KAWASAKI ZX6R in a CLUB CAR CARRY ALL

tbirder

Hey there everyone,
I guess it's time to jump in here and start sharing my Carry All build.
I've always wanted to drop a bike engine in a golf cart, but had second thoughts about handling and safety. I've had a lifted Yamaha for years and even after adding heavier suspension, at speed (especially with people on the rear) it felt like you were riding on a "beach ball". There was no way I was going to do a swap in a cart like that.
But along comes my Carry All. It rode like a tank, but with the longer wheel base, heavier suspension and hydraulic brakes I thought it was the right candidate for a bike engine.
So here goes!

For those of you that missed my post on the re building of the body and seat set up, here's just a few shots of that.

HERE'S WHERE WE STARTED

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NEXT TRICK IS TO FIT THIS ENGINE IN THE CARY ALL.
THIS THING WAS OVER 33" TALL WITH THE STOCK AIR BOX.

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HAD TO COME UP WITH A WAY TO SHAVE MANY INCHES OFF THE TOP, SO AGAINST MUCH ADVICE FROM A COUPLE OF THE NINJA FORUMS, I DECIDED TO REBUILD THE AIRBOX/SECONDARY INJECTOR LOCATION.

BGW

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deerhunter30

That is going to be nasty when your done, thanks for sharing.

tbirder

Hey there,
I sure hope so. I put a ton of thought and twice as much work so far! I think once I get all the bugs worked out, it'll be a lot of fun.
And having a clutch and a shifter, that ought to eliminate about 90% of those people that "wanna drive it" too!

smallblock450sl

Nice job on the Carryall How do you plan to run the chain to the transaxle? Jackshaft?

tbirder

Hey there,
Yep, that's it exactly!
Plan "A" is a chain driven jackshaft.
But I'm going to complicate things by doing away with the conventional style of mounting the new engine to the transaxle like the stock set up.
I think that adds a ton of "unsprung weight" to the rear end, and slows the rear suspension reaction time.
So I'm going to move the engine as far forward as possible and mount it directly to the Carry All frame instead of the transaxle. I'm hoping a good spring loaded idler sprocket will take care of the slack needed between the engine and the jackshaft to allow the rear end to travel up and down
.

smallblock450sl

If it turns out as well as your stock Carryall build, I'm shure it will be great. Might check out "the fristers" build, seems he had some issues with the jackshaft set up. Alway's better to learn from others indevures. Please keep us posted on the build

tbirder

Hey smallblock,
Thanks for the encouragement. I'm banking on it working the first time. Keeping my fingers crossed won't do any harm either.
And thanks for the point to fristers build too. I just went through his posts and I think I've got my gearing issues whipped.
Plan "A" is just what you said, chain from bike engine to jackshaft, across the back side of the transaxle then from the jackshaft to the transaxle input shaft. I only have to make one sprocket, but that's not an issue.
I have a plan "b" and even a plan "C", but this will be the least expensive....so I hope it works!

tbirder

First on my list of "to do's" is to see if I can shorten the overall installed height of the engine. Stock is about 33" and I have about 22" to work with.
I joined a couple Ninja forums to ask if anyone had ever messed with the intake system's on their bikes. Stuff like changing angles and distances from injectors to valves????
It was a resounding NO, and I got 20 warnings about the terrible things that would happen if I tried it....so I tried it.

STRIPPED THE OLD AIRBOX OF THE STUFF I NEEDED.



THEN I TOOK A PIECE OF ALUMINUM BOX TUBING, CUT IT TO WIDTH AND LENGTH. THEN CUT OUT THE HOLES FOR THE THROTTLE BODY BOOTS AND SECONDARY INJECTORS. DRILLED AND TAPED FOR VACUUM AND DRAIN LINES.

tbirder

Even though I shaved a bunch of height off the Airbox it self, the biggest gain came in building little aluminum extension runners and leaning the throttle bodies back at about a 60 degree angle. This was the part that the Ninja forum guys said would mess it all up to where it wouldn't run.
I bought pre bent aluminum elbows, cut them to length, rolled a bead on each end to clamp to and stuck it all together for a test fire on the shop floor.

I'VE ALREADY CUT ONE END OFF AND ROLLED THE BEADS HERE.





RUNNERS ALL DONE AND READY TO INSTALL.



HERE THEY ARE INSTALLED AND READY TO FIT THE AIRBOX.



AIRBOX INSTALLED AND SEEMS TO FIT OK.

bokeasmowl

Sweet....man you got skills.