We're building on offroad shifter kart buggy! The base frame for this new project is a Manco Deuce go kart with a semi-independent rear suspension. For the power plant of this build we will be using a 2001 Kawasaki Ninja 250r Motor, which should have more than enough power and the 6 gears should help us have tons of torque and a decent top speed for this crawler! We used spring assisted shocks in order to allow for a much longer radius of travel within our rear suspension section, we also added a lengthened pan hard bar to allow for less change in our rear alignment as the suspension articulates. For the front suspension we added upper hoops in order to make it have clearance for the front shocks. With the front J-arm suspension dialed in we made mounts for our go power sports rack and pinion system, which gave us plenty of adjustment for suspension travel and dramatically limited bump steer.
Thank you guys for watching and be sure to subscribe to see us finish this thing and rip it!

MUSIC

Music - Background and Montage Music Is From Endemic Sounds
https://www.epidemicsound.com/creator-subscription

MERCH

MERCHANDISE CUSTOM DESIGNED BY YOURS TRULY
https://teespring.com/stores/build-break-repeat
—————PARTS—————
22 x 11-8 Knobby Tire
https://www.gopowersports.com/22-x-11-8-knobby-tire/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Go-Kart Steering Kit Complete
https://www.gopowersports.com/go-kart-steering-kit-complete/?gclid=EAIaIQobChMI7ZSjzt7y5QIVjIzICh22TgAlEAQYASABEgJJr_D_BwE/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
20 x 7-8 Knobby Tire
https://www.gopowersports.com/20-x-7-8-knobby-tire/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Wheels
https://www.gopowersports.com/8-wheel-4-x-4-pattern/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Spring Assisted Shocks - https://www.summitracing.com/parts/gab-43049

Do y'all, like the last name, where we finish up the rear suspension on this thing, so in this one it's gon na make a huge transformation. Those of you who don't know this is our Mako deuce with a ninja, 250 motor and right now we're doing all the long travel suspension discs. So with that being said, we have some awesome. 22 inch tires to the rear and 20 spur up front from go power sports.

These are some of the coolest Tigers, they've gotten from them, and then after we get the rear tires on we're gon na start, making up our front suspension. Wait long travel basically we're gon na make like hoops kind of like a prerunner truck alright. So let's get started with putting the new tires on out with the old, very very flat. You still got some life left and with the new baby.

Actually it works out. Well because our final room design is going to be white kind of the white army, green, look kind of like our first Kart Sputnik, so cool. Now, let's get some shots of this and move on to the front and a plan for the front suspension is. We have the exact same basically coil over Springs to the front.

These are actually just spring-assisted shocks from a car. We're gon na mount them right up about here and we're going to build a hoop that comes off this back section here with that. We're gon na use our pro tool Pro Tools, tubing bender, actually for like the first time project. So that's me really cool and then, after that, we're gon na get to mounting our go power, sports, rack and pinion piece.

All the links to these parts are me in the description, but I guess let's first start by jacking up the front end here and seeing what kind of ride height you want to shoot for fine or ride height a little bit higher we're looking at the front Jams and they're really stiff becoming a hammer on them and probably on with a crowbar they're moving a little bit. We did it the same problem with the Odyssey, so we'll see we been getting the free up and if not, then we'll just take them apart and maybe get some rust out. There move the lot yeah see if it like she's still stuck where he's hitting it. Stop it like an inoperable position, ready, yeah, that's your more fruit! I actually really did.

That was less for good hi. Now we're gon na have to hammer it down how many options yeah she's the same in the repair manual but bird that we're desperate. Now, Oh almost better, oh dang, oh wait! We have it with hacks. Now we're gon na be looking around then two days prior bunch hours into this, but we finally figured it out.

We started to spin it and that was working and it's starting to back off a little bit and I pulled out sledgehammer and started hammering on it and now it's coming out, so we got the camera so we're crossing our fingers. Hopefully, all I have to do is hit this a few times there we go. This is nasty, that's all just metal shavings and crap over years. The bushings are actually in really good shape.

So I think what we're gon na do is clean out the bushings. I don't even need to come out of here sand all the rust off of that, and then we can put it on we're. Gon na have a damn good suspension, hey guys. This is what it should be like.
If I even I don't even know how I was in the factory, but we definitely say in a lot of material off because we prefer looser and if it ever rust a little bit at all we'll be covered on that base. So we did drill the hole here. So what we're going to do now is right now we're going to move on to our suspension, but later we're gon na slide these off and we're gon na put in a grease fitting there, because I think, if there's a healthy amount of grease, that's going to Really prevent some of that rusting that occurred so now we need to do this all over again with that side. My word has gone down since the last time, we're at this point on both of our J arms.

So that is awesome, and what we did is because the Manko deuce has like kind of a different size, bold than like got a lot of go power. Sports stuff and the hub's are kind of old, bearings, worn-out and stuff. We went with our go power sports hubs that sit on five minutes bolts, so all we did was cut Bowlin off, make sure we had the camber correct and all that, and now we have our new hubs along with our new front go-cart sport wheels and tires, And I'll get these bolted up on both sides and we can finally start getting this thing. Suspension worked out ever mocked up the springs right now, just as is Zagreb way too high was don't you put the hoops up, but the spring weight is actually pretty good.

It's more on the stiffer side, but also with our steering we're not going to be able to have too much flex or to move that much. But I mean right here: we have the jack fully extended back tires front tires all on the ground, so it's gon na be really nice and also give us some stability, not having it too floppy up front yeah see some about have about four inches in case We do hit a bump at full compression yeah, and then you can see we're not even close to being maxed out in the front and like the backs. Hardly working. This thing is gon na have a stupid amount of flex.

So I think what we're gon na do now is hit up our Pro Tools, bender and end up someone easy. This is the reason why you upgrade these things are both dead-on 105 degrees perfect, and we have the option to actually bend past like 60, which is what we had before so now. We're going to do is these are just going to fit right up in here. We'll weld them up, we'll just do some quick tacks and then we can test the suspension.

Well, it Foley up yeah. We know good yeah to people yeah, let's see right, yeah, that's a nice see, there's a good dress. Oh actually, like I like the back. I mean less compressing than the bag felt like we have actual here, get up and get back in it.

Okay, thanks everybody, bad thanks, yeah, there's a run here. We got like six, probably at 6 or 7 inches of travel yeah, that's what you can't even roll! It forward a little bit really nicely they're very chalky. Yeah. Listen! That's amazing! Though man cuz like we need to get a flex test of this thing.
Yeah, hey you just a good, probably case you don't okay, see forgot. We got the same way, independent, rear the tires I will say for a bogie this size. The tires are a little on the small side, but big tires just massive gearing and stuff, especially for small stuff, that really it's a good look. I really like it really yeah drying off like a shiny, chippy, the middle yeah.

Let's see the Mack definitely needs more. I think our sister spent 12 hours you the front. I think what happened was now that there's a larger radius and the shocks up right. It's a lot more force sweet, let's get a flex test, i jack is max, so there's still more room to give.

But this is our perfect spring setup guys because we are stuffing in the front and there we have just enough downward flex to where it actually is the tire still on the ground. And this is just ignorant back here for go-kart guys where we start on all the steering stuff. We want to have some closure disease on hoops here. So what i did is i notched up.

Some support bars just for gusting and it's going to look really good. So we're gon na have one here and then one right about here, so we'll get these welded in and then we can finish up our Stern all right. So now we've got our wheel off. The first step is we're gon na cut out the steering, shaft and the braces up front and then start putting in our new student steer right now, we're both enough our go power, sports rack and pinion before we've just used like? U bolts to bolt them in on smaller carts, but because these are 20-inch tires and they're gon na be steering over rocks and stuff.

I went ahead and made up these brackets. That kind of fit right up in here there's a lot of hammer marks and stuff on them, but I'm actually pretty proud of this cuz. I mean it's hard to bend stuff around curves and this stuff is really tight. So what I'm gon na do is I'm going to tighten these bolts and then we can go over to the cart and weld them up.

Okay, here's the rack! All tacked in this is going to be more of like this good. So we got the rack all installed. We change a little bit the steering, so we get a little bit more angle than stock, but everything's looking really good. So now we're just going to test that when we're moving the suspension up and down - and it's flexing that nothing's binding and the rack is enough, like adjustment in it.

So I guess what we're gon na look for is. If, when we jump on the suspension, if the wheels turn it all, it shouldn't really be an issue, because it's a J arm sure when any stealing is to specific bits. Is it I think, there's just the boot bit sticking in it's really close, alright, so yeah? This is what we're doing. The whole steering looks like uh-huh, but now what we did was basically moved it forward a little bit, so it would eliminate some rough bump steer because it's closer to our pivot point of the junior gerron's are just kind of weird cause.
It like moves like this and your steering's here, but we got the best we could and it actually doesn't have very much jump bump steer at all, I'm going to bounce on it and then also, if you look here, our driver side hit at full flex before And now, there's buy-in still an inch of room at full flex, so we're not gon na have any issues there. You can sear it real you're, still staying relatively straight yeah yeah. So what we're gon na do now is we'll take this all apart, weld it up. Finally, it's all good now and then that's gon na wrap up our front suspension, steering bed.

Okay, a ton of work went into this video. This was definitely one of the more complicated things we had to do the deuce, but we have our super awesome records and in steering it's not too heavy or anything. I don't get talking a bump out of our hands and we get ruts and stuff. Our suspension looks awesome with our hoops and stuff and our spring-assisted shocks.

So thank you guys for watching. Thank you. Go power sports all the parts when the steering assemblies from coal power sports and be sure to stay tuned because we're working on getting the ninja engine running in this thing, and it's going to be an absolute blast. You can really see it coming together.

Now that all the suspension is done, so thank you guys for watching see you next time.

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By YTB

30 thoughts on “Kawasaki ninja offroad buggy build pt 2 long travel front suspension and steering”
  1. Avataaar/Circle Created with python_avatars Gerardo peña says:

    Esa es la suspensión de un beetle viejo? Dónde las consiguieron

  2. Avataaar/Circle Created with python_avatars Aaron Farrin says:

    I love ur channel I love the manco deuce think that thing would be sweet with some bigger tires on the back probably go better too

  3. Avataaar/Circle Created with python_avatars Ben says:

    im planing on building a yzf 600r engine swapped chinese go kart(because its newish) any tips?

  4. Avataaar/Circle Created with python_avatars Kimo Armstrong says:

    One like for all that flex. Even if I think triangulated 4-link would have been easier. Your way proved worked great.

  5. Avataaar/Circle Created with python_avatars Scott Szabo says:

    pop the roll pins out and take arms all the way off..clean up the bushings regrease and reassemble..thats what i di to my deuce!

  6. Avataaar/Circle Created with python_avatars LNR Ridez says:

    Any GPS black friday sales codes coming out?

  7. Avataaar/Circle Created with python_avatars Ahmed OBM says:

    What is the type , length and price of the rear and front shocks?

  8. Avataaar/Circle Created with python_avatars Drago Werx says:

    Wow, those shock hoops really changed the look of the front end, that thing looks sweet!

  9. Avataaar/Circle Created with python_avatars Alasdair says:

    Brilliant, I now have a solution to my front suspension dilemma.. J arms! No intrusion into the footwells.
    Cheers.

  10. Avataaar/Circle Created with python_avatars plumberman19 says:

    “Flex” = ARTICULATION in the suspension world.

    That severe lack of rebound on those front shocks will be a problem..

  11. Avataaar/Circle Created with python_avatars Handyman Mark says:

    Really awesome build. I like the way you're keeping it simple. this thing is going to be a blast to drive

  12. Avataaar/Circle Created with python_avatars roguesquatcher says:

    Looked like Ray Charles teaching Stevie Wonder how to drive….

  13. Avataaar/Circle Created with python_avatars Gavin Robins /thewolfdog says:

    You know what's crazy me and my dad are building a Kawasaki ninja 600 dune buggy.

  14. Avataaar/Circle Created with python_avatars Fantaman900 says:

    So car shocks with helper springs means those shocks are valved for a much stronger springs. We can see it stay in place when you jump on it, it will work for crawling but for anything faster you basically got no suspension.

  15. Avataaar/Circle Created with python_avatars Dennis Koop says:

    Electric power steering??? Toyota is a simple and compact setup. Love your builds guys. 👍🏻

  16. Avataaar/Circle Created with python_avatars King Ave Garage says:

    With all that flex. you'll lose traction before flexing all that out.

  17. Avataaar/Circle Created with python_avatars PhatSphinx says:

    Maybe make some collers for the shocks to put some pre tension on the springs, maybe double up some 4 mm ally pipe or summin

  18. Avataaar/Circle Created with python_avatars AryanM3 says:

    Dude this build is sick! That rear suspension/trackbar setup flexes like crazy, similar to a Jeep. We have to get together and film some stuff around cstat sometime👍🏼

  19. Avataaar/Circle Created with python_avatars 99 miles away says:

    Hell yeah guys, that thing is gonna be awesome

  20. Avataaar/Circle Created with python_avatars The Generous Degenerate says:

    You should be giving some thought NOW about rollover protection. ie: toebox, doorbars etc. Just make sure all your bits stay in the cab and stay attached if it takes a tumble. God knows its gonna be quick enough to get in trouble.

  21. Avataaar/Circle Created with python_avatars Kart nerds says:

    Weird flex… But OK. 😆🤣 nah that things awesome!

  22. Avataaar/Circle Created with python_avatars Dan Hambrick says:

    That thing is gonna be a blast to drive… 😁

  23. Avataaar/Circle Created with python_avatars Gary Burbank88 says:

    The Manco Deuce / Manco Dingo Deuce and Manco Silver Fox are actually side by sides Manco Deuce and Manco Dingo Deuce started today's Side by Sides

  24. Avataaar/Circle Created with python_avatars james lewis says:

    Damn I really like you but have you ever seen a standard poodle?¿?

  25. Avataaar/Circle Created with python_avatars Cesar Ruiz says:

    I saw that you guys rebuilt a Honda Odyssey I need to wire up my Honda Odyssey but don't know how to do it I've already looked at the schematic and still can't figure it out

  26. Avataaar/Circle Created with python_avatars Moto Mule says:

    Looking good guys!!! Should be a ton of fun when you get it going!!! Keep it up!

  27. Avataaar/Circle Created with python_avatars Josh Miller says:

    WHAT IS INTRO SONG, I’VE SEARCHED THE LYRICS FOR OVER 30 MINUTES AND FOUND ABSOLUTELY NOTHING

  28. Avataaar/Circle Created with python_avatars Bradley Dunten says:

    To stiffen the front suspension up some you would need to tip the top of your shock forward and move the lower rearward on that style suspension I do believe. Either way it will be sweet just wondering how it would be with 2 people in it?

  29. Avataaar/Circle Created with python_avatars D L says:

    If you drill, tap, and install grease fittings into the j-arms you can loosen them right up with a couple good shots of grease for future reference learned that trick on the center frame pivot on a 1970's simplicity 7013 (it already had the zerk but the pivot probably hadn't been greased ever and had seized solid. It took me a week to get it freed up with a pump or 2 twice a day and applying cross pressure (a 4×4 block of wood under the left front tire and one under the right rear tire leaving the other 2 tires hanging in the air) after a week without any other contact (except to add the grease) I went to the garage and found the 2 tires diagonally across the pivot that had been in the air sitting on the ground and the pivot moving freely).

  30. Avataaar/Circle Created with python_avatars Crabtree Media says:

    You guys should do a tour of all the toys and jeeps/cars/trucks, that would be awesome, great vid

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