Author Topic: KX500 shifter kart build  (Read 82807 times)

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Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #75 on: August 04, 2012, 11:50:34 PM »
Well failure #1 is the option of kickstart method. There simply isn't enough arc stroke of the kick lever to adequately turn the engine over. Even with the kick lever re-positioned as far forward as I can attach it, the lever contacts the rear drive axle prematurely. DAMMIT !!  :x

Now I have to explore push starting. "Human" push starting a 125cc kart is a breeze, but i am realizing now there is a TON of compression resistance factored in to the overall 500cc kart chassis (thank GOD I had Larry W do the comp release mod) .  I might have to fabricate a custom rear "push bar" and use my truck to push start the kart.
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Offline outlawqrc

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Re: KX500 shifter kart build
« Reply #76 on: August 27, 2012, 06:40:49 PM »
I have push started our outlaw kart once before, but it has a cage to push on, i don't think it would be an easy feat to accomplish pushing a flat kart. Would be extremely hard on the drivers shoulders and hard to stay in the seat, at the track everyone uses a 4 wheeler, i think using a truck would be a little dangerous if the kart got crossed up it does happen every once in awhile. any how good luck :-D

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #77 on: August 27, 2012, 09:48:01 PM »
i think using a truck would be a little dangerous if the kart got crossed up it does happen every once in awhile. any how good luck :-D

Yea, i though long and hard of the danger of vehicle pushing. The driver of the push vehicle won't be able to see the kart. I was thinking of a tall ATV orange whip flag bolted to the kart as a guide, but still a dangerous scenario. I might have to call in some favors and borrow a buddies'  utility ATV if I can't "human" push start my kart.
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Offline Magnus

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Re: KX500 shifter kart build
« Reply #78 on: August 28, 2012, 10:56:09 AM »
Well failure #1 is the option of kickstart method. There simply isn't enough arc stroke of the kick lever to adequately turn the engine over. Even with the kick lever re-positioned as far forward as I can attach it, the lever contacts the rear drive axle prematurely. DAMMIT !!  :x

How about making an extension for the kick shaft and a bracket with a bearing so you could have the kick start on the side of the kart?

Really cool kart btw, looks like the engine just grew a little bit :-D

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #79 on: August 29, 2012, 07:46:31 AM »
Well failure #1 is the option of kickstart method. There simply isn't enough arc stroke of the kick lever to adequately turn the engine over. Even with the kick lever re-positioned as far forward as I can attach it, the lever contacts the rear drive axle prematurely. DAMMIT !!  :x

How about making an extension for the kick shaft and a bracket with a bearing so you could have the kick start on the side of the kart?

Really cool kart btw, looks like the engine just grew a little bit :-D


Yea, I kinda thought of this modification too, I need about another 1.5" of shaft length  to effectlively clear the kick lever from hitting the end of the rear axle. My issue is how do I find a "female" type spline extension that matches the KX500's kick shaft spline ?
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Motorrad

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Re: KX500 shifter kart build
« Reply #80 on: August 29, 2012, 08:28:51 AM »
You don't
You buy another shaft.  And weld them together


Well failure #1 is the option of kickstart method. There simply isn't enough arc stroke of the kick lever to adequately turn the engine over. Even with the kick lever re-positioned as far forward as I can attach it, the lever contacts the rear drive axle prematurely. DAMMIT !!  :x

How about making an extension for the kick shaft and a bracket with a bearing so you could have the kick start on the side of the kart?

Really cool kart btw, looks like the engine just grew a little bit :-D


Yea, I kinda thought of this modification too, I need about another 1.5" of shaft length  to effectlively clear the kick lever from hitting the end of the rear axle. My issue is how do I find a "female" type spline extension that matches the KX500's kick shaft spline ?

Offline tobys 2 strokes

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Re: KX500 shifter kart build
« Reply #81 on: August 29, 2012, 08:31:45 AM »
if you scroll down you can see how I made my extended kicker I have ran it for 3 or 4 years with no problem and its got to be in the neigbor hood of 15 to 1 copression I cant kick it with out the compression release.

http://www.kawieriders.com/forum/kawasaki-tecate/80294-tobys-kfx500-making.html
« Last Edit: August 29, 2012, 09:00:20 AM by tobys 2 strokes »

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #82 on: August 29, 2012, 09:27:50 AM »
if you scroll down you can see how I made my extended kicker I have ran it for 3 or 4 years with no problem and its got to be in the neigbor hood of 15 to 1 copression I cant kick it with out the compression release.

http://www.kawieriders.com/forum/kawasaki-tecate/80294-tobys-kfx500-making.html

Nice job ! Now I have some fresh ideas, love the mental talent on this site !
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #83 on: February 04, 2013, 09:38:26 PM »
Well, i'm back at the Kartzilla project, and i've all but scrapped the manual kick start method. My next attempt is a 12V remote start system that runs off the flywheel. This method is used to start drag bikes, and hillclimber alcohol bikes.  I think I can make this work, as long as the starter I chose has enough torque to spin the beast over. I got a lightweight gear reduction Toyota starter. I modified the gear bendix to be fully extended all the time, and welded a 7/8 deep socket on the end of the starter gear. The next step is to fabricate a mount plate with a couple of handles.





01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #84 on: March 04, 2013, 01:24:24 PM »
Well, after continuous and aggravating setbacks with the electric outboard starter I just went back to basics, and fabricated an extended kick shaft, and cut come length off the rear axle. And FINALLY :  

http://www.youtube.com/watch?v=NKt-EWiK7aY
« Last Edit: March 04, 2013, 01:29:44 PM by Polar-Bus »
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Offline sandblaster

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Re: KX500 shifter kart build
« Reply #85 on: March 04, 2013, 01:28:01 PM »
Awesome!
Now lets see some 100+ mph track runs on it  8-)
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline USMC 500

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Re: KX500 shifter kart build
« Reply #86 on: March 04, 2013, 03:52:34 PM »
I wanna see a video of that thing in action.....too cool!! :-o
I once heard my buddy Bill ask Danny Hamel after a race....
"How can someone who looks like a high school band tuba player go so d**n fast on a bike?!"

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #87 on: March 04, 2013, 10:39:09 PM »
The kart is a BITCH to get started, thank the lord for Larry W's comp release mod, there is no way I would be able to get enough leverage on the kick lever stock. You can see I kinda have to kick rearward and down so you can't use your body weight like on a bike. It will just take some time to learn the new precise method of starting. On a side note this kart is gonna VaVaVaVaVibrate pretty badly I can tell !
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart

Motorrad

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Re: KX500 shifter kart build
« Reply #88 on: March 08, 2013, 08:35:10 AM »
Oh crap.   How did I miss the post that it was DONE.


sweet!


when Can I take it for a spin?

Offline Polar-Bus

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Re: KX500 shifter kart build
« Reply #89 on: March 10, 2013, 11:33:22 AM »
When I rev the engine i see fuel dribbling out the overflow hose. The only thing I can think of is my float height is a bit too high. I am going to try and lower it a bit. I hope the engine vibration is not causing the needle to bounce and flood the carb.

Here's a walk around vid :

http://www.youtube.com/watch?feature=endscreen&v=7c0CdkzvcVg&NR=1
« Last Edit: March 10, 2013, 11:36:44 AM by Polar-Bus »
01' KX500
'84 GPz1100
'87 GSX-R  750
'06 HD Fatboy
'73 Kawi H1
'03 CRG KX500 Shifter kart