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    KJ Raycing - Ninja 650 Crosskart Build
    #1
    Junior Member
    Join Date
    Apr 2021
    Location
    Gilbert, AZ
    Posts
    25
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    Actually started this project back in Feb 2021 and it is about done now in June 2022.
    I've gotten a lot of good info off this board during the build, so thought I'd detail my build with some info and photos.

    Donor engine came from a wrecked 2013 Kawasaki Ninja 650. Bike as purchased.
    Build1.jpeg

    Pulled the engine out and mounted on a makeshift stand. Plopped the gas tank on top
    and flipped the stock exhaust 180deg so I could work on the wiring and get the engine
    running on the stand.
    Build2.jpg

    Got rid of a good bit of the extra bike wiring I didn't need. Jumped the kickstand and
    clutch safety switches. Stripped off the emissions gear & added inline jumped resistors
    to emulate the purge and air switching valves.
    Build3.jpeg

    Added an open-element Spectre filter up top on a modified baseplate & mounted the
    intake air temp sensor there. Wiring cleaned up where I could before going in chassis.
    Build4.jpeg
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #2
    Junior Member
    Join Date
    Apr 2021
    Location
    Gilbert, AZ
    Posts
    25
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    Started with KJ Raycing plans and built the chassis jig from 1.5" box tube.
    Build5.jpeg

    Here is the basic chassis all tacked up in the jig. This is mostly 1.5" x 0.095" DOM.
    Build6.jpeg

    Basic chassis out of the jig.
    Build7.jpeg

    Needed to make some 1.25" bends but didn't have that size die. Made short straight &
    curved pieces from 1.5" x 0.120" wall tubing. Sliced them in half and used those pieces in
    my 1.5" die to make the few 1.25" bends I needed. Worked pretty well.
    Build8.jpeg
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #3
    Junior Member
    Join Date
    Apr 2021
    Location
    Gilbert, AZ
    Posts
    25
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    Decided to try building my own pedal box similar to those on the market.
    Lots of time figuring stuff out & making it, but was a fun project.

    Here is the fab in process. Using Wilwood 5/8" masters for brakes. Bought
    their balance bar assembly and used it in my fabbed pedal. Small foot plates
    are Wilwood pieces. Gas pedal piece is homebrew.
    Build9.jpeg

    Trying out a Venhill cable for the clutch actuation. Tried to make throttle
    and clutch linkages with some leverage adjustment.
    Build10.jpeg
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #4
    Duck in a Tux jimmyg's Avatar
    Join Date
    Sep 2016
    Location
    Bendigo AUS
    Posts
    620
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    Mate!!!!

    Out of no where roktoy hits the ground running!

    Keep it coming bud. Lovin it!
    All dressed up and waiting for the beer to arrive.
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #5
    Senior Member
    Join Date
    May 2015
    Location
    Northern California
    Posts
    289
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    Very nice work!
    Dune 500
    YXZ1000R
    Desert kart "Panther" build
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #6
    Junior Member
    Join Date
    Apr 2021
    Location
    Gilbert, AZ
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    Front ends uses a 14" steering rack as KJ Raycing recommends.
    I made extensions to match the tie rod pivot to the a-arm pivot point.
    Build11.jpeg

    Steering shaft uses two u-joints to get to the dash above.
    Build12.jpeg

    Spindles & wheel hubs, discs, etc. are from a Yamaha Raptor 660. A-Arms are
    Raptor pieces, 2 inches wider per side from Alba Racing. Trimmed the disc backing
    plates to bolt up Raptor 700 2-piston calipers (not installed here).
    Build13.jpeg

    Shocks are used Fox coilovers from a Polaris quad.
    Build14.jpeg
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #7
    Junior Member
    Join Date
    Apr 2021
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    Gilbert, AZ
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    After a lot of reading & thought, I decided to go with the Dodge Intrepid wheel hubs
    and homebrew uprights on the rear. I'd seen a lot builds with these from people on here.
    I wanted to use 4 on 156 quad wheels, so turned out adapters for the conversion.
    Build15.jpeg

    Upright for the Intrepid hub.
    Build16.jpeg

    All mounted together. Pivots are 1/2" bolts and Delrin bushings in 1.25" tube.
    Build17.jpeg
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #8
    Duck in a Tux jimmyg's Avatar
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    Sep 2016
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    Bendigo AUS
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    Holly crap! You built all that from scratch?
    All dressed up and waiting for the beer to arrive.
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #9
    Junior Member
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    Apr 2021
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    Gilbert, AZ
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    Quote Originally Posted by jimmyg View Post
    Mate!!!!
    Out of no where roktoy hits the ground running!

    Keep it coming bud. Lovin it!

    Quote Originally Posted by Calibuggy View Post
    Very nice work!
    Quote Originally Posted by jimmyg View Post
    Holly crap! You built all that from scratch?
    Thanks all. Built chassis and a good bit from scratch, along with some various ATV, street bike, auto parts....
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    Re: KJ Raycing - Ninja 650 Crosskart Build
    #10
    Junior Member
    Join Date
    Apr 2021
    Location
    Gilbert, AZ
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    25
    Default
    A had a hard time coming up with a center section I liked, but finally settled on
    something after I saw a post Brian Eddy (thanks again Brian) posted here:

    https://m.facebook.com/groups/414201...n__=%2CO%2CP-R

    These are the major pieces. Using one front Ninja rotor on a machined aluminum adapter ring.
    Ninja rear caliper. Vortex 452A series sprocket with center machined to fit/bolt on VW flange.
    Final assembly bolts are different.
    Build18.jpeg

    Fabbed center section that pivots and has caliper mount.
    Build19.jpeg

    Starting here to mount in chassis. Standard 930 CV for mockup.
    Build20.jpeg

    Another view of the center section being set up in chassis.
    Build21.jpeg





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