600 gsxr kart

[morepoweranything]

Ok guys new to the forum and ive lurked around here for a while. My real question is what electronics do I need to run the engine I mean in other words what can I strip away from the engine? Its an 06 gsxr 600 fuel Iinjected picked up the bike for 100 $ bill it was layed down and so far all I had to do to get it to run was change clutch cover and fuel pump and the engine only has 2000 miles on it. All help appreciated thanks!!!

 

[firemanjim]

Welcome! Great buy! As far as your question goes, why strip any of it? Utilize all of it, giving your kart lights,blinkers,brake lights, ect.... Thats really the only thing you can do away with, just lighting , IIRC. What kinda kart are you putting it in?
And if you can find another deal like that, let me know..... Thats worth the drive.....

 

[OzFab]

Depending on what you put it in & local laws, it may even be it street legal

 

[machinist@large]

X2 (maybe 3?) Don't hack anything until you figure out just what you want to put that thing into, if for no other reason than the factory wiring will be better than most of any aftermarket stuff you might have to purchase to replace it if you change your mind down the road...

 

[morepoweranything]

Im going homemade frame im using 1 1/2 by 2 inch box tubing with a 1/8 wall I know its a lil more than I need but id rather be safe then sorry. The frame is 6ft long and 28 inches wide also im going with 6x10 wheels for the back and 6x8 for front with prolly a 40 inch 1 1/4 axle. Has anyone ever utilized front brakes off of any type of machine for there kart!! I really am not interested in the lights working or any of that but I am not striping them. Im talking about the automated flap on the exhaust and like the pcv system has some type of electric valve I just wanna tidy up that part of the engine management.

 

[morepoweranything]

I also have a few other carts ive built and i really like driving them they are really simple machines. Also I do alot of small engine work I used to work at a small engine shop would still be doing it but theres no money involved with it in a small town. If yall have any engine questions feel free to ask I am also a welder by trade I work at a train yard so I am not lacking in that department.

 

[firemanjim]

I would suggest hitting up a gixxer forum and askin their opinion as they know them bikes in and out.... Sounds like youre off to a good start. With that kinda power, Id be using some BIG A§§ slicks front and back. Big disc in back and adapt the front brakes from a bigger kart . IIWM, id be doing front and rear suspension and it would have mudding tires in back and M/C tires on aluminum rims up front. The bike tires will let you steer in mud/dirt and grip good on pavement , when set up properly. I know lots of sand rails running that type set up , some are high $$ machines too. And with that much power on tap, donuts will never be a problem regardless what tire you have in back.....

 

[fowler]

Gixxer forum would ba a good idea
If u can get any info our of them

Don't strip a single thing out if it till the engine is running in the frame

A few buggy people have done it

Got a bike with all the manuals studied the wiring diagram
Cut out all the unused wires then pluged the harness back in
And ...
Low & behold he should have taken out the yellow wire with the red strip not the red wire with yellow strip

On mine I just left everything

Mines an 08 off the top of my head even without using the dash I still only have proberbly 6 loose plugs
I just heat shrinked over the ends and tie them off
It looks neat enough

 

[1kk8]

Working on this exact project now.

I've converted to dual front brakes on the kart using custom machined hubs to accept the GSXR style rear rotors and calipers. The rotors had to be machined down a bit for me but this depends ultimately on your wheel size.

Wiring has been fairly straight forward, if you have the full wiring harness. You will no longer need the radiator fan relay, lights or brakes wiring. A PDF of the entire service manual for this bikes can easily be found online. Be careful if you decide to print it - it's a big file!

 

[morepoweranything]

Well what can be removed besides the lights and horn and so forth.

 

[fowler]

U do need a fan relay unless u decide to run flat out everywhere

U must have a radiator of the original bike size or bigger
And u can run a thermo fan off the original thermo fan relay

That oem sensor is mounted in they hermitage houseing
With is the best place for it
It is also tuned to activate the thermo fan at the right temperature

If u are using the original dash then u will have very few olugs left over

Not sure why u are so keen to rip apart the harness

Ever heard the saying
If it ain't broke don't fix it

I can't stress this enough with electronics
Anyone who's diagnosed electrical faults in any thing mechanical will tell u the stupidest little things can agut down a the whole system

The last person who pulled that plug put a but too much force on it and damaged one wire
Still has continuity but it's got double the ohms now
Now it's throwing strange signals around and the whole thing won't start

If it ain't broke don't fix if

 

[Scout]

I wouldn't strip anything off of it, if it has an electronic speedo (most do now) gear it to match what the bike was and mount the speedo on the kart.

I'd figure out how to mount the nose to the kart and keep the headlights, dash, etc.

 

[firemanjim]

I wouldn't strip anything off of it, if it has an electronic speedo (most do now) gear it to match what the bike was and mount the speedo on the kart.

I'd figure out how to mount the nose to the kart and keep the headlights, dash, etc.

Build a kart around the bike parts...... Strip the bike of all you csn use. Then design your frame using those parts in the design process. Get form and function......

 

[morepoweranything]

Wiring does not scare me just want to omit what I dont need I want to simplify the harness to keep it simple. Where can I find a pdf on the wiring harness? But in respect I totally understand what yall are saying! I am not familiar with that engine and emissions system. Basically what im asking is what can be removed kinda like saying im changing the carb to a holley on a 71 challenger and get rid off all those useless unnecessary vacumn lines.

 

[fowler]

Google the engine type if u are set in this

It's easy enough to work out what to strip

What u must keep

Ensure the brake circuit remains open
An applied brake makes the ecu limit engine power

Endure u use the original clutch lever
Or put a switch on your new clutch
When the clutch is applied the ecu uses a neutral map

Ensure the gear selector is plugged in
There is a differant map for each gear

U must put a 150 ohm resistor in the side stand circuit
If the side stand is down the engine won't run in gear
U can't just cross the wires
The ecu must see resistance in the circuit

It makes sense to use the oem fuel pump
So leave that

In my 08 bike there's a butterfly in the exhaust that closes up at idle to give the bike a bit better scavenging (steady now control your selfs stay on topic) and a bit more punch off the line
That is ecu cobtrolled as well
As my buggy won't drop below 8k during a race I was a coded it wasn't required to reinstall the butterfly in the new headers
But the actuator must be plugged in ithersise it throws a code

Assuming u will use the dash then u must find which 3 plugs are used for that and save them

1 plug on the front of the harness is where the front light harness plugs into

There's a horn plug
I'd leave that and put a horn in for novelty

I'd leave a rear brake light on again for looks and for simplicity with the ecu

There's a plug on the left and right of the end if the harness that does the rear indicators

U will use a thermo fan so leave that circuit

I can't think of anything else off the top of my head
I downloaded a wording diagram for your bike by accident a while ago but I deleted it I think

If I find it I'll post it

Not that I know anything about your skill
But make sure u follow every wire u want to remove right though the diagram
Follow every wire that connects to it
Again not to demean your skill but this is no old charger electronics

So people have had issues with fitting spot lights to the Buffy's
Just flashing the lights and that sudden current draw throughing ecu faults

I'm also not scared by it nor do I find it difficult anymore
But I took a very rapid and steep learning curve undertaking these things

Going from earthmoving and ag gear where there's a sensor for everything and up to 7 ecms ( when the machine won't start because the battery box lid is only half closed)

These little bikes just blow that away

Not trying to scare u off
Just a friendly warning

 

[morepoweranything]

Thanks fowler yeah the butterfly on the exhaust I kinda thought it may have been some type of engine brake or similar in design but the scavenging effect I under stand. I still have the stand switch I was thinking of installing it like a seat switch kinda like a mower in case off roll of or something to that effect! Really the butterfly was what I was looking to omit and its control box. Another ? I have is where can I get a sprocket I heard I can use a 50 series sprocket and I would have to work on the facing of it. How many tooth sprocket would you suggest?

 

[fowler]

The sprocket has everything to do with application

Mine is on a buggy weighting 450kgs and using about a 80 tooth
So I don't know for your

 

[morepoweranything]

Im going go kart with 15" tires at the biggest.

 

[firemanjim]

Man, with the power you at throwing at it, you can get away with a VARIETY of sizes, for tire burning ,stump pulling power, to spinning tire-fire in all the gears...... To be on the "safe" side , go with a high tooth count...... and your bike uses a 520 chain I believe.
O and yes, use the kick stand switch as a safety seat switch. MUST BE IN the seat for it to start. Good idea......

 

[fowler]

I wa going to say the seat switch would piss me off

But of course it still runs with no one in the seat

U just can't have it in gear with no one in the seat
Good idea