I have this posted in the Project Quads section, but thought I would see what you fellow Kawasaki guys think. Don't worry, this one will get built, it will just be a few years before it is done.

Here is the current list of parts for a project that I have had in the back of my mind for years. I always wanted to build it, but could never afford it. Well, now I can. I will start buying the parts while I am here in Korea so that when I get home, I will be ready to get started. I already know that the KX will vibrate, but I have a few ideas to calm it down. Besides, if it vibrates so bad that I can't do anything about it, I'll just build a big-bore Tecate 4 motor and drop it in there. This will be built for the dunes and some MX on the side. I hate drag racing, so the swingarm will only be extended a maximum of one inch over the stock 86-87 length. I want this thing to handle, not go in a straight line for a few seconds and be done. So, here's the list. BTW, this list is long.

<u>Chassis and Suspension</u>

Complete used aftermarket 250R based quad
Flip-up subframe (if possible)
DG or Moose aluminum engine skid plate
Minimum +2" a-arms (+2", +1" possible)
Anti-vibe +1" steering stem
Custom front engine mounts made from 3/8" tubing (with rubber mounts)
86-87 length aftermarket swingarm (+1" extension possible)
Minimum +2" extended axle
Billet rear axle bearing carrier
Billet rear brake rotor hub/locknut combo
Billet rear brake caliper mount
Billet rear sprocket hub
Stock front hubs
Stock rear hubs
Elka or Axis front and rear remote reservoir shocks
Billet shock reservoir mounts
Duncan Racing front bumper
Aluminum rear grab bar



<u>Drivetrain</u>

KX500 non-counterbalanced two stroke
Ignition stator with lighting coil
Complete KX500 wiring harness, CDI box, and AC regulator
Aftermarket 250R pipe with modified exhaust flange (for mock-up purposes, send out as a pattern to have one custom built)
Custom 250R style silencer with 500 sized tubing
Large capacity aftermarket radiator
Aluminum fuel filter
Aluminum air box
K&N air filter
Moose prefilter
Stock 250R air boot (possible LT500R air boot)
Billet oil fill plug
Custom billet aluminum 1/2" thick case saver
Hinson or Moose billet clutch basket
Heavy duty clutch kit
Parts Unlimited front sprocket
Moose stainless rear sprocket
RK 520 gold chain



<u>Body and Controls</u>

Maier 400EX one-piece racing front fenders (part # 117423)
Maier 400EX rear fenders (part # 117433, trim bottoms of fenders for kick starter clearance if necessary)
Maier 400EX side panels (part# 117413, green, if necessary)
Stock 400EX gas tank
Stock 400EX seat
Quad Tech NACA duct front hood with aluminum screen
Quad Tech gas tank cover
Gipper seat cover
Custom Kawasaki graphics (like the 1999 factory quad of William Yokley)
Custom vinyl numbers
OMF aluminum radiator screen and scoops
Billet gas cap
Moose or Pro Sport CR double-high aluminum motorcycle handlebars
Renthal USA bar pad
Lazer Star headlight/handlebar clamp kit
Lazer Star headlight covers
Smith medium compound grips
Stock 250R thumb throttle housing (if possible)
Parts Unlimited throttle cable (or custom to fit carb slide)
Stock 250R headlight and ignition switches
Billetanium hydraulic clutch kit with stainless steel line (must custom fabricate bracket that attaches to magneto cover bolts)
Parts Unlimited front brake lever
ASR stainless steel front and rear brake line kit with dual front lines
ASR billet front brake line clamps
LSR billet parking brake block-off
Roll Design Pro Series kick-up race footpegs
Stock KX500 shifter
Roll Design rear brake lever
New school dirt bike rear brake master cylinder (master cylinder/reservoir combo)
LED rear taillight (on ebay or billetbanshee.com)



<u>Vibration Reduction</u>

Balanced rotating assembly
Rubber engine mounts
Faast Company brass bar end inserts
Anti-vibe steering stem



<u>Colors and Finishes</u>

Green
Chassis
Lower a-arms
Front fenders
Side panels (if necessary)
Rear fenders

Black
Front hood (carbon fiber)
Gast tank cover (carbon fiber)
Gas tank
Gas cap vent line
Graphics (with silver and white reflective accents)
Seat cover
Prefilter
Handlebars
Handlebar grips
Headlight covers

Chrome
Front bumper
Upper a-arms
Tie rods
Steering stem
Front engine mounts
Exhaust pipe
Exhaust silencer
Magneto cover
Hydraulic clutch slave cylinder bracket
Clutch cover
Water pump cover and hose neck
Rear brake lever
Footpegs
Rear subframe
Swingarm
Rear axle

Polished Aluminum
Front hood screen
Shock reservoir mounts
Front brake line clamps
Radiator screen and scoops
Radiator tanks
Thumb throttle lever
Front brake lever
Clutch lever
Lazer Star headlights
Handlebar clamp
Gas cap
Fuel filter
Gear shifter
Kick starter
Oil fill plug
Rear brake master cylinder
Skid plate
Case saver
Air box
Rear axle bearing carrier
Rear brake rotor hub/locknut combo
Rear brake caliper mount
Rear sprocket hub
Rear parking brake block-off
Rear taillight housing
Rear grab bar

Bead Blasted
Front wheel hubs
Front brake reservoir (clear coated)
Thumb throttle housing (clear coated)
Hydraulic clutch reservoir
Engine cases
Cylinder
Cylinder head

Miscellaneous
Red, white, and blue bar pad
Gold chain
Gold, burgandy, and black (Elka) or black and gray (Axis) shocks

 

Sounds like you've done your research... I'm just begining a similar project, but am building a custom 4 wheel independant suspension, & 4 wheel drive... but I'm planning on using a later model ( mid 70's ), Kawi H2 motor ( 750 cc 2 cycle triple )... most of my project is in my head yet... looks like you've got a good parts list put together...