My 27hp Kawasaki Workhorse from start to finish

Xtreme Cartz · 12-26-2007, 02:21 PM

These are a few pictures of my Workhorse buggy build from start to finish.

It started out bone stock when I bought it about 5 years ago. I then slowly added upgrades to it a little bit at a time, first with a lift kit from BU and eventually the 25" mudlite tires. I drove this cart everywhere and used it for all kinds of work. Last winter I bought another EZGO to fix up and stripped parts off the workhorse to use on the other cart. This summer I came across the 27hp Kawasaki engine on ebay and grabbed it right away for the Workhorse. Since then I totally rebuilt the workhorse literally from the frame up.

Starting the tear down and the old engine removed.

Everything completely stripped off of the frame. Primed and ready to paint.

Engine arrive, even bigger than I had hoped for. :o B)

Now a rolling chassis, painted frame and with the rear end installed as well as a new 7" Big Buggies Lift kit and 26" ITP Mudlites on 12" ITP polished aluminum wheels.

Preparing motor mount for the 27hp Kawasaki. I had to cut out the plate and weld in a new one moved back a few inches.

Welds look like crap in the pictures. :newlaugh: They aren't really that bad looking in real life.

Getting ready to drop the motor mount and engine in.

Engine with Comet 1190 clutch installed

Test fitting. I was grinding near the exhaust, thats the reason for the paper towels shoved up the pipes. :bigthumbup:

Xtreme Cartz · 12-26-2007, 02:23 PM

There is a big jump in progress from the last picture to now. Unfortunately, I didn't have a camera handy when all the other work was done.

Mostly finished just need to add a few more last minute things.

Head lights, tail lights and soon to be added turn signals. Will be street legal in Georgia.

Chrome brush gaurd in front, polished diamond plate rockers. New two-tone seat assembly.

26" ITP Mudlite tires, 12" ITP Polished Aluminum Wheels

Painted the entire bed with Duplicolor spray on bed liner. Still working on the tailgate in this pic but it is now finished and installed.

Grant racing steering wheel.

Custom dash with Sunpro gauges (water temp, oil pressure, volt and hour meter) Equus tach soon to be added on the column.

Rubber diamond plate floor, custom grill for the radiator.

NO NO NO E-Z-GO! · 12-26-2007, 02:26 PM

OK, whose cart is that really?

Looks sweeeeet!!!!!!!!!!!!!

Now, we want videos! Jump it!

Xtreme Cartz · 12-26-2007, 02:26 PM

The 750cc water cooled big block Kawasaki engine with APC intake.

Built custom mounts for radiator. Had to mount an electric cooling fan on it in place of the original belt driven one.

Fabbed up some frame reinforcement and added a big a$$ battery to handle all of the electrical accessories.

Custom built exhaust with an Extreme ROL muffler.

Yamaha4life · 12-26-2007, 02:28 PM

Holy crap that thing is NICE! Such a big difference from the beginning!!!

slim67 · 12-26-2007, 02:55 PM

littlefuzz · 12-26-2007, 03:18 PM

Sweeet, that's a kick *** ride!

TheNewGuy · 12-26-2007, 03:20 PM

Xtreme ly nice work!!!!! Looks Great!!!

I would love to hear it cranked up!!

groundpounder · 12-26-2007, 05:45 PM

nice job looks awsome

club car man · 12-26-2007, 07:10 PM

Looks AWESOME!!! 8-)

12-26-2007, 02:21 PM	#1
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	My 27hp Kawasaki Workhorse from start to finish These are a few pictures of my Workhorse buggy build from start to finish. It started out bone stock when I bought it about 5 years ago. I then slowly added upgrades to it a little bit at a time, first with a lift kit from BU and eventually the 25" mudlite tires. I drove this cart everywhere and used it for all kinds of work. Last winter I bought another EZGO to fix up and stripped parts off the workhorse to use on the other cart. This summer I came across the 27hp Kawasaki engine on ebay and grabbed it right away for the Workhorse. Since then I totally rebuilt the workhorse literally from the frame up. Starting the tear down and the old engine removed. Everything completely stripped off of the frame. Primed and ready to paint. Engine arrive, even bigger than I had hoped for. :o B) Now a rolling chassis, painted frame and with the rear end installed as well as a new 7" Big Buggies Lift kit and 26" ITP Mudlites on 12" ITP polished aluminum wheels. Preparing motor mount for the 27hp Kawasaki. I had to cut out the plate and weld in a new one moved back a few inches. Welds look like crap in the pictures. :newlaugh: They aren't really that bad looking in real life. Getting ready to drop the motor mount and engine in. Engine with Comet 1190 clutch installed Test fitting. I was grinding near the exhaust, thats the reason for the paper towels shoved up the pipes. :bigthumbup:

12-26-2007, 02:23 PM	#2
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: My 27hp Kawasaki Workhorse from start to finish There is a big jump in progress from the last picture to now. Unfortunately, I didn't have a camera handy when all the other work was done. Mostly finished just need to add a few more last minute things. Head lights, tail lights and soon to be added turn signals. Will be street legal in Georgia. Chrome brush gaurd in front, polished diamond plate rockers. New two-tone seat assembly. 26" ITP Mudlite tires, 12" ITP Polished Aluminum Wheels Painted the entire bed with Duplicolor spray on bed liner. Still working on the tailgate in this pic but it is now finished and installed. Grant racing steering wheel. Custom dash with Sunpro gauges (water temp, oil pressure, volt and hour meter) Equus tach soon to be added on the column. Rubber diamond plate floor, custom grill for the radiator.

12-26-2007, 02:26 PM	#3
NO NO NO E-Z-GO! Gone Wild Join Date: Dec 2006 Location: ComplainAboutNoNo'sProfile-Ville Posts: 4,995	Re: My 27hp Kawasaki Workhorse from start to finish OK, whose cart is that really? Looks sweeeeet!!!!!!!!!!!!! Now, we want videos! Jump it!

12-26-2007, 02:26 PM	#4
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: My 27hp Kawasaki Workhorse from start to finish The 750cc water cooled big block Kawasaki engine with APC intake. Built custom mounts for radiator. Had to mount an electric cooling fan on it in place of the original belt driven one. Fabbed up some frame reinforcement and added a big a$$ battery to handle all of the electrical accessories. Custom built exhaust with an Extreme ROL muffler.

12-26-2007, 02:28 PM	#5
Yamaha4life The Overposter! Join Date: Nov 2007 Location: Dixie Posts: 1,586	Re: My 27hp Kawasaki Workhorse from start to finish Holy crap that thing is NICE! Such a big difference from the beginning!!!

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

12-26-2007, 02:55 PM	#6
slim67 Gone Wild Join Date: Oct 2007 Posts: 470	Re: My 27hp Kawasaki Workhorse from start to finish wow!
slim67 Gone Wild Join Date: Oct 2007 Posts: 470

12-26-2007, 03:18 PM	#7
littlefuzz Not Yet Wild Join Date: Dec 2007 Posts: 33	Re: My 27hp Kawasaki Workhorse from start to finish Sweeet, that's a kick *** ride!
littlefuzz Not Yet Wild Join Date: Dec 2007 Posts: 33

12-26-2007, 03:20 PM	#8
TheNewGuy Admin/Moderator Join Date: Dec 2006 Location: Ohio Posts: 18,052	Re: My 27hp Kawasaki Workhorse from start to finish Xtreme ly nice work!!!!! Looks Great!!! I would love to hear it cranked up!!
	Ron PLEASE VISIT Our Sponsors * BGW GEAR The Store The G2 Project * Swing Arm Drop & Repair * Geep1 Project

12-26-2007, 05:45 PM	#9
groundpounder Gone Wild Join Date: Sep 2007 Location: maine Posts: 3,352	Re: My 27hp Kawasaki Workhorse from start to finish nice job looks awsome

12-26-2007, 07:10 PM	#10
club car man Ford Join Date: Dec 2006 Location: New Castle, Pa Posts: 3,437	Re: My 27hp Kawasaki Workhorse from start to finish Looks AWESOME!!! 8-)

Similar Threads
Thread	Forum
What is best way to clean/was original finish	Electric EZGO
Workhorse with a 27hp Kawasaki	Videos
Selling my 27hp Kawasaki engine	Golf Carts and Parts
94 EZGO start to finish	Members Rides