A 115CC engine is fast for a go-kart. It should enable the driver to get some good speed. You can also use a 110CC engine.
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ALL you have to do is SUCK your own DICK. haha
The engine probably failed you might as well got to silver-streak-gokart-engine-american-sportworks.aspx they have a kit to replace the defective engine.
3/4 inch steel pipe if making a strong double layer frame.
Depends on what needs to be fixed. Could be $50 or could be $1000. If its a couple of average fixes I would say around $300
The term 100cc and 200cc refers to the displacement (size) of the bike's engine and in turn horsepower. A 100 cubic centemeter bike's engine is half the size of a 200 cc bikes engine. How fast you wanna go? Good luck!