KZ400 Shifter kart project

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Kaptain Krunch

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Well i cut the engine out, but the mosquitos got to me so didnt get much more done. Pictures basically explain themselves. This thing is heavy! there is gonna be a major weight bias when its done.

 

modelengineer

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Hey mate, looks like some good progress.

I wouldn't go with a 3/4" axle. If the sprocket is *RIGHT* up against one of the bearings then a 1" axle would be OK. If the sprocket is in the middle, and the wheels a long way outboard, then I'd go with 1.25" high tensile. That engine will be pumping out some serious power!
 

Kaptain Krunch

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Im using a 1" live axle, but was going to use 3/4 for the jackshaft. I tried to cut a keyway into the piece of 3/4 stuff i had only to find that its toohard forthe
mill to cut, so i will most likely buy a 1" and cut it to size for a jackshaft.
 

Kaptain Krunch

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Hardened steel, the rockwell tester at my tech school isn't working so i cant tell you how hard it is exactly, but hard enough that a carbide bit started to wear down pretty fast just trying to mill .010" off.
 

Kaptain Krunch

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So, not a while lot of progress since i got a cold, but i did so some small stuff. I cleaned out the master cylinder and caliper from the bike, they seem to work so i will most likely use those on the kart. I also picked out a good rotor to use, it was from a sled and had a perfect 1" keyed bore and should work nicely.

I also picked up a drill press today for $60, its in good condition and came with one jig for woodworking, and a table, its a 3/4hp 5 speed Cal-hawk.
 

Kaptain Krunch

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Yea she's got some bulk to her.

Today i got a free section of 1" keyed axle for my jackshaft, my shop teacher just gave it to me!
 

suzukigs550

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hey, great idea man, thanks again for commenting on mine and leading me to this. i got some great ideas from it. just wondering, why did you cut the frame on the bike? was it just to get it out easier or are you going to use the existing motor mounts on the cart. just wondering what to do in mine. looks like its coming along great.
 

Kaptain Krunch

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Yes, i will be using the original motor mounts, and that was one of the main reasons i cut out the engine, the other reason being that it would have been very hard to get out without cutting. Under normal circumstances i would make my own mounts, but we just moved and my shop is very un-organized and i dont even have a bench/vice to work with so making my own mounts would be very painful.

UPDATE
I cant do a whole lot since my angle grinder is dead, but i will be getting a new one hopefully sunday. Before my grinder died i was able to do a little more cutting, i completely took out the original motor mounts and added a few small braces to the frame. I also started to make a muffler at school.

I cut the original mufflers off the headers, and moved them around a bit. I think i'll cut the pipe on the right, and make a Y pipe right there for my muffler.

The engine mounts are cut out, and i added a brace across the bottom frame rail. I will add one more towards the front and at least one more on top.

I also put a few between the frame rails, im hoping to get 2-3 of these total per side.
 

skid20

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starting to take shape! looks good so far!

Are you mounting the engine on the rear of the frame or the side?
 

suzukigs550

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haha, it is extremely hard to get the engine out. good idea. i wasnt that smart when i took the engine out of my gs 550. it sucked. haha. lookin good
 

Kaptain Krunch

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starting to take shape! looks good so far!

Are you mounting the engine on the rear of the frame or the side?

Engine will be behind the seat, I have an electric radiator fan, so i'll hook that up to blow extra air on the engine.
 

lemegacool

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i'm kind of a noob to bike engines but what kind of power can you expect from that engine... like wheel lifting powerful, or just very fast accel powerful... imo it should be able to smoke the tires in 1's right?

i want to build a stupid vehicle (read, barstool or another shopping trolly) with a cb750 engine but everyone is telling me i'm going to die... you party breakers!
 

crazycart

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You will also notice that if you keep the pipes stock you will have more low end power. Considering you don't rejet. Looks good so far
 

modelengineer

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+1 vote for keeping the pipes as-is and rejetting. :roflol:

Its got between 34 and 41hp, and depending on what year it is it could be 400cc or 440cc.

If you can identify it's pic on here then you will have a better idea of its specs
 

Kaptain Krunch

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Yea, roll cage is on the list of things to do.

Crazy, i will be re-jetting it, i may be using a different carb setup in the end actually.

This engine is supposed to put out 36hp stock, i found the specs online, its either a 78 or 79. Im not sure if its got enough power to bring the front end up, but it should definitely roast the tires in 1st. The 100cc shifter kart i had would roast the tires in 1st and 2nd.
 
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