The First Build - Kawasaki KZ400

[Airious]

Alright, I just finished up posting my intro and putting myself on the map! As I mentioned in my intro this will be my first kart project. Originally the kart had a Kawasaki KZ305, however the engine was seized, so the other day I picked up a KZ400 which will be the new beast to power this mean machine.

I am going to need to do some additional fabrication to the frame for the bigger engine to fit in, otherwise i may be able to move the seat forward to allow for room for the 400 to fit in. At any rate, lets get some pictures posted, and post my to do list and go from there Thanks everyone!

To Do:

-Part Identification of parts needed (seperate thread for this)
-Fabricate front\back engine mounts
-New Carbs
-Exhaust Sealing Ring?
-Electric Start
-Fabricate hand shifter
-New Front Seat
-5 point harness

I am sure that I will find much much more to add to this list, plus whatever recommendations the community has

Now to the pics...

 

[Airious]

Attached

 

[Arkyhunter]

nice buggy more pics please

 

[Airious]

Absolutely It wasn't until I was uploading them that I realized I only had taken 1 picture of the actual buggy

I will get some more tomorrow, I have been waiting on a call back from someone that has an exhaust system and carbs for me, so I am hoping to have it turn over early next week sometime

 

[jman98]

the harness sounds like a good idea. good luck with the build and keepus updated!

 

[Airious]

Update Finally! Drove a good 6 hours today round trip to pick up a scrap KZ400; has everything I need ( except exhaust pipes which I will fabricate ) Taking the family to the zoo today ( well after I sleep lol ) so Wednesday we are going to get started.

Step 1) Sand and clean down the existing frame
Step 2) take as many detailed pics of the kz400 so i can remember where everything goes
Step 3) Strip down the kz400
Step 4) Start the build

My hope is to be by step 4 by this weekend, admittedly sanding and cleaning the buggy will take 90% of the above steps. I am truly hoping this engine will fit on the chassis without needing to extend the rear end, if I do though, guess where I will be posting

More pics of the buggy and the kz400 below (BTW That grass growing tall around it disappoints even me. 10 days and its like I am a lazy man lol)

 

[Airious]

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lol.

 

[mckutzy]

Could you post more pics of the rear axle. I like to see how those car tires were fitted on the axle.

 

[Airious]

I am planning on it, yes, I haven't had a chance to get out to the garage i am working on it in for a few days

 

[J_Walker]

for the exhaust sealing ring..

any auto place has some sort of exhaust gasket material. I think its like some sort of steel cardboard. easy to cut out with a pair of scissors or tin snips.

For the hand shifter, I'm not sure what their called exactly, but I've seen them on YT videos. Their long shifter poles that are maybe a foot or two long, with a lever on the handle.. Pull the lever in, it engages the clutch, push the lever forward [or to an angle of your liking] and it knocks up one gear, let off the clutch. Profit. To down shift, works the same way. from just looking at the diagrams on google images, looks like the KZ400 is a wetclutch, that's good. don't have to worry about clutch abuse all that much! Also looks like the clutch disc are pretty cheap.. just encase you burn it out...