Baja Warrior Mini Bike Clutch To Torque Converter Conversion

This is a how to video with step by step instructions on how to convert a Baja Warrior or Mini Baja to a torque converter clutch for more torque and more speed.
In the video I show all the steps then take it on a top speed run to see the difference.
It is a Comet TAV2 30 Torque-A-Verter for a 3/4 inch shaft and the 10 tooth sprocket for a #40/41/420 chain.
I hate hearing my own voice so I lowered the pitch of my narration a bit so it sounds like someone else lol. :P

[@marknye51.thefixitguy]

great video . i am working on basically the same bike for a customer and what i think was missing was the spacer for the shaft and the first plate which was rubbing against the bolts on the block.

[@MarcelsWorkshop]

ya, it makes it feel like a whole new bike. Best upgrade for these bikes IMO.

[@gunntrevor]

Im sorry.. I was tired. I was saying "Is that the best one out there?" haha. Sorry about that. And I was planning on keeping it stock and then bypassing it then going for the torque converter. I was riding it today, And it climbed the huge hill on stock speeds I was very impressed.. Thanks again.

[@MarcelsWorkshop]

Thanks! :D I would say the TAV is definitely worth the money. Makes a huge difference! Its almost like putting an engine twice the size on it because now the engine can make full use of its HP at any speed.

[@gunntrevor]

Oh, Okay. Well, I took the Governor off and it pretty fast. I think I'll keep it at this speed until summer and then maybe I'll have $200 saved up. But anyways thanks for the help. Its nice to have someone so helpful. Thanks again.

[@northerbrewer]

At BMI karts in the USA you can order the jack shaft assembly for the Yerfdog 3000 series karts. Use this with the longer belt and 7 inch secondary clutch. Make an engine mount thats 1 inch of rise for 4 inches of run to tilt the engine and jack shaft forward. No modifcations needed this will all clear the frame and protect clutch. Add 14cc clone head and after market air filter small 7/8" header, jetting required after. Add a helper spring to the governer keep the RPM under 5000

[@MarcelsWorkshop]

I used to get them right from the comet site but you can't seem to do that anymore, so try ebay or a lot of people seem to get them from gokartsusa. You just have to make sure it can handle 6.5hp, is for a 3/4inch shaft, and is for a #40, #41, or #420 chain size.

[@rweiii1]

I know this question wasn't directed at me, but i know the answer, so why not? LOL. Normally an engine is strained less when a torque converter is added because it has to work less to accelerate, and when you start accelerating, the converter changes ratios so you will have a higher top speed. So you have better acceleration AND speed. Big bonus.

[@MarcelsWorkshop]

has worked like a charm since like 2007.

[@MarcelsWorkshop]

@thatcrazycat11168 the torque converter I use is the Comet TAV2-30. But ya that sounds pretty good if all you need to do is buy a belt and put the torque converter on and your good to go.

[@MarcelsWorkshop]

Think torque converter is a general term and can be many things. If you look on any site that sells these, they classify them as torque converters. The reason they call this one a torque-a-verter is because it is asymmetrical.

[@mrbobsshow]

Wow excellent job and well documented thumbs up I wish they still had the star rating s because this is a 6 star forget about the old 5 stars awesome job very impressed

[@MarcelsWorkshop]

no problem! It all depends what you plan on doing with the bike. if you were racing it or just cruising around smooth paved streets CC would probably be the way to go but if your off roading and trail riding and that kind of stuff then TC is definitely the way to go. :)

[@XxXStellionXxX]

The chains more durable if you like to do serious off road and do a lot of it. With the belt you'll have to replace every now and then where as the chain, not so much. The torque converter allows for higher speeds.

[@MarcelsWorkshop]

it comes with a go-kart type clutch already on it, and if you wanted to you could remove the jackshaft and join the 2 chains together and run just straight clutch to back sprocket and you will get around 80km/h or more out of it doing that. BUT you would loose all your off-roading capabilities. it takes a while to get going, you wouldn't be able to drive up a steep hill from a stop and driving on rough terrain would probably just fry your clutch.

[@MarcelsWorkshop]

NP, glad you liked it! :D Unfortunately I can't sell the gear reduction kit because I'm currently using it on my other Mini Baja, because the one that came off that I ended up hacking up and using on my 50cc dirt runner when I converted it into a 6.5hp mini bike. :P

[@MarcelsWorkshop]

Its basically like putting an an automatic transmission on the bike, like a car. Much less strain on the engine compared to the stock gear reduction system because now it pretty much chooses the perfect "gear" for what ever situation it's in to make best use of the engines powerband.

[@MarcelsWorkshop]

This is a brand new bike, but the one I pulled the converter off of and often use for experiments is a few years old and dirty, yet everything still comes off just as easily. Although I store everything in a dry shed, I guess if someone stores there bike where water can get to it and everything is rusted on, it might be difficult to get apart. As for caked on grease, that can be fixed by just taking a pressure washer to the bike and giving it a good cleaning. :P

[@MarcelsWorkshop]

Thanks. I try to respond to just about everyone except for trolls. :P It definitely climbs better with the torque converter and doesn't slip as easily as the centrifugal clutch does if your starting a steep climb from a stop. It's the middle of winter here so I wouldn't be able to do that for at least a few months.

[@Copperrooney]

Fantastic camera work and great instruction. Invaluable!

[@MarcelsWorkshop]

it does, thats how even the stock clutch is held on.

[@MarcelsWorkshop]

ya I'd definitely say get the torque converter, it's not that hard to put on and you'll be getting a nice upgrade and something a more reliable then the stock gear reduction kit. I don't think you'll find one in a junk yard though. I'd try gokartsusa or ebay.

[@MarcelsWorkshop]

The GPS can calculate your speed based on the distance you cover and the time it takes to cover that distance. I've compared the speed the GPS calculates in real time while in my car and it is identical to the speedometer speed so it is accurate.

[@pauldew3453]

Could you tell me if an "impulse" type fuel pump would help the performance of a clone engine? Also, is there very much difference between the 196cc and the Predator 212cc engines? Thank you, any input would be helpful and appreciated.

[@MarcelsWorkshop]

Sorry don't really know enough about small engines to know if that fuel pump would make much difference. As for 196cc vs 212cc, I haven never tried one of the predator engines but I really can't see 16cc making much of a difference.. Perhaps someone that has tried both could better inform you though.

[@MarcelsWorkshop]

Sorry In order to do that I would have to pull my bike apart to get a good video and I don't really have the time to do that right now. Could you just go to a store that sells them and see how it is hooked up on the display bikes? Thanks! Glad you like my videos. :)

[@MarcelsWorkshop]

that depends. If you keep the jackshaft on it and put a smaller sprocket on the back it definitely will go faster but you will loose bottom end. If you put a torque converter on it, then put a smaller sprocket on the back, in theory it should go faster, but I've tried putting a bigger sprocket on the torque converter itself which in theory would be the same as putting a smaller sprocket on the back and all it did was make me lose bottom end but the top end stayed the same.. so idk. :P

[@MarcelsWorkshop]

@thatcrazycat11168 hmm not sure, perhaps the belt is just too burned up and not gripping right, or somethings wrong with the weights or spring in the driver or driven or maybe the moving parts need to be oiled up. (if you do oil up the moving parts though, make sure you don't get any anywhere the belt makes contact with)

[@MarcelsWorkshop]

@BraneDrane100 it's a Comet TAV2 Torque-A-Verter. I believe they are just saying the shaft of the engine needs to have a screw hole in the middle of it, which it should. I've never seen a TC2 so I don't know for sure, but according to the description on gokarts usa that one just mounts on with no mods needed..

[@jackhess4817]

I like the look of the warrior apposed to the mb 200 thats why I'm getting the warrior

[@MarcelsWorkshop]

Yeah I prefer the black over the red as well.

[@MarcelsWorkshop]

@andrewzb the top end would probably be a bit higher but it would take longer to get there. also you would loose a ton of bottom end and doing rough off roading or climbing would more then likely fry the clutch. The torque converter gives you more bottom end then the gear reduction kit while also giving you close to the same top end as straight chain to back sprocket. Also if you fry a torque converter belt its a lot cheaper to replace then if you were to fry the centrifugal clutch. :P

[@MarcelsWorkshop]

6.5hp engines are a 3/4inch shaft and you need one for a #40/41 chain to fit the baja.

[@bruceschmitz1984]

Watching you video I also think the holes in your TC cover is a good idea to cool the clutch

[@MarcelsWorkshop]

Yeah it probably helps.

[@MarcelsWorkshop]

Not sure. I think I recall seeing a video of someone putting a torque converter on with that setup and they found some sort of lug nut that fit perfectly and held the clutch on fine.

[@MarcelsWorkshop]

@soulevs Regular price on the bike here is $699, not sure what they go for in the states though. Then the torque converter is about another $200. I like it, it's fun. :)

[@MarcelsWorkshop]

It would be like locking your car or dirt bike in 5th gear and driving around like that, whereas torque converter gives you gears 1-3 and is constantly changing between them to give you best performance. Torque converter gives you, decent speed (70km/h) and lots of bottom end torque (can do wheelies and climb).

[@MarcelsWorkshop]

@thatcrazycat11168 Sorry, I wish I could tell you but I can't remember off hand. I would just start small and keep trying different sizes or combinations of sizes until you find the perfect fit.

[@AxeGodMusic]

We found him. The last known man to wear a wrist watch. :)

[@kristopherhasenbuhler5393]

most soldiers in basic training wear a watch! still a funny comment though😂

[@robbieallen899]

Axe Music Ironworkers still have them cause if u carry your phone at work it won't last long.

[@derekhansen6652]

I had this same minibike years ago and the factory jack shaft is junk... I ended up flipping the clutch 180 and running the chain direct. it was slow off the line but it went at least 70mph

[@SurviventheOnslaught]

bullshit it wont go 70

[@MarcelsWorkshop]

Comet TAV2-Torq-A-Verter, 3/4" Bore 10 Teeth, #40/41. Around $270 in Canada or $200 in the US. You can also find cheaper knock off versions of it too if you want.

[@UnlikelyHero]

Or just buy the Trailmaster MB200 which comes with a torque converter stock and has front and rear suspension so it rides way better than the Baja. It's also about 4" longer so it's a slightly bigger bike overall.

[@blackbandit1355]

The video is 10 years old

[@MarcelsWorkshop]

Stock with governor bypassed top speed was 34mph, once torque converter is on and working right top speed is 44mph.

[@mattandkatchristie2552]

Cool video...i notice in the comments some ppl just gotta spit out the 2cents worth they got lol... great job showing others how to do work themselves

[@MarcelsWorkshop]

@allezsport2010 gives you more bottom end torque and more top end speed. Its like putting an automatic transmission on the bike rather then always being stuck in one gear.

[@MarcelsWorkshop]

you might of bought a torque converter for a 1 inch shaft rather then 3/4 inch. Only thing I can think of is exchange it for the smaller version or if you can't do that you may have to buy a new 3/4 inch driver unit, or see if you can find some sort of adapter to go from 3/4 inch to 1 inch.

[@northerbrewer]

@MarcelsWorkshop Its a lot of work. But the difference is you get a much stronger system with a lot more grunt. A properly set up and braced 30 series is good for an easy 12 hp enging

[@70carlton]

Hello Marcel I did this job on my Baja Warrior without drilling extra holes between holes and I was able to keep the chain cover by just a slight trim. all you have to do is to flatten the side of the minibike frame tube behind my lower torqueaverter position. Works perfectly looks better and is stronger. let me know if you want a photo. Robert B

[@WillieJ.]

I want a photo

[@MarcelsWorkshop]

@croakar I use an impact wrench to take off the bolt and that gets the bolt out without turning the engine.

[@MarcelsWorkshop]

its 3/4 inch. the difference is the size of the shaft on the motor. yours will likely be 3/4inch. 4-8hp engines are usually a 3/4 inch shafts, less then 4hp is usually a 5/8 inch shaft and more then 8hp is usually a 1 inch shaft.

[@wickdogs01]

I recently got the Massimo MB200 and got the 1002B TC2 Torque Converter, from GoKartUSA which claimed to fit for all MB200 models. Anyone know if this will actually work?

[@MarcelsWorkshop]

But when I first added the torque converter to the original bike the governor wasn't bypassed and if I remember correctly, top speed was pretty much the same, it just took longer to get there and didn't launch as hard.

[@MarcelsWorkshop]

Too busy with school and stuff right now to make new videos, but you can get cheap key switches that you would cut the wire from the stock switch and then attach that wire to one end of the key switch then the other end of the key switch to a ground and now it won't start unless there's a key in the key switch and its in on position. Although this wouldn't be good for anti theft if that's what your trying to prevent because then they could just disconnect the ground and it would start. :P

[@MarcelsWorkshop]

NP. Although if you just want speed and don't mind loosing torque, you could always just remove the gear reduction system and attach the two chains together so your going straight from clutch to back sprocket. :P

[@bruceschmitz1984]

Nice video very straight forward

[@MarcelsWorkshop]

Thanks!

[@hotrodsho101]

I have my converter kit on!:D omg its the best upgrade you can get for these mini-bikes, I can actually keep up to cars going 80kph...not smart but AWESOME!

[@diontee1380]

This helped a lot

[@MarcelsWorkshop]

Good to hear!

[@MarcelsWorkshop]

no idea. :P if it broke off you may have to get a new unit, or Macgyver something, or just remove the whole unit and connect the 2 chains, that would gain you lots of speed but you would loose lots of torque. :P

[@MarcelsWorkshop]

Translate says "A good chain replaced the rubber crap? Why?" So I'm guess it means why replace the chain with rubber? If so, because the chain and clutch is single speed, the torque converter is variable speed, so more power + more speed. Also the centrifugal clutch the chain is connected to slips way easier then the torque converter does when it comes to climbing.

[@MarcelsWorkshop]

Definitely! The difference feel like you put on an engine twice the size. :D

[@MarcelsWorkshop]

"But its the one you have is the best you have?" hmm not quite sure what your asking. :P Ya if you've never rode before I'd keep it stock until your completely used to it, then from there I would bypass the governor to give you more speed and get used to that. Then once you get board of that go with the torque converter for even more power and speed.

[@MarcelsWorkshop]

@SuperConfederateMan Thanks! :D Apparently there's one gokartsusa sells, that was mentioned a couple comments down, that mounts right up with no mods needed. I've never used one of those ones before so I don't know anything about it, but it might be something to look into.

[@MarcelsWorkshop]

I have no idea sorry. I just have a pile of bolts and try em all until one fits. :P You may be able to find out if you look up a spec sheet on your engine?

[@MarcelsWorkshop]

@KiidJerkk323 can't remember, sorry. :P Did it a long time ago and Bikes at home and I am away for school so I can't check. :P I'm sure you could probably find the size online somewhere if you do a search for it.

[@MarcelsWorkshop]

I use the Comet 203589 belts or the equivalent by a couple other manufacturers. I usually get them from ebay stores.

[@MarcelsWorkshop]

No, should be fine. As long as you not stuck somewhere and just keep holding the gas and the tires aren't even spinning. :P A torque converter is a lot better then a centrifugal clutch for off roading.

[@PsychicX720]

I'm pretty sure that this is "leafy is here" (KZbin channel) but he secretly works on bikes

[@familysalamiabiola3998]

Pls were can I get a racing clutch to buy

[@familysalamiabiola3998]

Pls. Send me ur contact number

[@PSher28]

This helped so much, thank you for putting this video up

[@MarcelsWorkshop]

nah its a sealed slot, its solid a little ways down into it.

[@MarcelsWorkshop]

@XB0XFR34K Probably wouldn't be much slower, just wouldn't accelerate as fast. When the clutch is in its high gear the engine doesn't really have enough power to push much past the governed rpm if everything else is stock on it. My guess would be around 60km/h.

[@MarcelsWorkshop]

@ShityDurPirate like the sprocket things the belt sits in or the sprockets the chain sits on? The back plates of the belt sprockets should line up and same with the chain sprockets or you may get premature wear and not be getting the speed out of it that you could.

[@MarcelsWorkshop]

Ya I guess you could just cut the chain guard if you want to keep it. I just didn't care for it much so It was just easier to get rid of it altogether. Glad you got it to work with the original holes though. :D Although I'm not sure if I would want to start bending parts of the bikes frame because it might cause a weak spot. :P But who knows, I guess only time will tell, chances are it will be fine.

[@giovannichavez455]

What were to happen if you connect a centrifugal clutch straight to back sprocket wheel how come all setups have 2 chains instead one directly to the rear wheel

[@pancudowny]

I can see two advantages to this mod: The improved top-speed & improved low-speed (engine AND wheel wise) drivability.

[@MarcelsWorkshop]

Don't know off hand. I have a ton of bolts so I just keep trying different sizes until I find the match, but have no idea what size that match is. :P

[@gilaspinoytv]

someday i will make one for my kids...i have one convertion

[@vincentchaza8111]

got a HONDA XL 500cc,oil scrapper rings cooked,cam shaft lobes worn down bt could start wth lots of smoke.got it for USD$250.Piston still okay in bore(no play/slap).hw can I get piston kit std/next stage i.e. 10

[@nathanbowden745]

The only problem about bypassing the governor is that the motor would wear out faster. I would get a 6.5 hp 212cc at harbor freight and get a torque converter it would go bout 50 or 60 mphs. Also another why to make it go faster is to heavier valves

[@MarcelsWorkshop]

I've bypassed the governor in everything I own and haven't had an engine die on me yet.. :P (*knock on wood*)

[@nathanbowden745]

Yea bypassing the governor inst to bad, but taking off the governor completely is a death wish for the motor

[@noheart4334]

Where can I buy Parts from I have a Frame and I wanted to do a Build Up before my Birthday any advice any Onlines Shops I could visit?

[@MarcelsWorkshop]

@islandminisunlimited actually do you know what, I just remembered what I did with it. I put it on my old mini baja that I pulled the torque converter off of, because the one that was originally on that one I cut up and converted to a chain guard when I converted my baja dirt runner 49cc to a 6.5hp mini bike. I want to keep the old mini baja operational so I guess I cant sell the part. :P sorry :(

[@thatcrazycat11168]

ive added 3 clutch spacers ( thin washers ) and im still just a bit off, its damn near shredded the whole belt. it seems like when it supposed to have tighten and take off, sometimes it dosent grab and then when it does i dont get the most torque because the belts not riding right, then when its supposed to switch to " overdrive " the belt isint alligned so the driver wont close all the way and the driven wont open, so my top end lacks. i have to get a comet belt and get this sorted out

[@Mr_Tecumseh]

Why is a torque converter better than a clutch, particularly on these bikes? My stock baja can get up over anything and thru just about anything where 4 wheeler's get stuck and the bike is so agile it smokes 4 wheeler's in the woods. So from a terrain stand point these bikes are nearly unstoppable as they are. Would a belt driven torque converter be as good in that situation or would it make the bike less capable in the woods. Is the torque converter for more speed, not off road terrain? Because these bikes are awesome off road. I am honestly asking because I don't know. Let me know what advantages you get from a torque converter and any disadvantages too removing the chain driven clutch and switch to a torque converter. Thank's Okay after doing some research on the topic, the major advantage is speed, their is a disadvantage. If you use your bike off road primarily where 25 mph is enough speed, their is a tendency to wear those belts out a lot and have to keep replacing them. You also loose some traction that a chain powered clutch gives. So for me I would not want a torque converter because I use my bike out on trails with inclines and declines and mud. If you are using these on flat surfaces and on roadways where its clear a torque converter would be the way to go...

[@MarcelsWorkshop]

wow that sounds like it's going to take forever.. but it'll be pretty epic when its all done! :D

[@Nextgeneration57]

@MarcelsWorshop i have a mini baja and i guess it a older year because my clutch just doesn't come off if you pull it off you have to take off a pin, so when i got the clutch off their was a part that stayed on the shaft , so i cant take off the plate where the chains connect because i want to get in the engine because it been sitting for awhile

[@TheEdiphone]

i guess i missed the rear oil plug behind the torque converter install but its easier to get in w/o all that on the bike mine has 3 but i omitted ALL that and went clutch to wheel all ya do is flip clutch over align wheel lengthen chain n wala i was hangin with 450 yamaha flyin bout 75 80 mph may need to balance wheels also but it was scary fast not for inexperienced rider for sure good luck im on my 2nd one 5 clutches 4 motors a wad o chain n sweat blood foul language but was worth every bit of it later

[@MarcelsWorkshop]

Doing that you definitely gain more speed but you loose all your bottom end torque. :P

[@TheEdiphone]

so true but she is fast and also exstremely hard on chains sprockets clutch ect but removes the bulldozer feel of the drive section and pushing her is soooooo much easier whenst spacing of the fuel tank or other oopsies and no disrespect I know how it goes as to unexpected trials along the way a 15 to 50 ratio would help ease the torque n wear but im using 10 to 50 n I push her up the hills but on the flats shes a beast near 70 mph or more depending on wind spark fuel ect n I put gocart motor instead of back faceing head designed motor she has n it was a BIG gain in fun to ride n ill keep feedin the chain to her till she blows n do it again ha ha thanx

[@MarcelsWorkshop]

edwin nelson If that's what you like then power to ya! :D

[@MarcelsWorkshop]

Thanks! I've never seen the baja heat model so I have no idea. :P The torque converter comes with everything you need if you get the actual Comet torque converter kit. Not sure about the knockoff kits. If you look on my channel under How to and assembly videos, I have a un-boxing video of a brand new comet torque converter kit that shows you everything that comes with it. :D

[@MarcelsWorkshop]

I got mine at a Princess Auto. But in the US I think you can get them online at gokarts usa or mfg supply.

[@Outlaw-Josey-Wales]

I went with a smaller rear sprocket before with out changing the drive and eliminated the gov I also upgraded to a taller rear tire and made 68 mph

[@kylebaja3264]

I have a mini baja and the shaft on the back sprocket just like wore out and it doesnt drive do you know where to buy a whole new stock gear assembly

[@jorgegonzales878]

Very nice bike

[@MarcelsWorkshop]

hmm its probably either the driver and driven pully aren't lined up correctly, your trying to climb steep hills from a stand still causing the belt to slip and burn, or the belt inst on properly? Most likely misaligned, the back plate of both the driver and driven pully should be perfectly aligned, one shouldn't be more forward or back then the other. Give that a check.

[@micflynn1]

I just got one of these and it's throttle and governor assembly is took apart and I have no idea how or where the springs n stuff go, is there any way you could do a good slow film of how all the throttle governor assembly is linked and maybe a diagram in the video?? Would help me a lot! Thanks and I think your videos on "upgrades" are great!

[@MarcelsWorkshop]

again, don't know off hand. I have a ton of bolts so I just keep trying different sizes until I find the match, but have no idea what size that match is. :P

[@MarcelsWorkshop]

A Torque converter will greatly increase your off-roading capabilities! :D The belt system can handle a lot more then the centrifugal clutch system it comes with.

[@cegohmert17]

I’m having problems with my Coleman 200 trying to swap engine up to a 212cc

[@Jack-bv7om]

Would this work on a massimo mb200? I know all the 200cc bikes are pretty much the exact same bikes, but I can’t seem to find any videos for a torque converter on the massimo mb200

[@MarcelsWorkshop]

Depends on how the shaft is set up on the bike. If its just a regular shaft with a threaded screw hole on the inside then yeah. Some have a weird set up though with the threads on the outside and need some sort of lug nut work around to hold it on.

[@MarcelsWorkshop]

I would think they would come with it because that kit is supposed to have everything you need in it.

[@vinom7692]

Great video,you sound like Napoleon Dynamite,Kool!!!!!!!!!

[@delavalmilker]

Two questions/comments: 1) I know a TC helps for speed, but how does it affect slow speed torque? The reason I ask is because I use my bike in situations where I need to go over rough ground, up steep slopes, etc., where I need good torque and not necessarily speed. 2) My Baja Warrior doesn't have the tapped center bolt hole on the crankshaft end. I've heard some people get around this by using a lug nut from an auto Mag wheel. Have you ever heard of doing this?

[@MarcelsWorkshop]

+delavalmilker 1) TC greatly improves low speed torque. It's basicially like putting an automatic transmission on the bike so it will essentially switch to a low gear for climbing or starting then switch to a higher gear when you start to build up some speed. 2) I've seen videos with the lug nut work around for that problem but I have no experience with it myself.

[@MarcelsWorkshop]

Its a kit you buy. It's the "Comet TAV 2 Torque-A-Verter". There's also a knock off version by GTC industries and probably a couple others. I got mine at a local Princess Auto. But you can probably find online retailers that sell them.

[@MarcelsWorkshop]

@gabriel56440 I'd say around 60-75km/h depending on weight, wind direction, road surface, and how well tuned the engine and bike is. :P

[@SonnyGTA]

I actually wanted to see how to take off the clutch and stuff. have a SEVERE oil leak...anyway THANK YOU!

[@juddybatistalamar4866]

SonnyGTA 61thbv kkbjkmjlmm