I might have an idea for your "in gear idiot light". A few years ago I wired some idiot lights for my idiot son who like to roast belts because he would forget to take off the E brake on his FL350. Heres the link to the mod.

viewtopic.php?f=1&t=4685&hilit=neutral+brake


You might be able to install one of the actuators/switch near some transmission linkage to be able to actuate the actuator...

I didn't think of an actuator. Nice.

I think my plan was to have a solenoid energized to complete the starter-button-to-starter-solenoid circuit only when the ignition was on and shift was in neutral. So when the gearbox was in something other than neutral, no Starty McStart-Start. When ignition was off, no McAnything.

Will the fl350 trans already has two switches in it what not use them ?

I want to use the stock switch, but it was integrated into the FL350R electrical harness -- not the Rotax. The trans sensor is linked directly to the FL350R CDI (Capacitor Discharge Ignition), which won't exist. SO I'll have to get jiggy with the new harness.

Will FINALLY be done with my sidewalks this week, and have already started reviving my '87 Zilla project. Hoping to get back on the Rotax project FULL-TIME in early-to-mid October.

Hoping to work on the buggy this weekend, believe it or not!!!

Landed a 15.50" wide Kirkey racing seat with cover CHEEEEAP. Will be plumbing & wiring my brand new 5hp 60gal MaxAir compressor tonight (sold my $200 resurrected 80gal Speedaire for $500 on Monday ).

So will most likely spend time cleaning up quad and buggy parts on the bead blaster, want to get the airbox on the Engine, and want to get the starter wire completely connected to the starter so it will roll the starter over. Momentum should carry on from there.

Also (before Thanksgiving) planning to finish the 16x22 back room of my pole barn with stud walls, insulation, more lights, and a pair of 9' sliding doors. All so I can have some HEAT in the winter and some A/C in the summer to work on stuff.

Nice to see somthing getting done

Also got an airbox & filter for late 90's Dodge Dakota that should work perfect. Takes a FRAM CA3559 filter, pretty small in size, and will flow a-plenty for the 470-twin.

My plan is to get this 470 running, so I at least can start/run it every so often while its a work in progress. Then I want to get my FL350 water-jacketed cylinder/head on a rebuilt lower-end, and swap it into buggy #1. So...I'm hoping to get the Rotax running & on 4 wheels at least, #1 transplant done, and get my shop done before Christmas. EFFING CHRISTMAS!!

I'm soooooo sick of being a GD forum lurker!!! Need to post some progress and useful content! lol

Nothing new to report except for a pic of the Kirkey seat & cover I snagged for $100. Owner said it had been mounted but never actually used. Sweet. Figure I had 5 buggies with 4 seats and needed a seat anyways, so might as well be a Kirkey. I sat in it wearing my Carhart bibs (not lined) and there's still a little room in the 15.50" wide seat. So I know I'll still fit in it during the holiday season.

Spent the weekend sick along with my pukey/boogery 2yr old. Had yesterday off and worked on my '87 Zilla.

Here is the airbox I'll be using...

Dang ! What's that off of? I was looking for something exactly like that!

Easiest way to see what its off of is via the FRAM website search for the filter CA3559...which is mostly mid 80's to mid 90's Dodge/Chrysler/Plymouth 2.2L and 2.5L four-banger engines. Looking at the list of vehicles, you will very likely find one in a local junk yard, lol.

http://www.framcatalog.com/PartDetail.aspx?b=F&pn=CA3559

I got this one free from work in a bin of extra filter housings they were throwing out after we combined the Champ and FRAM test labs. I know there are at least 3 versions of the housing for the same filter, but this one is the simplest one. Has the inlet, outlet, and then a small vacuum/ccv port which will need to be plugged.

Very nice,thanks.

any progress?

Nope, nothing. Ordered a couple air filters for the airbox, but the buggy has been hibernating in the barn under a tarp and blankets. Did some thinking and sketching for the rear axle & trailing arm setup, but its all theory yet.

Wrenched on a '90 SkiDoo 440 a bit and going to get one of my stock FL350's an overhaul so I have a buddy-buggy to ride with. I did get my shop compressor room built, so the new "comp-zilla" has a heated/dry insulated room of its own with a door.

Winter has been too long & cold to get much of anything done, especially the last 45-50 days. Sucks. Rigs are cold. Tools are cold. Extension cords and air hoses are stiff. Pole barn is too much space to heat, and the back shop room isn't insulated yet.

Its supposed to get into the 40s Tuesday correct? Maybe some of us northern guys can work on our toys too

Hell yes! Although my wife, kid & I all have colds now. I'll be working on pulling a couple FL350 bottom ends apart -- NOT the Rotax buggy. I got propane delivered yesterday, so no more pesky conserving.

My wife is sick also and its a matter of time till I and the kids get it too. Good luck!!

Just noticed I now have my own "world" on here. Thanks Hoser!

I actually took the tarp off this project yesterday. But it was short-lived. I just put a few cc's of 2-poke oil in each plug hole and spun the clutch around a few times by hand to keep things lubed.

THAT"S called the THHNEAAS marriage mate! ...(The Honeymoon Hangover Never Ending After Affects Syndrome)..................OR

Its only gonna' get worse. My wife is preggo with kid #2 and due in August. AKA: July-November is booked full of non-buggy stuff. Its now or never!

I picked that same filter box up today. I think that I may be able to make it work, I was at the scrap yard and seen car getting ready for the crusher when I remembered this post. thanks!!

Awesome! Its a great-sized boxed for a 2-stroke buggy up to 1500cc's, really. The airbox is for a 2.0-2.5L auto Engine, but the 2-strokes turn more RPM, hence can move more air.

i ended up using the filter but the box was not going to work for me. There are pics of it in my my build post and in the tech section.

Soooo...my infant son is finally sleeping through the night, I am finally almost finished with the #2 Zilla project, and I've started to enclose and finish my 16x22 shop room in the pole barn. This means I may actually be working on the Rotax buggy again this winter!!!!

Step 1: Finish Zilla #2, tune it and put it up for sale (last parts arrive Tuesday).
Step 2: Finish shop room (frame in, insulate, wire, drywall, plumb air lines, install interior overhead door)
Step 3: Work on my FL470 in the heated shop room.

I was up on the barn roof last night...in the dark...while it was sleeting...adding more overhang to the shop room's roof thank to the previous owner taking shortcuts. Only had 1/8" overhang which allowed water to creep under and rot out a 2' section of timber behind the steel sheathing. Yuck.

Hoping to have the framing, insulating, 36" door installed, and interior overhead door installed and done in 2-3wks.

Well my conference call is over, which means I need to get back to work!

Have any pics of the Zilla you finished? Still for sale? Thanks!