[BitOffTooMuch]

Since ive made some decent progress I figured id start a build log. Bought the frame and motor for 350. I knew this would be a challenge, but not this much of a challenge. Either way, im making progress, slowly, but progress.

The frame is a Sun-L 150, the motor im using is a Kawasaki Ninja 500CC

Heres what I started with.Out in the elements for quite some time, thankfully the motor was some what covered.

All right, lets get this sum bxtch taken apart and slow the rust!

Luckily for me, Memphis decided to have a winter and my only time to work on this was after sundown...i think my fingers and toes are still numb, anyhow, layer of rustoleum applied to hopefully halt the rust for now.Color probably isnt final, still undecided on that, but this might due (with touch ups for the bare spots)

All right, few layers and we're looking a bit more presentable.

Now with that taken care of, lets get to the hardest thing ive done in my life lmao...troubleshooting the motor to get it running. I received a TON of help with this from the folks at ex-500 (haybaler,bpe,yorkie,ducatiman, and if i missed anyone PLEASE forgive my forgetfulness)

From the start i knew the carb was going to be a problem, i attempted to give it a shot rebuilding it, but the elements did too much damage, this had to be replaced before anything could begin.

That moment when your refurbed carbs come from ducatiman

Now where the hell do i start, Ive never worked on or even rode a motorcycle. Can't be too much diff than the mower engines im used to right? Haha.....ha..... This is where i start,And if you're like me, it looks like a foreign language.

But guess what, with nights upon nights freezing your butt off and trying to figure things out, you'll learn what it means too!

And im not joking...WEEKS of getting help working on this, ordering new parts, borrowing parts to test, and becoming one with the multimeter and a test light....we have life!

But the work isnt done, valves needed to be adjusted, im surprised the thing started with em out of spec like they were.

Valves done, lets see if she cranks

 

[BitOffTooMuch]

So far Ive replaced/added wiring harness, air box,air filter, PAIR delete kit,fuse junction box,starter solenoid, radiator from Geo Metro

Now lets get on to the fabricating, that i have no idea about.

Hmmm, this aint gon fit!

Have to stretch this swing arm in order for the motor to mount. Stupid me, didnt measure what length was needed to give enough clearance. After 3 weeks of welding when i could, its extended and thankfully it will fit(Thanks denny,madprofessor,and txluke over at diygokarts)

This was the last side i welded, i progressed a LOT compared to my first abomination of welds, still not pretty, but they hold!

And after all the welding, grinding, cutting, slag knocking and sparks flying, she's stretched!

Engine fits,but i'll have to see where on the arm i need to put it. Got a problem with the chain clearance, will brainstorm that once i have a chain to orient and figure out best routing

The orange strap is showing the clearance issue. Need to figure that part out.



To be continued...........

 

[BitOffTooMuch]

Now that I have some what of a little spare time.


Sketchy as hell !

Drilled holes in the original sprocket, mounted the motorcycle sprocket. Not comfy with how close the holes are to the edge of the kart sprocket. But for now ill move on and get started on mounting the motor and finding some shocks.

http://imgur.com/a/xLZZLwL

 

[efusco9796]

Cool project, looking forward to seeing the progress.

 

[haybaler]

Nice! I'm looking forward to the video of you ripping down the trail, big grinning smile on your face, cheers!

 

[BitOffTooMuch]

Not the update I wanted to make,but she's still alive. How does this sound? Seems lower pitched than what I remember. Also, anything I can look into with the hard starting when it makes that sound from starter ?

February 11, 2023

m.youtube.com

 

[yorkie]

sounds like the starter clutch is spinning and only catches by chance. and yeah the idle is to low should be 1100 to 1200 rpm at idle.

 

[BitOffTooMuch]

sounds like the starter clutch is spinning and only catches by chance. and yeah the idle is to low should be 1100 to 1200 rpm at idle.

Ok I'll bump up the idle.

Starter clutch needs maintenance or is it a replace only part?

 

[ducatiman]

Starter clutch needs maintenance or is it a replace only part?

requires a flywheel pull, using a flywheel puller to fully inspect. The 3 "bic pen" springs weaken in time, possible defective weld on the starter gear is a common problem as well. Need to pull, visually inspect, in any event.

 

[BitOffTooMuch]

requires a flywheel pull, using a flywheel puller to fully inspect. The 3 "bic pen" springs weaken in time, possible defective weld on the starter gear is a common problem as well. Need to pull, visually inspect, in any event.

Cool, think I know exactly where my puller is. Thanks y'all

 

[BitOffTooMuch]

requires a flywheel pull, using a flywheel puller to fully inspect. The 3 "bic pen" springs weaken in time, possible defective weld on the starter gear is a common problem as well. Need to pull, visually inspect, in any event.

Found some alarming things inside....

1.Please tell me the motor isnt trashed because of this?

Is there supposed to be something behind this gear to stop that?Theres a washer on the front(2), but nothing was behind the gear(3)

2.

3.

Also two of my bic springs were bent. Are these something i can find at a hardware or automotive store?

4.

Come too far to end up with a trashed motor lol.

 

[ducatiman]

I'd say the bent springs are clearly your issue here. Kaw p/n 92081-110 at just $2.90 each brand new from Kaw. Don't know what, if anything, that could be subbed.
I'd opt to replace all 3 with brand spankin' new. No, partsbook shows nothing behind starter gear.

 

[ducatiman]

I'd also suggest to lightly grind, dremel or sandpaper any high spots on the 2 crankcase areas left affected by the gear.

For clarity...by facetiously using the term "bic" springs.....I was referring to the ink pen as the springs are notorious for bending/deforming.

 

[BitOffTooMuch]

I'd also suggest to lightly grind, dremel or sandpaper any high spots on the 2 crankcase areas left affected by the gear.

For clarity...by facetiously using the term "bic" springs.....I was referring to the ink pen as the springs are notorious for bending/deforming.

Yeah im positve they arent ink pen springs, no other way to describe em. I dont see em online for that cheap.

And ill put the angle grinder away and get my dremel.

Thanks for the help! Ill be a damn motorcycle mechanic by the time this thing is running.

 

[bpe]

I dont see em online for that cheap.

Try Ron Ayers
2006 Kawasaki NINJA 500 (EX500D6F) Starter Motor | Ron Ayers

 

[BitOffTooMuch]

Cool, will get those ordered. Thanks y'all

 

[BitOffTooMuch]

A day before the adult santa claus (postal service) is supposed to arrive my wonderful car decides it doesnt want to crank. So ive been at it a couple hours now trying to remove a starter from a civic. And this is the most pain in the ass thing ive had to do on a car. Ive put 100k miles on it and now it wants to act up.Ill count my blessings. It atleast held on till i got home vs leaving work lol.


Anyhow....just had to rant.

 

[BitOffTooMuch]

Is this slack normal?

February 23, 2023

youtube.com

 

[bpe]

Yeah.

 

[BitOffTooMuch]

Springs replaced. Starter is still whining, catching less now it seems

Is using this an issue?

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