

Gear Configuration: 5

Gear Ratio

Forward: 25.5/ 16.6/ 12.2/ 10.2/ 9.1

Top speed : 70 Kmph

Optimum Speed: 35 Kmph

Weight and Dimensions

Weight: 110 Kg (Approx. with

riders & load)

Wheel base : 42.75 inch

Track width: 36 inch (front), 46

inches (rear)

Ground clearance: 1.5 inch

Wheels and TiresRim Dimension

Front: 5'' , Rear: 5''

Tire Dimension

Front: 10'' x 4.5'' x 5'', Rear: 11'' x 7.1'' x 5 ''

Material SpecificationMaterial for the chassis of the vehicle :

AISI 1018

ACCELERATION

KEY POINTS•The final drive ratio is changed to meet optimum required performance. •Most Powerful 125cc Engine.•Simple Chain Drive for better efficiency.

Gear 7000rpm

First 13.38

Second 8.73

Third 6.43

Fourth 5.39

Fifth 4.81

ENGINE SPECIFICATIONBajaj Discover 125 STCylindrical capacity: 125ccMax net power: 12.4bhp @12000rpmMax net torque: 11Nm @7000rpmGears: 5 manual

TRANSMISSIONPrimary Reduction: 3.4Gearbox Reduction: 3, 1.95, 1.44, 1.21, 1.08Final Reduction: 2.5Overall Reduction: 25.5, 16.6, 12.2, 10.2, 9.1CHAIN DRIVEFront sprocket: 14, Rear sprocket: 36

OUTPUTSMax Tractive Force: 2007.87 NMax Torque: 280 NmMax Speed: 65 KmphMax Tire RPM: 274-1307rpm

ASM-DISASM14:5sec

Brake & Accelerationa= 3.21sec for

100ft.Brake-OK

ENDURANCE & FUEL ECONOMY

• 10:40Min(5 lap)

• 600ml(6 lap 22.8km)

AUTOCROSS

• 29.5Sec (1PENALTY)

• 24Sec

SKIDPAD•24 Sec•20 Sec