ninja 250 build

newbrian

I am installing a ninja 250 engine in an ezgo st 2+2. When done it will have an air shifter operated by either buttons on the steering wheel or paddle shifters.
I built the engine cradle from scratch and raised the cart 2 inches for better ground clearance. I am using a chain drive instead of the belt drive. This required adding a clutch peddle. The gearing is going to have to be changed to allow reasonable engine speeds at 10mph. The current gearing is 13.5:1. I would like to go with 8 or 5 to 1. I have some pictures but they need re-sized before I can post them. hopefully I will be able to get them up tomorrow. I have modified the stock motorcycle exhaust to fit the cart. It was actually cheap and easy. I bought two 1.25 90 degree emt bends from lowes and they slipped right over the stock ninja exhaust. I then fabricated mounts to attach the mufflers to the rear axle. I mounted the radiator on the front of the cart behind the bumper. It uses 3/4 heater hose and I am hoping 3/4 emt will work for hard line for the cooling system. I have the ninja wiring harness separated and labeled ready for install and modification in the cart. After an 8 hour day tomorrow I hope to have the throttle, clutch and choke cables made and installed along with a finished cooling system.

BGW

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newbrian

I tried to post a link to my photobucket pics but I have to wait 7 days to post a link according to forum rules. I will post the link in a week.

newbrian

Here is the link to my photo bucket. The cart is operational! I still have a long way to go before it is finished. The gearing is way to low so I will be getting some 6:1 gears soon. I need to get my air box made for the air cleaner for noise and obviously clean air. Then I will work on the air shifter.

http://s1291.photobucket.com/user/ninjacart/slideshow/

rifter

Thats some nice fab work, keep the pics coming

newbrian

Thanks Rifter. I certainly will keep the pics coming. Have you played with any of the limited slip stuff for ezgo. Do they use a different carrier? I wish i could get a mini detroit locker for it.

rifter

I used a Mini Sprint car rear axle, the Golf Cart rear end wouldn't have lasted long.

newbrian

The beast is alive! I had to pull the carbs apart because they sat for 7 years and I never drained the gas. Every circuit was plugged. Finally got that squared away and made an airbox for the carbs and will attach a K&N air filter to it. I decided I am going to use the ninja 250 rotors and calipers for brakes. I will have to get another set but they are cheap on ebay. I will use a wilwood master cylinder to actuate them. I was pleasantly surprised by the cooling system. I thought the fan would run non stop but it hardly ever kicks on just cruising around. I was going to make a shroud so it would pull air across the entire radiator but it looks like it will be unnecessary. I will get some more pics this weekend.

TxPowderCoater

looks great, I'm not feeling the homemade ubolts for the axle. That threaded rod stuff is made from pot metal thats softer than runny bird poop.

newbrian

The u bolts are a temporary solution as it is what I had at the time. The tensile strength on them is 7800lbs. I don't like them because they look cheesy. I had a nice set I made out of round stock but they were too short when I lifted it and I ran out of round stock. I will have to get some more round stock and make new ones this winter.

newbrian

I am uploading some more pictures of the ninjacart. I made an air box for the filter to quiet the intake noise down. I modified a chain tensioner to work with my setup. The air shifter is coming along. I painted the air tank to look like a nitrous bottle and bought a Nos sticker for it. I am hoping to get the high speed gears in it before winter but I am in the process of moving which is going to kill working on the cart. I will have to get a video to post soon.