KX500 shifter kart build

[Polar-Bus]

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 !! 

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.

[outlawqrc]

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

[Polar-Bus]

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

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.

[Magnus]

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 !! 

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

[Polar-Bus]

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 !! 

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

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 ?

[Motorrad]

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 !! 

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

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 ?

[tobys 2 strokes]

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

[Polar-Bus]

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 !

[Polar-Bus]

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.

[Polar-Bus]

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

[sandblaster]

Awesome!
Now lets see some 100+ mph track runs on it 

[USMC 500]

I wanna see a video of that thing in action.....too cool!!

[Polar-Bus]

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 !

[Motorrad]

Oh crap.   How did I miss the post that it was DONE.


sweet!


when Can I take it for a spin?

[Polar-Bus]

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