Build log "I'll name this buggy later" Sun-L 500cc

BlackThought

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Since ive made some decent progress I figured id start a build log. Bought the frame and motor for 350. I knew this would be a challenge, but not this much of a challenge. Either way, im making progress, slowly, but progress.

The frame is a Sun-L 150, the motor im using is a Kawasaki Ninja 500CC :D:D:D:D:D

Heres what I started with.Out in the elements for quite some time, thankfully the motor was some what covered.





All right, lets get this sum bxtch taken apart and slow the rust!



Luckily for me, Memphis decided to have a winter and my only time to work on this was after sundown...i think my fingers and toes are still numb, anyhow, layer of rustoleum applied to hopefully halt the rust for now.Color probably isnt final, still undecided on that, but this might due (with touch ups for the bare spots)



All right, few layers and we're looking a bit more presentable.





Now with that taken care of, lets get to the hardest thing ive done in my life lmao...troubleshooting the motor to get it running. I received a TON of help with this from the folks at ex-500 (haybaler,bpe,yorkie,ducatiman, and if i missed anyone PLEASE forgive my forgetfulness)

From the start i knew the carb was going to be a problem, i attempted to give it a shot rebuilding it, but the elements did too much damage, this had to be replaced before anything could begin.



That moment when your refurbed carbs come from ducatiman





Now where the hell do i start, Ive never worked on or even rode a motorcycle. Can't be too much diff than the mower engines im used to right? Haha.....ha..... This is where i start,And if you're like me, it looks like a foreign language.

But guess what, with nights upon nights freezing your butt off and trying to figure things out, you'll learn what it means too!









And im not joking...WEEKS of getting help working on this, ordering new parts, borrowing parts to test, and becoming one with the multimeter and a test light....we have life!


But the work isnt done, valves needed to be adjusted, im surprised the thing started with em out of spec like they were.



Valves done, lets see if she cranks

 

BlackThought

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So far Ive replaced/added wiring harness, air box,air filter, PAIR delete kit,fuse junction box,starter solenoid, radiator from Geo Metro :)

Now lets get on to the fabricating, that i have no idea about.

Hmmm, this aint gon fit!



Have to stretch this swing arm in order for the motor to mount. Stupid me, didnt measure what length was needed to give enough clearance. After 3 weeks of welding when i could, its extended and thankfully it will fit(Thanks denny,madprofessor,and txluke over at diygokarts)




This was the last side i welded, i progressed a LOT compared to my first abomination of welds, still not pretty, but they hold!




And after all the welding, grinding, cutting, slag knocking and sparks flying, she's stretched!




Engine fits,but i'll have to see where on the arm i need to put it. Got a problem with the chain clearance, will brainstorm that once i have a chain to orient and figure out best routing




The orange strap is showing the clearance issue. Need to figure that part out.



To be continued...........
 
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Looks good! Can't wait to see this when its all done. What gearing did you go with?
Also, Btw I ran into the same issue as you and ran a 520 idler sprocket so it would clear & a smaller front sprocket helps clearance. It was off a Buell motorcycle if I recall. I also ended up using a half link rather than a tensioner. I still have a tensioner just in case I need it in a pinch though.
 

BlackThought

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Looks good! Can't wait to see this when its all done. What gearing did you go with?
Also, Btw I ran into the same issue as you and ran a 520 idler sprocket so it would clear & a smaller front sprocket helps clearance. It was off a Buell motorcycle if I recall. I also ended up using a half link rather than a tensioner. I still have a tensioner just in case I need it in a pinch though.
Havent thought about gearing, wasnt expecting the clearance issue. What tooth axle sprocket did you go with?
 

BlackThought

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13 tooth from sprocket specialists on the front which helps a decent bit with clearance. Too much smaller and the chain might rub on the outside of the case. Might be able to get away with a 12T. I have a 50t on the rear.
Learned the hard way that chains have a difference. 🤦🏿‍♂️ Stock is 520, the rear on kart is a no go. Waited a week for delivery and now the search continues.
 

BlackThought

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Now that I have some what of a little spare time.

Sketchy as hell !
Drilled holes in the original sprocket, mounted the motorcycle sprocket. Not comfy with how close the holes are to the edge of the kart sprocket. But for now ill move on and get started on mounting the motor and finding some shocks.


 

BlackThought

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Pllhighthhoooouuught..(tongue stick out....spraying spit noise)

It ain't close until you have to weld the washers to the part :p

So...eta....1st drive video,.....covid 21 :unsure:
Busy busy busy. Everyone suddenly needs MY help. Oh well. Im confident i can have it moving by Aug.
 

BlackThought

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Any updates on the build?
I became so frustrated with this damn thing that i stopped working on it months ago. Past 2 weeks im making progress again.What pushed my patience was mounting the engine and chain clearance. what I thought was going to work wasnt no matter how stubborn i was to make it work. Have to mount the motor lower than i wanted and take a new approach.
 

BlackThought

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Mounting the engine low is not a bad thing. It will lower the center of gravity.
Everything lines up much better with it low. WIll still put a chain tensioner on. My reservation is instead of the motor sitting on the frame,im welding so it can sit low. I trust my welds, but id feel more comfortable if it sat on top.
 

Denny

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Everything lines up much better with it low. WIll still put a chain tensioner on. My reservation is instead of the motor sitting on the frame,im welding so it can sit low. I trust my welds, but id feel more comfortable if it sat on top.
Why? On top or in between it is only going to be as strong as the material and welds. The benefits of lowering the engine are many. Lower CG, the engine will push the frame instead of trying to lift it are just 2 off the top of my head. I can’t see a down side if done properly. Can anyone else?
 

BlackThought

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Why? On top or in between it is only going to be as strong as the material and welds. The benefits of lowering the engine are many. Lower CG, the engine will push the frame instead of trying to lift it are just 2 off the top of my head. I can’t see a down side if done properly. Can anyone else?
Doing it properly is the concern. Im new to welding and had better confidence with it sitting on top. Ive cut a few pieces and looked at my weld up close. What i did in the past wasnt the greatest. But now theyre looking good after slicing. Still makes me worry.
 

Denny

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I’ll tell you like I have told others. Take 2 pieces of scrap steel the same dimensions. One piece about 6” the other 12”- 1 foot long and weld them together in an L shape. (Now comes the fun) Secure the long piece in a vice, large boulder, neighbors truck bumper or whatever and wait until about 2:00 am. The start beating the snot out of it like a crazy man with the biggest hammer you own (at least 2#) trying to break that weld. If the material bends or tears your golden. If the weld breaks go back and practice some more! That’s how an old time welder taught me.
On second thought, you may not want to follow what I did exactly. The cops get mad when all your neighbors call them. Even if your 9 years old and the cop is your best friends dad. On another thought, better not use the neighbors truck bumper either. They won’t like you when your done. There’s probably some other things you should not do but my thumb is getting tired from typing. You’ll figure it out. Man I had fun as a kid! Neighbors, not so much!
 

madprofessor

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I’ll tell you like I have told others.
So will I here. After doing the above, get 2 scrap pieces of differing thicknesses, like a piece of stiff sheetmetal and a piece of heavy angle iron. Lay the angle iron on the sheetmetal and clamp together. Practice starting your arc near the edge on the heavy metal, getting a puddle started, and expand it to the sheetmetal, back and forth. Purposely blow some holes in the sheetmetal by staying on it too long as you experiment, learn what it takes to make a puddle that's melted to both pieces for a solid bridge. It will inform you on many other types of joinery later.
 
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