KJ Raycing - Ninja 650 Crosskart Build

[roktoy]

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

[roktoy]

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.
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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

[roktoy]

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

[jimmyg]

Mate!!!!

Out of no where roktoy hits the ground running!

Keep it coming bud. Lovin it!

[Calibuggy]

Very nice work!

[roktoy]

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

[roktoy]

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

[jimmyg]

Holly crap! You built all that from scratch?

[roktoy]

Mate!!!!
Out of no where roktoy hits the ground running!

Keep it coming bud. Lovin it!

Very nice work!

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....

[roktoy]

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