Go Kart Project

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Central Polytechnic College, Thiruvananthapuram PAGE NO - 1

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1. INTRODUCTION
There are many motor sports in the world. Bikes, Cars, Formula
one are examples of them. The drivers in these are very professionals and
accurate. They can drive it very fast. But there are also motor sports
which do not need professional drivers and need no great speed. The
vehicles used are also very cheap. Such a motor sport is Go-Karting.
They resemble to the formula one cars but it is not as faster as F1 and also
cost is very less. The drivers in go-karting are also not professionals.
Even children can also drive it. Go-karts have 4 wheels and a small
engine. They are widely used in racing in US and also they are getting
popular in India.

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2. SCOPE OF THE PROJECT
Go-Karting is a big craze to the Americans and Europeans. It is
initially created in United States in 1950s and used as a way to pass spare
time. Gradually it became a big hobby and other countries followed it. In
India go-karting is getting ready to make waves. A racing track is ready
in Nagpur for go-karting and Chennai is also trying to make one. Indian
companies are also producing go-karts in small scale. MRF and Indus
motors are the major bodies in karts and they are offering karts between 1
lakh and 3 lakh. But to make go-karts popular, the price must come down.
For that, many people are trying to build one under 1 lakh and we had
also take up the challenge and make our under 25 K. This is a dream
come true. A go-kart just under Rs. 25,000/-. So we are sure that our
project will have a high demand in the industry and also we are hopping
to get orders from the racing guns.

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3. A BOUT GO – KA RTS
Go-kart is a simple four-wheeled, small engine, single sealed
racing car used mainly in United States. They were initially created in the
1950s. Post-war period by airmen as a way to pass spare time. Art Ingels
is generally accepted to be the father of karting. He built the first kart in
Southern California in 1956. From them, it is being popular all over
America and also Europe.
A Go-kart, by definition, has no suspension and no differential.
They are usually raced on scaled down tracks, but are sometimes driven
as entertainment or as a hobby by non-professionals. Karting is
commonly perceived as the stepping shone to the higher and more
expensive ranks of motor sports.
Kart racing is generally accepted as the most economic form of
motor sport available. As a free-time activity, it can be performed by
almost anybody and permitting licensed racing for anyone from the age
of 8 onwards.
Kart racing is usually used as a low-cost and relatively safe way to
introduce drivers to motor racing. Many people associate it with young
drivers, but adults are also very active in karting. Karting is considered as
the first step in any serious racer’s career. It can prepare the driver for

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highs-speed wheel-to-wheel racing by helping develop guide reflexes,
precision car control and decision-making skills. In addition, it brings an
awareness of the various parameters that can be altered to try to improve
the competitiveness of the kart that also exist in other forms of motor
racing.
3.1 Go-Karts in India
Go-karts emerged in India in 2003 from MRF, which has a 250cc
two-stroke engine, which produce 15 bhp of power, which costs around 3
lakh. Indus motors are also offering Go-karts for 1 lakh to 3 lakh. There
are racing tracks in Nagpur for go-karting, which is known as the home of
go-karts in India. Many people take part in the racing and is getting
popular.
3.2 Go-Karts in Foreign Countries
Go-karts in foreign countries have much more performance than
the Indians. One type is a single engined 160cc 4-stroke kart with a
maximum speed of around 40 mph and second type, a twin-engined
320cc 4-stroke kart used in outdoor with a maximum speed of 70 mph.
There are hundred of racing tracks in US for karting and also they are
much more professional than the Indians.

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4. PA RTS OF A GO – KA RT
In a Go-Kart, there are mainly six parts. They are
1. Chassis
2. Engine
3. Steering
4. Transmission
5. Tyres
6. Brake
7. Electric Starter
4.1 CHA SSIS
The chassis is an extremely imported element of the kart, as it must
provide, via flex, the equivalent of suspension to give good grip at the
front. Karts have no suspension, and are usually no bigger than is needed
to mount a seat for the driver and a small engine. Chassis construction is
normally of a tubular construction, typically GI with different grades. In
this kart, we use GI B class tube with 1” diameter. The chassis support
the power unit, power train, the running system etc.

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4.2 ENGINE
An engine of a go-kart is usually a small one. About 100-200cc. In
this kart, we use a Kinetic Honda Single Cylinder 98cc 2-stroke petrol
engine, which produces about 7.7 BHP of power at 5600 rpm. We use 2-
stroke engine because this is used for racing. So there is no need of
mileage. Only power.
4.3 STEERING SYSTEM
The steering of a go-kart is very sensitive. Because of lack of a
differential, a kart’s natural direction of travel, forwards, is very difficult
to change. However, the two rear wheels are attached by a solid axle, and
must therefore move together, so in order to turn, one of the wheels need
to skid over the track surface. In this kart we use a special kind of steering
system, disc and link mechanism. This mechanism with modification is
widely used in racing cars especially formula one cars.
In this system, the steering spindle is connected to a disk or plate
and this disk is connected to the front two wheels using two links. When
steering rotates, the disk also rotates and as a result, the link actuates and
the wheel will turn according to the rotation of steering.

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4.4 TRA NSMISSION
Transmission means the whole of the mechanism that transmits the
power from the engine crankshaft to the rear wheels. In this vehicle, the
power from the engine is transmitted to the sprockets using chain, i.e. this
is chain drive. The driver sprocket has 12 teeth and driven sprocket has
44 teeth.
Usually go-karts do not have a differential and so we eliminate
differential from our vehicle also. And also this go-kart has no clutch and
gears because this is automatic transmission. Belt and pulley type CVT is
used in this kart. The power from the engine is transmitted to the rear two
wheels using chain drive. We use chain drive because it is capable of
taking shock loads.
4.5 TYRES
For go-karts, wheels and tyres are much smaller than those used on
a normal car. The tyres will have increased grip and a hard one. And also
it can withstand the high temperature. In this kart, we use tyres having
14” dia for front and 16” dia for rear. This is used for an aerodynamic
shape. The tyres must have pressure of at least 18 psi.

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4.6 BRA KE
Typically, go-karts will have single rear drum brakes, which is
situated on the rear axle. The brake will capable for stopping the kart
running in 40 mph. The pedals actuated by the left leg operate the brakes.

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4.7 Electric Start
Both Otto cycle and Diesel cycle internal-combustion engines
require the pistons to be moving before the ignition phase of the cycle.
This means that the engine must be set in motion by an external force
before it can power itself. Originally, a hand crank was used to start
engines, but it was inconvenient and rather hard work to crank the engine
up to speed. It was also highly dangerous. Even though cranks had an
overrun mechanism to prevent it, when the engine started, a crank could
begin to spin along with the crankshaft. The operator had to pull away
immediately, or else risk a broken wrist, or worse. Moreover, as engines
evolved, they became larger and compression ratios increased, making
hand cranking an increasingly difficult matter.
Electric starter
The modern starter motor is a series-wound direct current electric
motor with a solenoid switch mounted on it. When low-current power
from the starting battery is applied to the solenoid, usually through a key-
operated switch, it pushes out a small pinion gear on the starter motor's
shaft and meshes it with the ring gear on the flywheel of the engine. The
solenoid also closes high current for the starter motor and it starts to run.
Once the engine starts, the key-operated switch is opened, a spring in the
solenoid assembly pulls the pinion gear away from the ring gear, and the

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starter motor stops. Modern starter motors have a "bendix" — a gear and
integral freewheel, or overrunning clutch, that enables the flywheel to
automatically disengage the pinion gear from the flywheel when the
engine starts.
STA RTER MOTOR A SSEMBLY
Other than the main parts, the kart also contains some parts such as
Mufflers. The muffler we use is Baffle type. In baffle type, the exhaust
gas passes through a series of baffles, which causes maximum restriction
and hence back pressure. The noise reduction takes place because the
length of travel of exhaust gases increases considerably.
Other main part is the headlight. Head light is provided at the front
of the kart for sane night racing. The requirement of automobiles is that

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these should illuminate the road ahead at a reasonable distance with
sufficient intensity.
Also there is a plastic seat in the kart for the driver. The kart is
single seated. There is also a bumber in front of the kart.

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5. SYSTEMS USED IN A GO – KA RT
Like every automobile, go-karts also have various systems. Mainly
there are 4 systems in this kart.
1. Fuel system
2. Ignition system
3. Lubrication system
4. Cooling system
5.2 FUEL SYSTEM
The purpose of fuel system in SI engines is to store and supply fuel
and then to pump this fuel to carburetors. The fuel supply system also
prepares the air-fuel mixture for combustion in the cylinder and carries
the exhaust gas to the rear of the vehicle. The basic fuel supply system
used in the vehicle consists of the following.
a) Fuel tank
b) Fuel strainer or Fuel filter
c) Air cleaner
d) Carburetor

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Chemistry of Combustion
The type of combustion that takes place in an engine is commonly
called Burning. Burning is an example of chemical change. In a chemical
change as substance losses those characteristic by which we recognize it
and is changed to a new substances with different properties. The petrol is
burned in the engine and the products that result no longer resemble
petrol.
The petrol in the fuel lines differs from the petrol that is drawn into
the engine. As it passes through the carburetor and intake manifold and is
mixed with aim some of the petrol is changed from liquid to vapour. This
process of vaporization is called a physical changed. No new substance is
formed since the petrol vapour is still recognized as petrol. Diesel fuel oil
and petrol are both mixtures of volatile hydrocarbons compounds of
hydrogen and carbon. A compound is a substance that can be separated
by chemical means into two or more simpler substances. Hydrogen and
carbon are examples of elements. In chemistry an element is defined as a
substance, which cannot be separated into simpler substances by chemical
action.
AIR
CLEANER
FUEL FUEL CARBURETOR ENGINE

TANK FILTER

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Fuel Tank - It is reservoir of fuel oil for an engine. It is kept in and
elevated position so that the fuel will flow to the carburetor through the
filter by gravity. Our fuel tank has a capacity of 1 litre and there is also a
fuel level indicator in it.
Fuel Filter - Dust, particles of dirt or other unwanted particles might be
present in the petrol. This petrol should be free from these particles.
Therefore, the petrol filter is used.
Air Cleaner - Since the atmospheric air is highly cornices and contains
dust and dirt particles, it is allowed to enter the engine intake manifold
only through an air cleaner.
Carburetor - The mixture of petrol and air burns in the combustion
chamber of the engine. The carburetor is a device to mix the petrol with
air in the proper ratio for the purpose of combustion. The quantity of
petrol and air can be indifferent ratios. The quantity of petrol can
sometimes be more and sometimes less. The speed of the engine changes
according to the richness of the petrol in the mixture. Function of a
carburetor is to
a) Meter the quantity of charge to give correct air-fuel mixture.
b) Atomize petrol into fine particles so that it burns quickly.

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5.2 IGNITION SYSTEM
The ignition system used for small two-stroke engine is flywheel
magneto type. The advantage of this system is that it is set combined. The
flywheel magneto is basically used only for a single cylinder engine
though ones suitable for multi-cylinder engine have also been developed.
The principles of this type of ignition can be easily understood with
following description.
Magneto Generator
The ignition magnet of a magneto generator, which produces
alternating electrical impulses in a low-tension armature winding or coil.
At an appropriate moment the circuit through the winding is broken by
means of an interrupter, which forms an integrate part of the magneto. A
condenser connected across the breaker assures rapid cessation of the
primary current, and this results in the induction of a high tension impulse
in a fine wire secondary winding, which either surrounds the primary
winding or is surrounded by it, both being wound on a magnetic coil. An
advantage of the magneto is its self-contained character. All the demands
of the system are in on compact unit from which it is necessary only to
run a low-tension cable to the lighting system and high-tension cable to
the spark plug.

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FLY WHEEL MA GNETO ( ROTA TING MA GNET TY PE)
1. Ignition Coil 5. C. B. Point
2. Condenser 6. Sparck Plug
3. H. T. Coil 7. Ignition Switch
4. Cam 8. Flwwheel Magnet
Figure shows the different views of a single cylinder design of
flywheel magneto. A small magnet is provided with laminated pole
pieces and the assemblies cast in the engine flywheel, which also acts as a
cooling fan. In addition to the magnet, the magneto consists of a coil with
a w-shaped or three pole laminated core, an interrupter and a condenser,
all of these parts being mounted on a base plate or starter plate. The two
curved slots in the stator plate permit of adjusting the spark timing.

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As the poles of the core pass those of the magnet, the magnetic flux
passes through the coil first in one and then in the opposite direction and
alternating electric impulses are induced in it. When the flux has been
well established the primary circuit is closed and a moment later when the
primary current is at its maximum, the circuit is broken by the interrupter,
which is actuated by a cam on the crankshaft. Magnetos also have a
device coupled to it so that the timing is advanced as the engine speed
increases. This helps in ignition of the charge in the cylinder.
The magnetos are either fitted with build-in type of two coils – one
ignition coil and the other lighting coil or alternately they have separate
ignition coil. These are attached to a starter or fixed plate and terminate in
soft-iron pole-pieces closely matching the shape of the flywheel which
rotates around them.
Ignition Coil
The coil consists, in fact, of two coils which may be considered as
separated electrically, although they are both wound on the same iron
core and share a common terminal. One coil, known as the primary, is fed
from the battery, and the principle of operation depends upon the fact
that, if the supply to this coil is suddenly interrupted, then the voltage is
created or induced in the other coil known as the secondary. The voltage
in the two coils can be considered for our purpose to be in the same ratio

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as the number of turns of wire on the two coils, so that by providing
relatively few turns on the primary winding, and a very large number on
the secondary the necessary, high voltage is obtained.
The voltage required to cause a spark between the sparking plug
points depends upon both the pressure of the mixture with the cylinder
and the gap between the points under average conditions a voltage of the
order of 10,000 volts is needed.
Earlier it has been stated that the development of the higher voltage
in the secondary winding of the ignition coil only occurs when the
electricity supplied to the primary winding is suddenly interrupted. This

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interruption is arranged to take place at the correct time by the contact
breaker points.
Spark Plug
An essential part of the ignition system is the provision of
electrodes within the engine cylinder, across which the ignition spark can
discharge. It is desirable to arrange that these electrodes shall be easily
accessible and they are, therefore, mounted on a screwed-in plug.
A sparking plug consist essentially of a steel body which bears the
earthed electrode, an insulator, and a central rode which forms the other
electrode, fed from the distributor. The lower part of the body is threaded
to suit a screwed bole provided in the engine, the length of the threaded
portion known as the reach and varying with the plug design. The body of
the plug seats on to a soft steel washer when it is screwed into the engine.
The insulator operates under particularly arduous condition since
not only must it withstand the high ignition voltage, but it’s lower and is
subjected to the full bear of combustion and it is also liable to mechanical
shock. At one time, the insulator was mode from porcelain but modern
plugs use ceramics based on sintered aluminium oxide.

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The central electrode is seated into the insulator and is provided
with a screwed terminal at the upper exposed end, often shaped to accept
a snap-on connector. The tip of the electrode, at which the spark occurs,
usually has an insert of heat-resisting metal such as nickel.
The ignition voltage is about 25,000 volts and the distance between
the central and earthed electrodes is about. 202 inch and is adjusted by
bending the outer electrode.
5.3 LUBRICA TION SYSTEM
It is a common known that if two rough surfaces are rubbed
together, there is a resistance to the motion and heat is generated. In an IC

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engine surface which rub together are not tough by normal standards, yet
if they are allowed to run in direct contact get one another, the
temperature more rise to so high a degree that local melting will occur
and the surfaces will slide to seize. It has been shown than even if the
surfaces are super finished, seizing will occur unless lubrication is
provided.
The primary objective of lubrication is to reduce the friction and
wear between bearing surface. Lubrication accomplishes this requirement
by interposing a film of oil between the sliding surfaces. Other function
of lubricating oil in internal combustion engines are, such as the pistons
by packing up heat and dissipating it through the crank case and reducing
compression losses by acting as a seal between the cylinder walls and
piston rings.
A lubricant must be able to perform certain task in order to
accomplish its purpose satisfactorily. It must posses sufficient viscosity
and oiliness to protect mechanical devices of the necessary speeds,
pressures and temperatures.
Types of Lubricants
Lubricants are classified in three forms - fluid, semisolid and solid.
Fluid oils are used in automobile engine lubrication systems, semi solid

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oils are used in chassis lubrication. Solid lubrication is done by using
graphite and mica. Graphite often with oil to lubricate automobile
springs. The use of these types depends upon the work required and the
surface to be lubricated.
Splash Lubrication System
The lubrication system used in the engine is splash lubrication
system. In this system, oil is splashed over different working parts of an
engine. Oil is contained in a through or sump. The big end of connecting
rod is provided with a ‘spoon or dipper’ or ‘scoop’. When the piston is at
the bottom of its stroke, the big end of connecting rod and crankpin dip
into oil. The dipper picks up oil and as the crankshaft rotates, oil is
splashed up due to centrifugal force.

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The splashed oil is in the form of a dense mist sprayed into fine
particles over surfaces in contact. Small cups are provided close to the
bearing of the crankshaft. There are small holes in these cups. The
splashed oils fills up these cups from where it is supplied to the bearing.
Oil that is splashed onto cylinder walls speeds well when piston
reciprocates while the piston rings scarp the oil and get themselves
lubricated. Drops of splashed oil drip from the inner side of the piston and
lubricate the gudgeon pin and bearings. The crankshaft bearings, valve
mechanism and timing gears are also lubricated by splashed oil.
5.4 COOLING SYSTEM
A lot of energy is produced due to the combustion of fuel inside the
engine cylinder. Only 30% of heat energy is converted into mechanical
work. Out of the remaining heat (about 70%) about 40% is carried away
be exhaust gases into the atmosphere. The remaining part of heat energy
(about 30%) is absorbed by engine cylinder, cylinder head, piston and
engine valves. It causes thermal stress in the engine parts, reduces
strength of the piston, decomposition of lubrication oil, burning of valves
and it also reduces the volumetric efficiency of the engine.
In order to avoid the harmful effects of over heating, it is essential
to provide some cooling system for IC Engines. Generally, there are two

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main types of cooling system. Water cooling and air-cooling. In two-
stroke petrol engine, air-cooling system is employed.
Air Cooling
A IR COOLING
For this cylinder is cast with a number of fins around the cylinder.
This type of cylinder is used by motorcycles and scooters and also in go-
karts. The air from the atmosphere dashes against these fins and remove
the heat from the cylinder.

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6. W ORKING OF TW O STROKE
PETROL ENGINE
The engine we used in this kart is a 2-stroke petrol engine. The 2-
stroke engine has no valves. Ports serve the purpose of admitting and
exhausting the charge. These parts open into the cylinder; they are
covered and opened by the sliding piston.

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1st Stroke: Suction and Compression
The piston compresses the fuel-air mixture in the combustion
chamber as it travels towards the TPC position.
In this process, the piston uncovers the inlet port. Fresh charge of
fuel-air mixture enters the crankcase owing to vacuum produced in it.
This is due to the upward movement of the piston. Thus, in one stroke of
the piston, two operations, via suction and compression are carried out.
The crankshaft on the follow-through moves through one half of a
revolution.

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2nd Stroke : Expansion and Exhaust
As the piston reaches the TDC position, a spark ignites the fuel air
mixture. There is enormous pressure due to the combustion of fuel. This
pressure pushes the piston downwards executing the expansion or power
stroke.
In doing so, the piston uncovers the exhaust port and allows the
spent gases to go out of the cylinder to the atmosphere.

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The pre-compressed fuel-air mixture travels from the crankcase to
the combustion chamber through the transfer port. The fresh fuel air
mixture is fed into the combustion chamber with the help of a deflector
on the piston head. It guides the mixture through the transfer port into the
combustion chamber towards its top.
The deflector also allows expulsion of exhaust gases by the fresh
fuel-air mixture. This process is known as scavenging.
We conclude that during the second stroke, two operations, viz.
expansion and exhaust are completed. The crankshaft moves through the

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other half of a revolution. Thus the four cycles of operation, viz.,
admission, compression, expansion and exhaust are completed in one
revolution of the crankshaft.
The four-stroke engine completes this cycle of operations in two
revolutions of crankshaft.
It is expected from this argument that a two-stroke engine must
produce nearly double the power of a four-stroke engine of the same
dimensions. The difficulties encountered by the two stroke engines, i.e.
mixing of fresh charge with exhaust gases, loss of some fresh charge to
the atmosphere and incomplete scavenging, reduces to a great extent, the
brake horse power of the engine.
The PV diagram is shown in following figure.
p – V Diagram of 2 – Strok e Petrol Engine

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7. W ORKING OF A UTOMA TIC
TRA NSMISSION
This go-kart has no gears and clutches. The transmission we use is
not manual, its automatic. For this purpose, we use continuously variable
transmission. We use pulley and belt system type CVT.
This type of CVT uses pulleys, typically connected by a metal-
levered rubber belt. A chain may also be used. A large pulley connected
to a smaller pulley with a belt on chain will operate in the same manner
as a large gear meshing with a small gear. Typical CVTs have pulleys
formed as pairs of opposing cones. Moving the cones in and out has the
effect of changing the pulley diameter, since the belt or chain must take a
large diameter path when the conical pulleys halves are close together.
This motion of the cones can be computer controlled and driven for
example, by a servomotor. However in the light weight VDP
transmissions used in automatic motor scooters and light motor cycles,
the change in pulley diameter is accomplished by a variator, an all
mechanical system that uses weights and springs to change the pulley
diameters as a function of belt speed.
The variable-diameter pulleys are the heart of a CVT. Each pulley
is made of two 20-degree cones facing each other. A belt rides in the

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groove between the two cones. V-belts are preferred if the belt is made of
rubber. V-belts get their name from the fact that the belts bear the V-
shaped cross-section, which increases the frictional grip of the belt.
When the two cones of the pulley are far apart (when the diameter
increases) the belt rides lower in the groove, and the radius of the belt
rides lower in the groove, and the radins of the belt loop going around the
pulley get smaller. When the cones are close together (when the diameter
decreases) the belt rides tighter in the groove, and the radius of the belt
loop going around the pulley gets larger. CVTs may use hydraulic
pressure, centrifuged force or spring tension to create the force necessary
to adjust the pulley halves.

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Variable-diameter pulleys must always come in pairs. One of the
pulleys, known as the drive pulley (or driving pulley), is connected to the
crankshaft of the engine. The driving pulley is also called the input pulley
because it is where the energy from the engine enters the transmission.
The second pulley is called the driven pulley because the first pulley is
turning it. As an output pulley, the driven pulley transfers energy to drive
shaft.
The distance between the centers of the pulleys to where the belt
makes contact in the groove is known as the pitch radius. When the
pulleys are far apart, the belt rides lower and the pitch radius decreases.
When the pulleys are close together, the belt rides higher and the pitch

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radius increases. The ratio of the pitch radius on the driving pulley to the
pitch radius on the driven pulley determines the year.
When one pulley increases its radius, the other decreases its radius
to keep the belt light as the two pulleys change their radii relative to one
another, they create an infinite number of gear ratios-from low to high
and everything in between. For example, when the pitch radius is small
on the driving pulley and large on the driven pulley, then the rotational
speed of the driven pulley decreases resulting in a lower ‘gear’. When the
pitch radius is large on the driving pulley and small on the driven pulley,
then the rotational speed of the driven pulley increases resulting in a
higher ‘gear’. Thus in theory, a CVT has an infinite number of ‘gears’
that it can run through at any time, at any engine or vehicle speed.

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8. SPECIFICA TIONS OF A GO – KA RT
Engine Displacement (cc) = 98 cc
No. Of cylinders = 1
Type of Fuel = Petrol
No. Of Strokes = 2
Maximum power (bhp) = 7.7 bhp @ 5600 rpm
No. Of gears / variator = Variator
Max. Torque = 1.0 kgm @ 5000 rpm
Overall Length (mm) = 1650
Height (mm) = 710
Wheel Base (mm) = 1270
Ground Clearance (mm) = 203
Kerb Weight (kg) = 70
Fuel tank capacity = 1 litre
Brake = Drum
Type of Cooling = Air cooling

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9. DESIGN A ND DRA W INGS

Chassis
Type of Material = GI
Quality = A class tube
Diameter of tube = 1 inch
Axle
Type of Material =MS
Length of Axle = 44 inches
Dia of axle = 25 mm
Brake
Position = Single Rear
Type = Drum Brake
Brake Dia = 110 mm
Sprocket
Type of Material =MS
Outer radius of sprocket = 80 mm
No. Of Teeth = 44
Fuel Tank
Material = Plastic
Capacity = 1 Litre

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Steering Spindle
Dia of tube = 1 inch
Material = GI
Pedal
Type of material =MS
Dia of Rod = 5/8 inch
Muffler
Material = Aluminium
Greater diameter of muffler = 2 inches
Total Length = 27.5 inches
Smaller diameter of muffler = 1 inch

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16 “
7“
7”
5”
8“
12”
4“
10 “
18 “
34 “
CHASSIS

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90 mm
6“
50 mm
21.5 “
2“
MUFFLER

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1“
160 mm
SPROCKET

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DRA WINGS OF ENGINE
CYLINDER, CYLINDER HEA D
1. Cylinder 2. Gasket 3. Cylinder Head 4. Gasket

5. Bolt 6. Stud 7. Spark Plug

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CRA NKSHA FT, PISTON
1. Crankshaft Components 2. Piston Rings 3. Piston

4. Piston Pin 5. Woodruff Key 6. Ball Bearing
7. Bearing Connect Rod End 8. Piston Clip Pin

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10. FA BRICA TION

CHASSIS
First of all, the chassis is constructed. The GI pipe is taken as per
dimensions and bends in required places using bending machine. Then
the pipes are welded rigid
AXLE
The required shaft is taken as per the dimensions and turned on
the lathe.
SPROCKET
The sprocket is welded on the axle at required place.
BRAKE
The brake is also placed in the axle in the left side. The boredom
is connected to it and is connected to left pedal in front of kart.
ACCELERATOR
The accelerator pedal is placed is the right side of the front of the
kart and is connected to the engine.
ENGINE
The engine is mounted in the chassis and the chain is connected
to the sprocket and engine.
FUEL TANK
The fuel tank is placed in the upper position of the engine level
using clamps and bolts.

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MUFFLER
The two pipes are taken as per the dimension and join together.
Then 3 ‘ V ‘ Shaped cuts are made in large cylinder and 3 washers are
placed inside it and the ‘ V ‘ cuts are re welded and grinded. The inlet end
of muffler is bolted to the exhaust of engine and also a rubber bush is
placed to support the muffler.
REAR WHEELS AND TYRES
The 2 wheels are connected to the both ends of the axle and
bolted together. Then the assembly is connected to the chassis using 2
bushed bearing.
STEERING
The steering spindle and steering are made as per the dimensions
and bolted together. This is connected to the plate and link mechanism.
This mechanism is connected to the 2 front wheels.
SEAT
First the seat is mounted on seat stand using bolts and the seat is
bolted on the chassis.
ELECTRIC START
The battery is placed under the seat and connected to the starting
motor using wires. And the switch is placed in the steering spindle stand.

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PAINTING
The painting is done to increase the appearance to the kart. The
chassis, steering and steering spindle, wheels, seat, muffler, engine cover
etc are painted using different colors. The pedals are also painted.

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11. PERFORMA NCE STUDY

First of all, we say that this is not a performance machine. We are
taking a two – wheeled engine and connected to four wheels. So the
performance also deferrers. We tested this vehicle at standard conditions.
Engines are tested to find out the variations of Brake Horse Power,
Torque, Fuel Consumption, Frictional Horse Power and Specific Fuel
Consumption at different engine speeds.
PERFORMA NCE CURVES
1. Torque Vs RPM
From the graph, we see that during medium speeds, torque
increases with speed. The volumetric efficiency being higher during this

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period (cylinders get enough fuel – air mixture to burn), higher
combustion pressures produce more power.
At high speed, engine cylinders induce less amount of fuel – air
mixture reducing combustion pressures and hence the torque, the curve
drops down.
2. BHP Vs RPM
From the graph, we see that the brake horsepower of an engine
steadily increases with the increase of engine rpm. At a certain engine
speed, the bhp drops down instead of increasing. This is due to two
reasons.
1. At high speeds, the volumetric efficiency of the engine decreases
considerably, i.e. it takes in decreased quantities of fuel – air
mixture producing lower combustion pressures and hence lowers
engine power.
2. We also know that frictional losses in an engine increase five times
as the engine speeds up from 1000 to 3000 rpm, decreasing the
brake horsepower.
3. FHP Vs RPM
Frictional Horse Power increase in speed. Frictional loses are lower
at low engine speeds. These losses increase considerably with the
increase in rpm. The horsepower lost due to friction increases five times
as the engine speed increases from 1000 to 3000 rpm.

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The frictional losses in an engine may be due to friction between
rings and cylinders, valves and valve guides, timing gears, bearings,
hydraulic resistance of inlet and exhaust valves etc.
The major source of friction loss in an engine is between piston
rings and cylinder, which contributes to 70% of the total engine friction.
4. Specific Fuel Consumption Vs RPM
The specific fuel consumption decreases with the increase of
engine rpm. The fuel consumption per hp/ hr in the case of diesel engines
is less at all engine speeds.
As shown in the graph, at engine speeds above 2,500 rpm, the
specific fuel consumption increases in both petrol and diesel engines.
When engine load decreases, the specific fuel consumption increases
slightly.
Therefore, we conclude that brake fuel rate is higher for slow speed
engines, increases a little for medium speed engines and increases more
for high-speed engines. This is because at low and maximum speeds, a
rich mixture is required.

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12. SERVICE & MA INTA NA NCE
Servicing
a) Only qualified service personnel should carry out servicing
activities on this machine.
b) Always use standard engine components as specified.
c) Servicing must be done at regular intervals.
Maintenance Schedule
a) Daily
i) Check the lubrication oil in the sump. Tap up necessary.
ii) Keep the fuel tank full. The tank should be fitted in completely
with clean petrol at the end of the day’s work.
iii) Check the tyre pressure. The pressure must be at least 18 psi.
iv) Clean the engine at the end of day’s work, if there are any
leakages, dust will collect at the leaky spots during next day
work. Such leakages should be attended properly.
b) Every 50 kms
i) Inspect fuel lines, throttle operation, brake shoe, wheels and
tyres, etc.

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ii) Adjust throttle operation, carburetor, valve clearance, etc.
iii) Clean the carburetor, air cleaner, spark plug, etc.
c) Every 250 kms
i) Lubricate the braking system.
ii) Check all bolts and nuts.
d) Every 500 kms
i) Replace fuel filter
e) Every 750 kms
i) Thoroughly clean out the fuel tank and refill fresh fuel.
ii) Knock out soot from the exhaust silencer.
iii) Remove the cylinder head and de-carbonize.
f) Every 1000 kms
i) Adjust carburetor
ii) Replace spark plug.

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TROUBLE – SHOOTING
a) Engine does not start
Lack of petrol Check that chock is operated when starting engine
from cold.
Too much petrol a strong smell of petrol will be present near the
(Engine flooded)
carburetor and the outside of the carburetor may be
quire wet. The trouble is that the mixture drawn is not
been fired by the plug. Check as for next.
Lack of spark Take out plug and see if wet (condition previous
above) or excessively dirty. Clean plug and readjust
points, if necessary. If engine is already flooded, kick
over smartly half a dozen times before replacing plug.
If plug is still not sparking, remove again and hold
against side of engine and kick engine over. Spark
jumps the plug: check that the spark jumps the plug
about ¼ in. to engine casing.
If lead sparks but plug does not, fit a new plug.
If load does not give proper spark, check under
ignition fault.

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Ignition trouble Remove flywheel domed cover and check points for
(Other than plug)
(a) incorrect gap (b) points dirty or worn. Adjust or
correct, as necessary.
Check for broken, bread or disconnected leads to coil
(green wires) or earth lead (black) broken off from
crankcase.
b) Engine starts but soon after turn off
Lack of petrol If the petrol tap is not turned on, the engine may start
on the petrol in the carburetor but will run of fuel very
soon after.
Ignition fault Check wires for loose connection.
c) Engine runs badly (Idling and moderate speeds)
Incorrect mixture Adjust idling screws on carburetor.
Check that throttle slide in carburetor is not sticking.
Mixture too lean Check for air leaks, e.g. carburetor top loose, gaskets
faulty, etc.
Mixture too rich Check that chock has not been left out.
Check the atomizer jet is not enlarged.

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Check that carburetor flat has not stuck or become
‘holed’ and sunk.
Ignition fault Check plug first then contact breaker.
Observe plug to see if type is matched to engine.
d) Engine runs badly (Engine speeds)
Poor Carburetor Check as above. Check also that carburetor is vertical,
not displaced, causing float to stick.
Ignition fault Check as above.
Check that contact breaker arm is not seized or stiff on
its pin.
Check that contact-breaker spring is intact and not too
weak.
Condenser may be faulty. Check it in garage and
change sparking plug which may be defective. In such
a case not fault will be felt at low speed but as the
road speed increases, erratic running of the engine will
be felt and unpleasant sound from the exhaust will be
heard. Change spark plug. To check that the fault is
because of the spark plug, replace it with a new or

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used spark plug and run the vehicle. If no fault is
observed then original spark plug needs changing. The
test for condenser may also be done in the same
fashion.
e) Engine lacks pulling power
Poor Carburetor Check as above.
Ignition fault Check as above
Engine Blocked with carbon
Engine and silencer needs decarbonizing (not before
500 kms on a new machine or 1000 kms, if the
machine is driven hard.
Mixture too rich Check if choke is on.

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13. PROJECT PLA NNING

INTRODUCTION
The kind of small-scale industry that we are intending to start is an
assembling industry. We are sure to manufacture the product according to
the customer’s require ments. We are not making only go- karts in this
industry. Only secondary production is kart. Primary production is
motorcycle with the same engine. The manufacturing of karts will be
according to orders. Our manufacturing shop will be well equipped with
all machines such as lathe, drilling machine, grinding machines, milling
machine, power hacksaw, welding machine, etc. So that we can do any
production work in connection with replacement of worn out parts of the
job.
We can also provide job opportunities for 6 technical and 3
managerial staff.
Using present equipment either it may be loss of our valuable
energy and time or otherwise it may be loss of money. Our venture is a
solution for that.
In near future we plan to develop our industry and increase the
production according to customer requirements.

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MA RKET SURVEY
Before establishing our plant we conducted a market survey to
know the trend of the market. Since our project is one which gives much
important to time saving and energy loss main customers are attracted.
Hence our survey was made to collect the opinions and suggestions from
those who in racing field. The points we have covered during our survey
were:
a) Methods of present system
b) Advantages of present system
c) Disadvantages of present system
d) Expense of present system
e) Suggestion of new systems from them
f) Presentation of our project before them
g) Their opinion about the proposal
h) Feasibility of the project in their work
i) Convincing them of our reliability

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SUMMA RY OF MA RKET SURVEY REPORT
Survey reveals the attitude of customers towards the projects. 70%
of them were against the present system because the present system may
either be energy and time consuming or it may be costly. So wastage of
money and valuable time is a problem. 10% of them were satisfied with
the present system, because they have the ability to bear the cost. The
next 10% of them were satisfied by the cheap equipment because of their
poor living condition. The remaining 10% were indifferent to this
question because they don’t have enough knowled ge in this field.
Anyhow 100% of the customers welcomed the new proposal. They
guaranteed their extreme co-operation.

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PLA NT LA YOUT
Plant layout means the disposition of the various facilities
(equipment, material, manpower, etc.) and service of the plant within the
area of the site selected previously. Plant layout begins with the design of
the factory building and goes up to the location and movement of a
worktable. All the facilities like equipment, raw materials, machinery,
tools, fixtures, workers, etc. are given a proper place. In deciding the
place of equipment, the supervisors and workers who have to operate
them should be consulted.
OBJECTIVES OF GOOD PLA NT LA YOUT
In a good plant layout:
1) Material handling and transportation is minimized and
efficiently controlled.
2) Bottlenecks and points of congestions are eliminated (by line
balancing) so that the raw material and semi-finished goods
move fast from one workstation to another.
3) Workstations re-designed suitably and properly.
4) Suitable spaces are allocated to production centres and
service centres.

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5) The movements made by the workers are minimized.
6) Waiting time of the semi-finished products is minimized.
7) Working conditions are safer, better (well ventilated rooms,
etc.) and improved.
8) There is increased flexibility for changes in product design
and for future expansion.
9) There is the utilization of cubic space (i.e. length, width and
height).
10) There are improved work methods and reduced production
cycle types.
11) Plant maintenance is simpler.
12) There is increased productivity and better product quality
with reduced capital cost.
13) A good layout permits materials to move through the plant at
the desired speed with the lowest cost.

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PLA NT LA YOUT
STORE
INSPECTION
OFFICE &
RECEPTION
PAINTING
GRINDING
ASSEMBLING TABLE
LATHE
DRILLING
MACHINE MILLING
DRILLING
MACHINE
DRILLING
POWER SCRAP
MACHINE
HACKSAW
TOILET

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PLA NT LOCA TION
Hardly any location can be ideal or perfect. One has to strike a
balance between various factors affecting plant location, which is
discussed below.
Concept and Factors Governing Plant Location
A plant is a place, where men, materials, money, equipment,
machinery, etc. are brought together for manufacturing products.
The problem of plant location arises when starting a new concern
or during the expansion of the existing plant. Plant location means
deciding a suitable location, area, place, etc. where the plant or factory
will start functioning. Plant location involved two major activities. First,
to select a proper geography region and second, selecting a specific site
within the region. Plant location plays a major role in the design of a
production system the cost of
a) Getting suitable raw material
b) Processing raw material to finished goods; and
c) Finished products distribution to customers.

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Hardly any location can be ideal or perfect. One has to strike a
balance between various factors affecting plant location, which are
discussed below:
1. Nearness to Raw Material
It will reduce the cost of transporting raw material from the
vendor’s end to the plant. Which consume raw material in bulk, or raw
material is heavy, is cheap but loses a good amount of its weight during
processing (trees and saw mills), must be located close to the source of
raw material.
2. Transport Facilities
A lot of money is spent both in transporting the raw material and
the finished goods. Depending upon the size of raw material and finished
goods, a suitable method of transportation like roads, rails, water or air is
selected and accordingly the plant location is decided. One point must be
kept in mind that cost of transportation should remain fairly small in
proportion to the cost.
3. Nearness to Markets
It reduces the cost of transportation as well as the chances of the
finished products getting damaged and spoiled in the way (especially

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perishable products). Moreover plant being near to the market can catch a
big share of the market and can render quick service to the customers.
4. Availability of Labour
Stable labour force, of right kind, of adequate size (number), and at
reasonable rates with its proper attitude towards work are a few factors
which govern plant location to a major extent. The purpose of the
management is to face less boycotts, strikes or lockouts and to achieve
lower labour cost per unit of production.
5. Availability of Fuel and Power
Because of the wide spread use of electric power, in most cases
fuel (coal, oil, etc.) has not remained a deciding factor for plant location.
Even then steel industries are located near source of fuel (coal) to out
down the fuel transportation costs.
It is of course essential that electric power should remain available
continuously, in proper quantity and at reasonable rates.
6. Availability of Water
Water is used for processing, as in paper and chemical industries,
and is also required for drinking and sanitary purposes. Depending upon
the nature of plant, water should be available inadequate quantity and

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should be of proper quality (clean and pure). A chemical industry should
not be set up at a location, which is famous for water shortage.
7. Climatic conditions
With the developments in the field of heating, ventilating and air-
conditioning, climate of the region does not present much problem. Of
course, control of climate needs money.
8. Financial and Other Aids
Certain states give aids as loans, feed money, machinery, built up
sheds, etc. to attract industrialists.
9. Land
Topography, area, the shape of the site, cost, drainage and other
facilities, the probability of floods, earthquakes (from the past history),
etc. influence the selection of plant location.
10. Community Attitude
Success of an industry depends very much on the attitude of the
local people and whether they want work or not.
11. Presence of Related industries

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12. Existence of hospitals, marketing centres, schools, banks,
post offices, clubs, etc.
13. Local bye-laws, taxes, building ordnances, etc.
14. Housing facilities
15. Security
16. Facilities for expansion

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LOCA TIONA L ECONOMICS A NA LYSIS
1. Locations considered
a. Location - 1
It is Veli, situated 12 Km from Thiruvananthapuram city. It is a
sub-urban area.
b. Location - 2
It is Kamaleswaram, situated 2 Km from Thiruvananthapuram city.
It is an urban area.
Factors Location – 1 Location – 2

Cost of (Veli) (Kamaleswaram)
Land 20 (cents) 10,000 (Rent) 25,000 (Rent)
Water Less More
Power Less More
Labour Less More
Transportation More Less
Taxes Less More
Community facilities Good Good
Community attitude Encouraging Indifferent
Housing facility Medium Very Good
Cost of Living Medium Large
Community Size Medium Large

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Studying the data obtained by locational analysis we can see that
transportation charges for location-2 is less than that of location 1. But all
other situation favors location-1. Hence location-1 seems to be a better
choice.
Veli is 12 Km away from Thiruvananthapuram City. We will be
obtaining a shed from here at a rent of Rs. 600/- month. The shed is well
suited for the proposed maintenance concern. Electric supply is already
there and water is already available. Transportation will be available here.
The area of building is 4,500 sq.feet, which is very much to
accommodate. Climatic and atmospheric conditions are very good.

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To THUMBA
To VELI
KSEB
Proposed Site
KOCHUVELI RAILWAY STATION

To ALL SAINTS JN.
To AIRPORT
TTP PREMISES
To TTP

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14. ESTIMA TION A ND COSTING

Costing may be defined as systematic procedure for recording
accurately every item of expenditure, incurred on the manufacture of a
product by different departments of any manufacturing concern.
Objectives of Cost Estimation
Main objectives of costing are as follows:
a) To help the producer in deciding the manufacturing and
selling policies.
b) To help in filling up tender enquiries.
c) To decide the amount of overheads, this helps in comparing
and checking the actual overheads of the factory.
d) To decide the wage rates of the workers after carrying out a
time study.
e) It helps to decide whether a particular material should be
purchased from the market or to be manufactured.
f) It helps in improving the designs, which may reduce the cost
of production.

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Functions of Cost Estimation
a) To determine the cost of material to be purchased from outside.
b) To determine the cost of tools, equipments, etc. to be purchased
from.
c) To determine different overhead charges including selling.
d) To determine selling price after adding due profit to the total cost.
e) To conduct time and motion study.
f) To refresh one-self with modern methods and equipments used in
manufacturing their products.
g) To keep the previous records of estimates in a systematic way for
future reference.
h) To keep contact with other departments regarding methods of
quality of material and products, etc.
i) To keep control over selling expenses with the help of sales.
j) To find the most economical procedure for the design.
k) To submit estimates to the sales department for selling.

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Sl. No Description Quantity Cost in Rs.

1. Chassis 1 3500/-
2. Engine (Kinetic Honda)* 1 5000/-
3. Steering System 1 750/-
4. Wheels and tyres 4 1500/-
5. Brake (Drum) 1 400/-
6. Rear Axle 1 300/-
7. Transmission System 1 1200/-
8. Fuel Tank 1 100/-
9. Seat 1 100/-
10. Electro Plating 1500/-
11. Muffler 1 500/-
12. Extra Fittings 650/-
13. Painting 300/-
14. Labour Cost** 2000/-
15. Indirect Material Cost*** 200/-
TOTAL Rs. 18,000 /-
* Kinetic Honda Engine with whole fuel system
** Labour cost includes cost for welding, boring, drilling, lathe work etc.
*** Indirect material cost includes cotton waste, emery paper, oil,
kerosene, grease etc.
The whole cost producing one kart is Rs. 18,000/-
After taking 25% profit, the cost will be Rs. 22,500/-
After giving discounts and commissions, we can sell a go – kart at
Rs. 22,000/-

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15. FLOW PROCESS CHA RT

Part Name : Chassis Part No : 1
Total Time : 348 minutes
Sl Activity Time in
Minutes
No.
1. Materials lying in the store
2. Moving to marking table 2
3. Marking 10
4. Cutting 90
5. Bending 60
6. Moving to drilling Machine 2
7. Drilling 60
8. Moving to welding section 2
9. Welding 70
10. Moving to grinding Machine 2
11. Grinding 40
12. Inspection 5
13. Move to assembly shop 2
14. Waited for assembly 3
15. Store

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Part Name – Axle Part No : 2

Sl Activity Time in
Minutes
No.
2. Taken to lathe 2
3. Held the rod 3
4. Turning is done 40
5. Thread cutting is done 50
6. Inspection 5
7. To assembly shop 2
Part No – Sprocket Part No : 3

Sl Activity Time in
Minutes
No
2. Taken to lathe 2
3. Fix the sprocket 5
4. Thread cutting is done 35
5. Inspection 5
6. To assembly shop 3

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16. ENTERPRENERSHIP
An entrepreneur is defined as an agent of charge. He is the most
critical factor. In the economic development of any region, he plays a
very important and catalytic role in activating the factors of production
leading to the overall economic development. This is the view of
economists on entrepreneurship. Entrepreneur should posses judgment
perseverance, knowledge of the world and business and also the ability to
superintend and administrator. He is often described as engineer of
industrial progress and chief agent of production.
To summarize entrepreneurship can be described as a creative and
innovative response to the environment such response can take place in
any field of social endeavor business, industry, agriculture, education,
social work and life.
An analysis of the above viewpoints on entrepreneur behavior
highlights the following features.
a) Entrepreneurial behavior is a result of an interaction of individual
factors and situational factors and situational factors of
psychological factors and experimental factors.
b) Individual differ in their potentiality for entrepreneurship.

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c) Even a high differ in their potential need not invariable result in
entrepreneurial success.
d) Factors such as training and institutional support and other factors
assume importance in entrepreneurship development.
Entrepreneurial Characteristics
a. Need for Achievement
The need to sell known as achievement is the single psychological
factor that has been extensively researched of in relation to
entrepreneurship. Mr. Clelland had demonstrated that achievement notice
is a critical factor for entrepreneurship. Entrepreneurship are people with
high drive and high activity level, constantly struggling to achieve
something which they could call their own accomplishment. They are
moderate risk takes at the same time they avoid high risks. They work
long hours, most of them assess their own strengths and weakness and
opportunities and threat from the environment.
b. Sense of Efficiency
A sense of effectiveness is yet another important psychological
dimensions that contributes to successful entrepreneurship. They solve
problems instead of avoiding it. They will show initiative rather than

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conformism confidence and action, orientation is their essential
characteristics. They should have clear goals for the future and tend to
live in the present with involvement. Entrepreneurs are basically inclined
to test out their capabilities whenever an opportunity arises and are open
to feedbacks from such tests.
Time Orientation
The entrepreneur is neither completely future oriented nor
completely past oriented. He is programmic, he looks into the future, uses
his past experience but lives intensively the present.
c. Competition
Entrepreneurs are certainly competitive in their orientation. They
collaborate well with other parties when they see such collaboration is to
their advantage. Their competition is against the goals set by themselves
rather than with the goals set by others.
d. Flexible Authority Relation
An entrepreneur has to show different leadership styles at different
stages of growth of the enterprise. To the employees he will be
benevolent in the initial period and dispensing later once the employees
have built up legally to the organization.

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Social Consciousness
The concern for society for the good of other people pre-supposes a
certain kind of social consciousness. Entrepreneurs should be able to
appreciate the sources and reasons for socio-economic backwardness and
underness and understand the significance of employment and underness
and industrialization in the context of social change.
e. Saving for Future
Successful entrepreneur shows high sense of dignity of manual
labour and have tendency to save for future and to invest for further
development. They have along term involvement with their goals.
f. Development of Entrepreneurs
Entrepreneurship Development Programmes (EDPs) have been
widely recognized as an effective measure in promoting small-scale
industry in our country.
Entrepreneurship is a function of several factors. At least four sets
of factors which mainly influence it could be identified they are:
i. The individual
ii. The socio-cultural factors

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iii. The Support system
iv. The Environment.
i. The Individual
The individual constitutes the mode important element in
entrepreneurship. He takes; the decision to start an enterprise and it is the
he who strives to make it a success. It is necessary, therefore to
understand the various factors which influence an individual. Three main
factors influence behavior are:
• His / her motivational factors
• The skill that entrepreneur posses
• His / her knowledge of several relevant
Motivational factors may be considered as most crucial to
entrepreneurship. It has three major elements.
• The entrepreneurs motivation
• Personal efficiency
• Copying capability

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The following skills are also found most crucial contributing to
entrepreneurship.
• Project development
• Enterprise management
• Enterprise building
• Knowledge and environment
• Choice of industry
• Knowledge of technology
ii. Socio-Cultural Factors
Socio-cultural factors like family background and the names and
values of the immediate social circle contribute substantially to
entrepreneurial developments the individual worker under some pressure
of the values inherited from this behavior which reflect inclinations
towards initiative and risk taking dependence or independence. Working
with one’s own hands on tasks requiring man, manual handling, etc.
The following aspects of normative behavior are relevant to
entrepreneurship.
• Family expectations and pressure

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• Risk taking
• Independence
• Work
Personality Characteristics of Entrepreneurs
Φ Creative
Φ Calculated risk taking
Φ Not too discouraged by failure
Φ Future oriented
Φ Hard working
Φ Persistent
Φ Take personal responsibilities
Φ Sets realistic goals
Φ Drive for power
Φ Drive for independence
Φ Desire for feedback and learns from experience
Φ Goal oriented

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Φ Ability to exploit situation
Φ Willing to learn
Φ Self confidence
Φ Constantly under stress
Φ Person for integrity
Φ Likes to excel in work
Φ Pleasant personality
Φ Success oriented
Φ Makes decisions
Φ Non-structured
Φ Opportunity seeker
Φ Competitive
Φ Positive attitude
Φ Dreamer
Φ Time conscious
Φ Imaginative

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Φ Family and friends second to business
Φ Courageous
Φ Self starter
Φ Take failure a step to success
Φ Individualist
Φ Multifaceted interests
Φ Innovative
Φ Takes challenges
Φ Initiative and dynamic
Φ Impatient
Φ Sensitive and perceptive
Φ Thinks to improves always
Φ High tolerance of ambiguities
Φ Good communicator
Φ Hyperactive
Φ Intensive

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Φ Ability to grasp quickly
Φ Aggressive
Φ Leader
Φ Enjoys work play and living
Φ Dissatisfied with general life
Φ Average intelligence
Φ Want to make a lot of money.

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17. SMA LL SCA LE INDUSTRY

Procedure to start a Small Scale Industry
Starting of a small-scale industry is not a very task. At the same
time it is not very difficult too, if different factors are considered before
taking a decision to start it. For starting the first and most important work
is to select a suitable site and then to make the proper scheme and give it
approved.
Procedure to start small-scale industry consists of the following
important steps.
a. Selection of industry
b. Preparation of schemes
c. Approval of scheme
d. Registration of small industry
Selection of industry
Selection of industry or product that is going to manufacture on the
basis of
• Market survey
• Finance

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• Technical know-how available
• Economic viability
• Stability
• Experience in the time
Market Survey
Before starting a business, market survey is very essential to know
about what must be produced, how much to be produced, what will be the
margin of profit, etc. It provides necessary statistic helpful or forecasting
and planning a project.
Mainly the object of market survey is to inform the management as
to what the future hold for its products and proposed products.
Finance
Government Assistance of Finance
Small-scale industries require financial assistance not only to
purchase machinery and equipment but also for purchasing raw materials
and working capital. Today various organizations are came forward for
sufficient financial help for reasonable rate of interest.
i. National Small-Scale Industries Corporation
ii. State Directorate of Industries
iii. State Industry Development Corporation
iv. Finance Corporation
v. Public Sector and Other Bank

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National Small-Scale Industries Corporation (NSIC)
It provides the following assistances
• Supply of machines on hire purchase
• Marketing assistance to small scale industries
• Encouragement of export of small-scale industries products.
State Directorate of Industries (SDI)
It provides the following assistances
• Granting of essentially certificate for import of raw material,
components etc.
• Distribution of source and indigenous raw materials to the
industry units.
• Allotment of industrial plots/sheds to entrepreneurs.
• Arrangement of water and power.
• Provision of technical guidance.
Subsidy
15% subsidy on fixed capital investment is admissible to new units
set up in the backward area of certain districts such as Malabar, Idukky.
The maximum subdivision admissible in the areas declared backward by
the Govt. of India is Rs. 1 lakh. Wayanad is declared as non-industrial
district and central investment subsidy in the district is 25% for all the
other districts it is 10%.

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Engineer entrepreneurships who set up their own small industrial
units are eligible for interest subsidy. The difference between interest rate
of 7% per annum and the normal rate of interest charged on the loans.
Loans and Concessional Rate of Interest
Loans are advanced to the small-scale industries under the state aid
industries act and rules framed there under got construction of factory
building purchase of machinery and equipment and working capital.
Procedure to Get Loan
a) An application for loan is submitted to the district industries officer
/ assistant director if industries in a prescribed form. In case of
industrial co-operative societies the application should be
submitted to the Assist and register co-operative societies who will
forward the same with the recommendations to authorities
concerned.
b) SBI has introduced a scheme of financial assistance to small scale
units under which working capital is advanced against pledge of
goods under lock and key on factory type. Advances are also made
against hypothecation on goods and bills under sanction, as well as
against personnel guarantees.
Degree or Diploma holders in engineering who pass three months
entrepreneurship course from institution prescribed by Government of
India are eligible for interest subsidy.

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Technical know-how available
Owner should make him really converse with all acts, rules and
literature which may help him in setting up and rolling a small scale
industry literatures published by the state and central government are
available for the help of interested person.
A large number of model schemes also available with the Manager
of publications. Civil line direct of industries and civil supplies also helps
in selection the products which have scope and which do not scope. Their
lists are revised from time to time considering different factors changing
with development of small-scale industry and demand.
Economic viability
The manufacture of the proposed product should be economically
viable. The brake even of the level of product should be below 40 – 50%
of the installed capacity to withstand the possible price cutting on other
dislocation by the competitions. The proposed should have come out
from the laboratory and pilot project level to commercial exploitation.
Stability
The proposed product should have stable sales all the year round
otherwise the cost product may go up than making the product unstable.

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SET UP A ND MA NA GE A SMA LL SCA LE INDUSTRY
Material
A manufacturing organization required of material which may
consist not only raw material but also semi processed, semi assembled
parts and components. It is advisable to have always make than one
supplied for every material to ensure prompt and regular supply of quality
material.
There should be minimum stock of various materials to avoid any
stock out. In other words on the basis of the consumption rate and lead-
time determine.
a) The maximum and minimum quantity of any material to be stored.
b) The re-order level and re-order quantity, that is when to place the
order and for what quantity.
Marketing
It is normal responsibility to make goods available to people at
price they can afford to pay at a time they need it. There should be
sufficient sales to meet the entrepreneur’s experience and to leave behind
surplus. It is therefore essential to plan his marketing. It may also be
difficult to plan any product and procurement programme. In such cases it

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may be necessary to find out alternative uses for men, machinery and
equipment during the slack reason preparation of schemes.
After deciding the product to be manufactured and that place of
industry detailed is prepared. This scheme should contain the type of
machines their approximate cost, quantity or raw materials and cost,
details of land, building, number of workers, location proposed,
infrastructure facilities available, factory layout, etc.
Management
The entrepreneurs should have initiative drive clarity of ideas and
action and should be in a position to enlist the willing co-operation of the
workers to achieve the common goal. That is successful management of
his unit. The success of unit depends upon the attention the entrepreneur
pays to the various problems like arrangements for regular supply of raw
material scheduled production. proper management labour, timely
arrangement of finance adhering to the delivery schedules and
ascertaining the cost of product strategy.
Decide the size of market and the type of product we want of to
offer. Also study the customers for who want to cater, the price and
quality requirements of the customers. A study of the size of the market
should also include the future growth prospect for the unit. Every product

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has a definite life cycle introduction (infancy), growth (childhood) and
adolescence maturity and decline.
In order to retain a reasonable return on our investment consistent
with the growth of our units it is essential to plan in advance
improvements strategy or our product. Satisfied consumers are the base
for the survival of any organization.
Steps to Set Up a Small Scale Industry
1. Identification of a suitable product
2. Choice of location
3. Registration of the firm
4. Provisional registration
5. License from local administration
6. No objection certificate or license
7. Consent for electricity connection
8. Formulation of project report
9. Approval / license from other agencies
10.Approval of building plant

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11.Apply for term loan
12.Land development and construction building
13.Ordering machinery
14.Application of margin money loan
15.Erection of machinery
16.Obtain service connection
17.Recruitment and training of personnel
18.Procurement of raw material
19.Trial run
20.Sales tax registration
21.Sales
22.Application for permanent registration
Facilities to Small Scale Industries
Government have also offered a number of facilities, incentives
and concessions to the small industries to encourage the industrial
development. Some of these are:

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• Hire purchase of machinery
• Tax concessions
• Procurement of raw materials
• Power supply
• Water supply
• Market assistance
• Technical assistance
• Testing facilities
• Export promotion
• Import licenses
• Industries reserved for small scale sector
• Purchase programme
• Reservation of items
• Price preference

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A dvantages of Small Scale Industry
Π It provides better and quick employment
Π It is labour intensive and capital saving
Π With small investment production can easily and quickly started
Π No much sophisticate machines and modern technology is
needed
Π It attracts small savings and diverts them to productive channels
Π It provides economic development by rapid industrialization
Π It provides check in monopoly
Π It reduces in balance of income property

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18. PROJECT A LBUM
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19. CONCLUSION
The 98cc, 2 stroke, 4 wheeled racing car, Go-Kart, we finally made
one under 25K which is a big truth. But we made just a protype of that
performance machine. The materials we used are not up to the mark of
automotive standard. Big companies will design one go-kart at a
minimum of 2 years. But we made this from two months. We do not
recommend driving this go-kart at a speed of 80 km/hour but it is best
suited in 30-40 km/hour speed.
The project report is prepared in such a manner that every layman
can understand the details pertaining to the project. The report is prepared
in simple language and described well. The report give adequate idea and
design guide line for making suitable report is expected to prove valuable
to the successor students of mechanical engineering to know the
essentials of a project and project report.
The matter discussed in the early pages just give a broad outline of
small-scale industries. We have, tried to cover all the aspects concerned
with our project.

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20. REFERENCE
Automobile Engineering R. B. Gupta
Automobile Engineering Kripal Singh
Industrial Engineering and Management O. P. Khanna
Automotive Technology H. M. Sethi
Thermal Engineering M. Zakria Baig
Auto CAR Magazine, February 2004 issue
www.go-karting.com
www.howstuffworks.com
www.answers.com
www.wikipedia.org

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Central Polytechnic College, Thiruvananthapuram PAGE NO - 1

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2. SCOPE OF THE PROJECT

Go-Karting is a big craze to the Americans and Europeans. It is

India go-karting is getting ready to make waves. A racing track is ready

to get orders from the racing guns.

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Go-kart is a simple four-wheeled, small engine, single sealed

is generally accepted to be the father of karting. He built the first kart in

Southern California in 1956. From them, it is being popular all over

America and also Europe.

A Go-kart, by definition, has no suspension and no differential.

as entertainment or as a hobby by non-professionals. Karting is

commonly perceived as the stepping shone to the higher and more

expensive ranks of motor sports.

Kart racing is generally accepted as the most economic form of

motor sport available. As a free-time activity, it can be performed by

Kart racing is usually used as a low-cost and relatively safe way to

introduce drivers to motor racing. Many people associate it with young

Central Polytechnic College, Thiruvananthapuram PAGE NO - 6

highs-speed wheel-to-wheel racing by helping develop guide reflexes,

precision car control and decision-making skills. In addition, it brings an

awareness of the various parameters that can be altered to try to improve

3.1 Go-Karts in India

Go-karts emerged in India in 2003 from MRF, which has a 250cc

two-stroke engine, which produce 15 bhp of power, which costs around 3

3.2 Go-Karts in Foreign Countries

Go-karts in foreign countries have much more performance than

maximum speed of around 40 mph and second type, a twin-engined

320cc 4-stroke kart used in outdoor with a maximum speed of 70 mph.

much more professional than the Indians.

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4.1 CHA SSIS

The chassis is an extremely imported element of the kart, as it must

normally of a tubular construction, typically GI with different grades. In

the power unit, power train, the running system etc.

Central Polytechnic College, Thiruvananthapuram PAGE NO - 9

An engine of a go-kart is usually a small one. About 100-200cc. In

stroke engine because this is used for racing. So there is no need of

mileage. Only power.

4.3 STEERING SYSTEM

The steering of a go-kart is very sensitive. Because of lack of a

differential, a kart’s natural direction of travel, forwards, is very difficult

system, disc and link mechanism. This mechanism with modification is

widely used in racing cars especially formula one cars.

In this system, the steering spindle is connected to a disk or plate

the wheel will turn according to the rotation of steering.

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4.4 TRA NSMISSION

Transmission means the whole of the mechanism that transmits the

Usually go-karts do not have a differential and so we eliminate

wheels using chain drive. We use chain drive because it is capable of

taking shock loads.

shape. The tyres must have pressure of at least 18 psi.

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