shifter kart build

[Ognib]

I'm an old man. Just turned 70. Been building stuff like this since I was a kid. Can't stop now, still have that fire in my belly.

Wife thinks I'm crazy, but I don't care...she's certainly entitled to her opinion...same as me.
I still get up & go to work every day. I keep the bills all paid on time & she doesn't have to get out & fight the rat race. So, if I want to indulge myself in a bit of good time with my projects...that's just the way it is.

The engine I've bought for the kart is a barn find KZ650 with 5 speed. Been a few years since it last ran.
Everything's all crusty & gummy.
I've got WD40 in the cylinders to loosen it up in there.

Carbs are 32mm Mikuni's. They need to be cleaned & kitted.

Frame will be full tube with a cage.

 

[Bubba_Z]

Your as old as you feel OG. Some days I feel 25 again when building, Truth is I am more than double that
Please post your progress, The people here love a scratch build.


Bubba
My current project : http://www.diygokarts.com/vb/showthread.php?t=36133

 

[Ognib]

Yup, I neeed something like this to keep the juices flowing both physically & mentally. Can't imagine being an old fart & just setting around waiting to croak!

I've checked out your vids & like your approach to different aspects of your build.

 

[Bubba_Z]

Thank you. Check tomorrow night for my test run videos.
Weather = Sunny with a chance of O my god I'm gonna die.

 

[Ognib]

gotta live without fear...dare to be bold!

 

[Ognib]

Get the chain off of the drive sprocket & the engine is ready to lift out of the frame.
However, I'm thinking that I'm going to cut the engine cradle loose as indicated by the blue tape & incorporate it into the design & construction of the cage for the kart. It's well engineered & the engine fits it very nicely.
Save me a bit of design & fab time.

 

[Ognib]

Got my money work done for the week & I've been playing with my toys all day today.
Finished the tear down on the bike. Ready to cut it apart. Still need the rotor & caliper off the front disc brake, but I'll wait till the engines out so I can wrassle it around without help.

Here's what it looks like today.

https://www.youtube.com/watch?v=WXuqgh9nf5A&feature=youtu.be

 

[Flyinhillbilly]

That should be a fun kart. I ride an 81 KZ750 and love it. If there's anything you need advice on pertaining to the engine, just ask as i'm well versed in those.

 

[Ognib]

Ya, should be a blast. I'm excited to actually be getting started on it! I'm still undecided on a couple of things...part of me wants to set it up for asphalt & do the autocross/road race type thing. But then I think it would be cool to take it to the dirt.

I appreciate the offer of engine advice. This one is an 82. I'm well versed in 4 stroke theory, having been inside a bunch of v8's in my time. However this is my first bike engine & I'm sure I'll have questions as to how aggressive a timing curve they'll tolerate, advancing/retarding the cams for best performance, etc.

 

[Ognib]

Sunday. A bit o progress on the buggy.

https://www.youtube.com/watch?v=wcP8WsyDLd8&feature=youtu.be

 

[Flyinhillbilly]

The big thing on those engines is valve adjustment. You have to pull the cams and shim them at the lifters which is a pita, but they are tough as nails.

 

[Ognib]

Do you check valve lash with a feeler gauge like on my old solid lifter chebbys?

 

[Flyinhillbilly]

Yes, just roll the cam until the base circle is over the lifter and check it with a feeler quage. An old Kawasaki dealer mechanic told me to forget the book and set them at .008 across the board. It's worked great for me.

 

[Ognib]

What do you know about the different induction systems that have been used on these engines?
The info on this one indicates that it's Calif. compliant for new 82's...it shows non adjustable for idle air fuel mixture setting.
I'd like maximum tunability for this engine...want as much power out of it as can be produced.
Any suggestions?

 

[Flyinhillbilly]

I turbocharged mine, it was nuts. Anything can be adjusted depending on your skill level. You can adjust the low speed jetting by restricting the idle air bleed. I use small brass set screws and drill them to the size I want. It's a lot if trial and error, but it works good once you get it sorted.
I'd try it as is before changing anything though.

 

[Ognib]

Does yours have the mikunis like on this one? Agreed on get it running stock first.

 

[Flyinhillbilly]

Yes, I built a 4 into 1 intake for it when it was turbo'd, when I wore out the turbo I went back to the mikunis.

 

[Ognib]

Thanks for all the info...mucho appreciated!
This is exciting for me.
First time working with overhead cams & first time dealing with more than 2 carbs...syncing them should be a real trip.
I really like learning new stuff, so I'm a happy camper for a while.

Thinking how to go about building a seat...want to set in it semi reclined like in a F1 car.
Want the overall profile looow & sleek.

 

[Bubba_Z]

"part of me wants to set it up for asphalt & do the autocross/road race type thing. But then I think it would be cool to take it to the dirt."

Looow n sleek sounds like street to me.....have you made the hard choice yet?
Dirt is a whole dif. animal. compare these....extreme examples.
https://www.youtube.com/watch?v=cZGV5fImxDk
vs
https://www.youtube.com/watch?v=ggbLt_qvinM

BTW the second guy is a better builder then driver...Lol.
My little sister could drive better then that !

 

[Ognib]

As I research this project, I'm finding I'm more attracted to the asphalt buggies.
But I don't think drifting is where it's at for me.
Hard to go through a corner really quick when the tires are spinning...I like to feel the G's.

I've studied the James Carroll vids. He builds some really nice stuff!