Here to Share My Suzuki TL1000S Powered Go kart

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S1000rrsteve

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This project was started October 2016. After about 2 grand and countless hours of building, she's running, driving, and braking!

I started this project with an old buggy frame and a salvage titled '00 Suzuki TL1000S bike that barely ran. I got the bike running after sending the fuel injectors out to be cleaned. And a throttle body sync. Pulled the motor, stretched the go cart frame, and built motor mounts around the engine. This being the first thing I've ever build, I learned a lot of things the hard way. I used a rear swing arm, axle and rear brakes from a '03 polaris predator 500. Which ran 520 sprockets. I had a 10' long custom braided brake line made to run up to the front brakes, so the two front disc brakes would work and so would the rear at the same time.

Wheel to wheel this thing is 8feet long. I used steel round rod as shifter linkage. Basically used half a handle bar for the shifter. The clutch lever is on the shifter so it's weird getting used to. But you pull in the clutch, then go forward or back. Along with all this, was bypassing some safety switches, I had to extend the wiring harness 5ft so the speedo and gauges would all work and be in sight. I have 3 different sets of tires. So knobbys, 13" Street tires off an old rx7. And some mud tires.

First attempt at driving, the chain snapped. The clip style master link just wouldn't hold. (tried it 3 more times before I went full rivet).
Also bought wheel spacers for widen the back wheels. The supplied bolts weren't strong enough. Lost a wheel in the neighbors field.
Now everything seems to be worked out. Took it for a few long cruised on the back country roads. Even got it up to 75mph with my buddy riding shotgun. The 4point harnesses feel everybit of necessary.

This project was definitely very difficult. Wanted to quit, idk how many times. But here she is. If you guys have any questions or anything, I'd love to talk about it!
 

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S1000rrsteve

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Ebrownie

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That looks pretty awesome! I am in the process of building a kart with a 2 stroke dirt bike engine right now. I was going to use the exact same idea for my clutch/shifter. A pedal seems like it would take up too much space, be too complicated, and take longer to shift.
 
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