Clone Limited Modified Build Up

After receiving a new cylinder head from Minidragbike and a bigger cam from DynoCams, I thought it would be good to tear down my motor, clean it up, install some new piston rings and put it back together. Many people have emailed me with questions about engine assembly, so I thought I would put together a step by step video. To keep the file size down and still allow me to explain the details I opted to use stills. At the end of the video is a test fire of that same motor after mounting it back onto my kart.

The video explains everything I did to assemble the motor. I know that all of you have your own way of doing things that are just as good and in your opinion better than my process. I am not here to teach old dogs new tricks, simply to provide insight into how I do it. If you are new to engine building, then this video will explain a lot of good tips for you. If you have been building engines for a long time, or at least pretending on 4cycle.com like you have been at it for a long time, please spare me your comments unless they are to build upon what was explained in a positive attitude.

And don’t forget to put in your pushrods, I know I forgot to mention them in the video. In this motor I used the shorter pushrods available from Burris.

For the test fire I am running alcohol which is supplied from a bottle hanging above the motor. I did this so I would not have to run gas through the whole system after the test fire, just through the carb and motor. I can’t wait for some good weather so I can track test this motor.

Feel free to comment in the box below with your thoughts, experience or additional tips you might have.

Clone Limited Modified Engine Build Up

Clone Limited Modified Engine Build Up

Clone Limited Modified Engine Build Up

17 Responses to Honda Clone Limited Modified Build-up


  1. Nelson
    Sep 01, 2011

    I’ve found this blog very helpful. I have built a decent amount of turbo engines for cars, but this will be my first clone build. Giving up running around on the street for karting. Pretty excited to do some real track racing. Hope you put up some more videos of the nasty cone build.

    Thanks again,
    -Nelson


    • Jerad Hill
      Sep 11, 2011

      Hi Nelson, I plan to. I hope to get more time for karting as the year unwinds for me. I am in the middle of working on a rebuild right now with my father since the failure with my current motors cylinder head.
      Let me know how the track racing goes for you!


  2. LWT
    Sep 20, 2011

    Very helpful video, thank you! What type and setup carb are you using? Also, is that a stock crank?


    • Jerad Hill
      Sep 20, 2011

      Currently I am running alcohol so I am using a Tillotson alki carb. However with the clones unless you are running a high compression motor you can get away with gas. I would just suggest using higher octane gas if your motor is modified.


      • kim
        Jun 26, 2012

        you done a great job on the clone. your video will help a lot of guys building these motors i have built racing flat heads for years. sorry to say but the flat head is just about gone the clone make more hp with less money. they last longer also


  3. B_jamin
    Jun 21, 2012

    Looks so sick. I am just getting into karting at 26 , feeling it out for my five year old son and the speed demon from within. As of now i have a grayhound 6.5 honda clone on a wildkart frame. what would you suggest that i do first, remember I’m a noob.


  4. Sam
    Jul 03, 2012

    Hey, great video! I was wondering what modifications you would recommend for someone on a fairly low budget for a recreational go kart. Thanks.
    -Sam


    • Jerad Hill
      Jul 05, 2012

      Hey Sam, there are several great mods you can get for cheap. I would suggest starting with an open header pipe if you have not already. The main restrictor of these motors is the exhaust. After that I would suggest upgrading your carb. Getting one of those blueprinted carbs is just a waste of money. I believe I reviewed one on this website a while back. I would suggest a small tillotson carb or one of the larger bore stock looking carbs. I have seen them on the NR-Racing website. You can google it. You could also go with a slightly larger cam before having to worry about replacing the stock rod with a billet one. I would suggest one of the cams from DynoCams. Their stock racing cams are pretty good. My brother runs their cam and wins races with it. It is easy to get a lot of money tied up in your clone motor. After these mods I would get a good clutch. If you go beyond what I have listed here you will probably want to look into a disc clutch but I have had good luck with a Noram clutch as well, and they are pretty cheap.


      • Sam
        Jul 09, 2012

        Thanks for the advise. I will definitely look into your suggestions.


  5. chris
    May 21, 2013

    GREAT INFO A LOT OF GUYS NEED HELP MODIFYING THE HARBOR FRIGHT CLONE MOTORS HERE’S SOME GOOD ADVICE:FIRST DISSASSEMBLE THE MOTOR COMPLETELY.THIS WILL MAKE YOU LEARN HOW EVERYTHING WORKS AND GOES TOGETHER.NEXT DRIVE OUT THE GOVERNER FROM THE OUTSIDE DRIFTING THE SHAFT WITH A PUNCH.HAMMER A SCREWDRIVER BETWEEN THE GOV GEAR AND THE CRANK AND IT POPS OFF.THE FLYWHEEL COMES OFF BY HITTING THE INSIDE EDGE WITH A HAMMER ROTATING IT A COUPLE OF TIMES.USE A BIG HOSE CLAMP TO HOLD THE RINGS AND TAP IT BACK IN WITH OIL.INSTALL A RACE CAM AND CLOSE UP THE BOTTOM END.INSTALL A 22 MM MINKUNI CARB KIT 120.00 ON E BAY FOR ALL THE PARTS YOU NEED. NEXT A 50.00 PORTED HEAD.PUT IN HIGH LIFT ROCKER ARMS AND MODIFY THE GUIDE PLATE FOR CLEARENCE.INSTALL A STRAIGHT PIPE WITH MUFFLER.PLUG HOLES ON MOTOR WITH 1/4 INCH SET SCREWES AND RED LOCKTITE.FRONT HOLE GETS A BOLT WITH J B WELD.INSTALL IT ON YOUR MACHINE AND GET READY TO LEARN THE MEANING OF FEAR…AROUND 15 HP…NICE I ALLSO ADDED THE ALUM. FLYWHEEL FOR SAFETY AND BETTER ACCELERATION.AFTER THIS MY MINI KICKS BUTT…HOPE THIS HELPS


  6. chris
    May 21, 2013

    I FORGOT YOU NEED TO ADD A 4 DEGREE ADVANCED FLYWHEEL KEY AND 18 POUND VALVE SPRINGS YOULL NEED THESE ALLSO TO HIT THE 15 HP MARK GOOD LUCK AND RIDE SAFE…CHRIS


    • Jerad Hill
      Oct 15, 2013

      Thanks for the tips Chris!


  7. chris
    May 23, 2013

    IF YOU WANT THE CARB INSIDE THE FRAME (ON A MINI BIKE)CUT THE INTAKE MANIFOLD IN HALF USE A MULTI BEND RADIATOR HOSE AND CUT A PIECE ABOUT 5 INCHES LONG WITH THE RIGHT ANGLE AND HOSE CLAMP IT ON.THIS ALLSO INCREASES LOW END AND SAVES IT FROM CRASH DAMMAGE.DONT FORGET TO TRIM THE INTAKE GASKET SO NOTHING IS STICKING IN THE INTAKE. NOW YOU ARE READY TO GO…


  8. joshua
    Oct 15, 2013

    hi jerad, im building a motor similar to that… tell me what you think

    14cc head
    ported/polished
    milled .020
    28.5/27 mm valves
    1.2 billet rockers
    isky 315 (260* duration)
    isky billet lifters
    isky 5.070 pushrods
    arc max stroke crank
    std boar gx200 flat top piston .005 in the hole
    copper head gasket
    tilly 304wx
    .990 j pipe
    60lb dual springs (spring pocket cut)
    arc 6619 flywheel (32* timing)

    according to the compression ratio charts i should be making 15.1:1 comp ratio
    running race gas (cant run alky)
    dave lewis is doing my head, do you know if he does good work?
    how much power do you think ill make

    how hard does your engine pull, and how much power,
    do you think i will be able to out run a briggs stroker .010 over same carb and springs?

    you do some nice work :)

    thanks-josh


    • Jerad Hill
      Oct 15, 2013

      Thanks Josh. That sounds like a strong setup. Can’t say I know exactly how much power you will have but I know that motor will be a powerhouse.


  9. joshua
    Oct 15, 2013

    does anyone know about the max stroke crank from bsp, i have one, and i have a gx200 crank the max stroke is hardened and balanced witch i would think is more durable, anyone have opinion

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